Hydro assist on the cheap

[NCK4L]

does anyone know how much fluid goes in your stock power steering system? i just finishe this assist mod and added a small double row cooler and modified my stock reservoir and i only got about 1.5 quarts in the system before it was full . does that sound about right? how much fluid are most of you guys getting in?

[superyota]

i didn't measure mine, but that sounds about right

[OldGold3VZE]

Figured I'll add mine for other's to reference.  I went a little different with my axle mount.  Took a piece of 1/4" square tubing and made an angled mount to the top of the diff and added a 3/4" bolt to act as my mount.  Yes, it's single-shear, but it's 3/4" and beefy.  Also, all the tie rod ends are single shear, and they seem to hold up fine.  This mount was really easy to install.  Couldn't be happier.





These pics suck, but here is where I mounted my cooler.  It's under the winch plate.  Plenty of air flow, and it's tucked out of the way, and not strapped to my radiator. 





Here's the winch mount for reference.

[Volcom]

does anyone know how much fluid goes in your stock power steering system? i just finishe this assist mod and added a small double row cooler and modified my stock reservoir and i only got about 1.5 quarts in the system before it was full . does that sound about right? how much fluid are most of you guys getting in?

Sounds about right for a stock reservoir. 

[Rob84pkup]

Nice cooler mount

[boomtacoma01]

Bump for a great thread. Got my Surplus Center parts on order.

[4runnin_87]

I just ordered my assist parts from surplus and I'm curious as to how the assist has been holding up for any of you guys that's been running for a while now. And updated tip/tricks or tried that and didn't work suggestions? Thanks

[OldGold3VZE]

It's the best $200 mod you'll do, and lasts a long time with no issues.  If you do it right, which is very easy, you'll be way stoked.

[4runnin_87]

It's the best $200 mod you'll do, and lasts a long time with no issues.  If you do it right, which is very easy, you'll be way stoked.

I can't wait to get this setup put on.. being locked in the front on 39.5 irocks there is just no turning sometimes. Now its time to read the tech thread once or twice more and ill be set when my box of goods show up.

[sjdeas87]

Finally found the receipt with the part numbers from Surplus Center. Also added them into my makeshift write-up

Ram                      9-4410-06
Hoses                    916-1436
3/8-1/4 bushings     9-1938
1/4 90s                 9-1922

which surplus store did you get these parts from??

[sjdeas87]

answered my own question. Thanks for all the tech help.

[chandogg]

can't wait. this is one of the last upgrades i'm waiting to do.

[twistedtoy92]

Just ordered my hydro assist! 

[OldGold3VZE]

can't wait. this is one of the last upgrades i'm waiting to do.

Should be one of the 1st for how cheap it is. Can't beat it! 

[89MiniTruck]

Sweet.

[matholland]

I have read several pages on this, and it is a lot to go through.  I was hoping that someone could assist me in this.  I have a 81 toyota (whats left of it) that has the IFS steering box (I think, because the pitman arm moves side to side), dana 60 one ton axles with spools front and rear.  I believe that I need to go with a cooler and a bigger resivore.  I am not 100% sure on what size ram that I need, or fittings.  I am basically ready to order everything, I just need some assistance on getting all of my parts lined out so that I do this the right way.  Here is what my front end looks like.

https://plus.google.com/photos/116424294864098183298/albums/5871284572784230817/5913300055907691090?banner=pwa&authkey=CNOvo_Xj2Z6TMw&pid=5913300055907691090&oid=116424294864098183298

[John Doe]

I have read several pages on this, and it is a lot to go through.  I was hoping that someone could assist me in this.  I have a 81 toyota (whats left of it) that has the IFS steering box (I think, because the pitman arm moves side to side), dana 60 one ton axles with spools front and rear.  I believe that I need to go with a cooler and a bigger resivore.  I am not 100% sure on what size ram that I need, or fittings.  I am basically ready to order everything, I just need some assistance on getting all of my parts lined out so that I do this the right way.

To find the proper length ram:
Start with your wheels straight, attach some sort of straight edge to axle or ground that gets at or above the height of your tie-rod. Make a mark on the tie rod with a marker where that straight edge is. Turn full left, make another mark, full right and make another mark. Measure the distance between the outer marks, that is the length of ram you will need. Do the above with your axle on jack stands.

Now keep in mind it is very possible and in your case highly likely that your axle can turn further then your IFS steering box. If this is the case I would highly suggest that you limit your ram to just short of the swing distance of your steering box. You can take the above measurements with and with out your steering box connected to your axle. Doing so will likely net you 2 different measurements. For Hydro asst you do need a cooler and bigger reservoir.

Reservoir mods for more capacity:
http://www.pirate4x4.com/forum/toyota-truck-4runner/424339-3-4t-hilux-build-begins-post7901853.html

[matholland]

Thanks for the reply!  Do you think that this will help me out with 42's without going fully hydraulic?  I think I have everything figured out...need an 8 inch ram...just need to figure out the cooler...what cooler is everyone using?  Do I need additional hoses/fittings in order to hook the cooler up?

[twistedtoy92]

Something of this nature will work just fine!

http://www.ebay.com/itm/New-Derale-6-Pass-Heavy-Duty-Automatic-Transmission-Cooler-7-1-2-x-16-x-3-4-/130970709057?pt=Motors_Car_Truck_Parts_Accessories&hash=item1e7e766c41&vxp=mtr

[BPINAZ]

I just finished my HA. I used all the Surplus Center parts from page one, plus some swivel NPT fittings I found at NAPA, couldn't believe how easy it was to do. Stock reservoir with a cooler that's about 2/3 bigger than stock.  I said a prayer before adding fluid and cranking it up, took about 20 minutes to bleed.

Driveway test run: both hubs locked, 9 PSI, both cases in low, on concrete.....two finger steering with a stock pump.  Using ATF DEXRON III.

However, I got ahead myself when mounting the ram.  I'll need to re-do my tabs to rotate the ram 90 deg.  My fittings are on the top, which is only about 3" from the oil pan.

[rcbro]

Would like to get this thread updated alittle bit. Doing my build alot of parts left me scratching my head.

HYRDO ASSIST PARTS LIST
Everything below is from surpluscenter.com

Ram
Quantity: 1
Item Number: 9-4410-06
1.5X6X.75 DA HYD CYL

Ram outlet is 3/8" which is alittle to large, this swivel end reduces it back down to 1/4" for your hoses
Quantity: 2
Item Number: 9-1501-6-4
3/8 NPTM x 1/4 NPTF 90 SWIVEL

90* swivels, Need these to connect your hoses to your box
Quantity: 2
Item Number: 9-1501-4-4
1/4 NPTM x 1/4 NPTF 90 SWIVEL

Hoses, these seemed to work well for me, however if you are taller, you may want a few inches longer
Quantity: 2
Item Number: 916-1436
1/4" X 36" 1/4 NPTM X 1/4 NPTM 2750 PSI HYD HOSE

Since your order parts, I'd suggest ordering at least 1 extra piece of each thing, simply to have extras on the trail.

limiting the ram is stupid easy. If you get lost, check out PSC motorsport Tech section for a how-to.

Originally I ran a stock RZ power steering pump. The motor has alot of empty space just behind it, so I extended the reservoir and added a baffle inside. For those who go this route, please note the upper ring is stainless. Try to stay below it.



I wasn't happy with the output of the stock pump so opted to get a PSC 3rz pump kit. It was not a direct bolt on, but wasn't horrible either.

The pump needs to sit flush against stock bracket. In order for this to happen, some grinding to the stock RZ bracket is needed. This picture below is alittle hard to tell what I did, but once you have the two in hand, its pretty self explanatory.



Next thing to do is drill out and tap the PSC pump. I tapped it for 10mmx1.50 threads. This is just a hair bigger then the stock holes and works perfectly.

Backside hole:


Front side:



The pulley is a huge PITA to press on. (yes I used a pulley installed) I left the pulley about 1/8" or so from sitting flush so the belt would align better when installed. Its not going anywhere as even getting it on this far was difficult.

The pump then mounts flush to the face of the RZ bracket.



Add a few washers on the back side to fill the gap, and its not being held on by 3 bolts.



With a simple 90* bracket, the reservoir fits barely lol







I ended up grabbing a 45* fitting for the reservoir to make the feed loop alittle smaller. The loop looks like  , but its all I can really do. These fittings are expensive FYI

The Hi-pressure line they supply is a DIY version. I think it should be ok, but may get a crimped version later down the road.

[rcbro]

The ram mounting for most setups should work great. (due to my low ride height, and rz motor I will be moving the ram forward of the axle. I have little uptravel and run into hitting issues with this setup. After a bunch of research, this was the best route, just not for my setup)

Pictures at full droop









Pictures are ride height (here you can see my clearance issues. Mind you, I'm low.

[HogCanyonHopper]

very nice. good job on getting that bracket to work. I cheated and bought one from Chilkat 

[OldGold3VZE]

I would suggest welding some rings on either side of that tie rod bracket to keep it from sliding. There's a lot of force there.

[rcbro]

I would suggest welding some rings on either side of that tie rod bracket to keep it from sliding. There's a lot of force there.

The welds are on the front side of the tiered, just hard to see with the picture angles. Due to clearance issues, I ended up purchasing a psc ram with heims ends so I could lay it flat.

[lostbuckaroo]

Ok dumb question:

I've got everything mounted except a final mounting location for my reservoir... I bought the basic alum. reservoir with that can be found at speedway motor (however I bought mine from Amazon).. If I've read everything correctly the reservoir has to be the highest component of the system..meaning the bottom of the reservoir must be higher than the pump inlet... This reservoir is 9" tall alone, ad the barbed AN elbow fitting on the bottom it's easily 10" tall all together... Where are you guys mounting this reservoir? The only place I can see I could mount it would be on the firewall next to the Brake booster. Anywhere near the fender would be too high to close the hood, and or too low to feed the pump properly... any help or suggestions would be much appreciated..

BTW i've got an 84' pickup/ Running a 22r - Thanks all

[lostbuckaroo]

Here's my redneck res mount... I threw together a bunch of left over stuff I had here, my first mount didn't work.. this is round #2 I put this thing as I high as I could possibly get it...  With the AN fitting on the bottom this thing is over 10" tall... Seems to work so far..

[HogCanyonHopper]

you dont want to see the  okie fenokee  mount for my res.   


             
               bailing wire and bungee cord  (temporary till I get something better fabbed in)

[lostbuckaroo]

you dont want to see the  okie fenokee  mount for my res.   


             
               bailing wire and bungee cord  (temporary till I get something better fabbed in)

[konayota]

My setup, stock pump, stock reservoir, small cooler. Works fine for what it is. I had a hard time steering with the Detroit front locker, now it's pretty easy. I definitely need a better pump and bigger reservoir though.