I decided to put this in here rather than in the build thread section so that people can ask questions or give me advice since I am no expert and like good feedback and ideas.
First off this mod is highly featured in Pirate and other forums but what I learned by looking at 100 threads was that no one really does a detailed job and I was left with a trillion questions. So here goes and I will try to update as I progress.
As many of you know you can buy a PSC kit and have everything from soup to nuts for about $1000. But **** that Im going to show you how to do it for about $180. The things you will need are,
1) A good well working stock 4wd or 2wd steering box.
2) A good healthy power steering pump
3) One hydraulic Ram
4) Two hydro lines
5) a bunch of NPT and JIC fittings
6) tabs to mount the ram to axle tube and tie rod
7) a Power steering cooler
8) new end plug with NPT fitting
9) tapped top cap with NPT fitting
(8&9 can be bypassed if you want to tap your box like all the Jeep guys do) But they probably wouldnt if they could get the caps like we can for the JK, XJ, and early YJ/CJ
Basically there are two ways to do this. Tap your box, which requires taking the steering box off your truck, drilling and tapping the side of the case where there are fluid ports, and placing fittings in there. Then a complete teardown of the box, to clean all the metal shaving out of it. Or the second way which is what I chose, tap your top cap of your steering box, and buy a new end plug with a NPT fitting already bult into it.This way you can leave the steering box in the truck, take the end plug and top cap off to modify them, put them back on and your done. ALso doing it like this you can re use the end plug and top cap should you ever grenade a box. You dont need to tap another box, just switch caps
Here is what I got, I got everything from Surpluss Center.com other than my end plug, and my o-ring/retaining ring
The first thing I did was hook up my cooler. Because of the intense heat the ram builds up you need to run one. Its a must. Run it from the return line on your pump. I used a simple tube and fin tranny cooler from summit I got for $35 bucks.
Also when I did this I replaced my return line on my box. I turned it oposite the way its supposed to be so that it ran towards my cooler instead of my pump. It worked out great this way.
the next thing I did was tap my top cap. This thing is very think and will be fine for tapping. Use a tap for a .25" NPT fitting. You need to drill the hole with a 7/16 drill bit, then use a .25" tap for NPT (its big). You can re use the gasket under the top cap. Be careful not to mess it up. When you remove this cap, put an allen wrench on the adjustment nut and unscrew the nut. Then screw off the top cap keeping the allen wrench there stationary so you dont throw off your stock adjustment. The top cap screws off that nut like a big nut. then make the hole in the cap. This is where the hole goes. (its the bottom one)
get it right in this area
Then tap
Next add your fitting. I used a 90* because I need it to turn that way, which most of you will too if its a GMT 400
Your done, put it on the truck
First off this mod is highly featured in Pirate and other forums but what I learned by looking at 100 threads was that no one really does a detailed job and I was left with a trillion questions. So here goes and I will try to update as I progress.
As many of you know you can buy a PSC kit and have everything from soup to nuts for about $1000. But **** that Im going to show you how to do it for about $180. The things you will need are,
1) A good well working stock 4wd or 2wd steering box.
2) A good healthy power steering pump
3) One hydraulic Ram
4) Two hydro lines
5) a bunch of NPT and JIC fittings
6) tabs to mount the ram to axle tube and tie rod
7) a Power steering cooler
8) new end plug with NPT fitting
9) tapped top cap with NPT fitting
(8&9 can be bypassed if you want to tap your box like all the Jeep guys do) But they probably wouldnt if they could get the caps like we can for the JK, XJ, and early YJ/CJ
Basically there are two ways to do this. Tap your box, which requires taking the steering box off your truck, drilling and tapping the side of the case where there are fluid ports, and placing fittings in there. Then a complete teardown of the box, to clean all the metal shaving out of it. Or the second way which is what I chose, tap your top cap of your steering box, and buy a new end plug with a NPT fitting already bult into it.This way you can leave the steering box in the truck, take the end plug and top cap off to modify them, put them back on and your done. ALso doing it like this you can re use the end plug and top cap should you ever grenade a box. You dont need to tap another box, just switch caps
Here is what I got, I got everything from Surpluss Center.com other than my end plug, and my o-ring/retaining ring
You must be registered for see images attach
The first thing I did was hook up my cooler. Because of the intense heat the ram builds up you need to run one. Its a must. Run it from the return line on your pump. I used a simple tube and fin tranny cooler from summit I got for $35 bucks.
You must be registered for see images attach
Also when I did this I replaced my return line on my box. I turned it oposite the way its supposed to be so that it ran towards my cooler instead of my pump. It worked out great this way.
You must be registered for see images attach
the next thing I did was tap my top cap. This thing is very think and will be fine for tapping. Use a tap for a .25" NPT fitting. You need to drill the hole with a 7/16 drill bit, then use a .25" tap for NPT (its big). You can re use the gasket under the top cap. Be careful not to mess it up. When you remove this cap, put an allen wrench on the adjustment nut and unscrew the nut. Then screw off the top cap keeping the allen wrench there stationary so you dont throw off your stock adjustment. The top cap screws off that nut like a big nut. then make the hole in the cap. This is where the hole goes. (its the bottom one)
You must be registered for see images attach
get it right in this area
You must be registered for see images attach
Then tap
You must be registered for see images attach
You must be registered for see images attach
Next add your fitting. I used a 90* because I need it to turn that way, which most of you will too if its a GMT 400
You must be registered for see images attach
Your done, put it on the truck
You must be registered for see images attach
Last edited: