sag pump + 4-bolt / 1-ton steering gear - Ford Bronco Forum
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  • 1 Post By BigBlue 94
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post #1 of 20 (permalink) Old 05-07-2016, 11:08 PM Thread Starter
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sag pump + 4-bolt / 1-ton steering gear

i'll skip the backstory but i decided to install a saginaw pump plus do the 1-ton / 4 bolt steering gear conversion. there is one thread with a lot of conversation and info but this is strictly detailing how i did it.

also, note i went through 2 pumps, 2 pressure hoses, and a couple modifications to the return hose.

my bronco - 1996 351w
saginaw power steering pump/bracket/pulley donor - 1st attempt: junk yard e-150 2nd attempt: reman from oreilly for a 1996 e-150 351w
steering gear - junk yard 2003 van
pressure hose - 1st attempt: 1996 van with custom fitting into the steering gear. 2nd attempt: custom hose. 90* bends at each end. 16" long bend to bend. compression fittings on the end to allow me to spin the ends to whichever angle was necessary.
actual fittings used: 06u756 on one end and then 06u755 on the other. i don't know what the sizes are for the part that connects to the steering gear or power steering pump. (sorry)
return hose - factory return hose with a modified fitting + a short piece of 3/8" oil hose + xrp 791615 (6AN male to 16mm x 1.5 male o-ring)
power steering fluid filter - wix 58964
serpentine belt - 1996 e-150 351w w/AC - goodyear 4061025/6pk2605
pitman arm - reused my factory arm
p/s fluid - valvoline maxlife ATF (full synthetic)

other specialty tools used:
tubing cutter & flare tool where i spliced the hose into the return line
heavy duty pitman arm puller like this loaner tool from autozone:

and a pulley puller / installer like this from oreilly, because i had to replace the pump.



keys to remember:
the bracket will bolt up
use the pulley on the saginaw pump
the saginaw pump has an o-ring fitting, the factory pump has a flare
the steering gear has o-ring fittings for both the pressure and the return hose, the factory pump had flares
doing both the pump + the gear will require a custom hose. no ford came with both
the return hose will need to be modified to fit the steering gear.
the pitman arm will swap over
the steering gear will bolt up

the conversion:
here are the parts from the JY


step 1 - remove the parts of the air intake that are in the way. and remove the serpentine belt.


step 2 - use a transfer pump to empty out the PS pump


step 3 - drop the steering gear. pro tip - with the steering shaft attached to the gear and the steering wheel locked, remove the nut holding on the pitman arm before you drop the steering gear.


step 4 - disconnect the a/c compressor. i left 2 bolts in a few threads while i disconnected the bracket. in hind sight, i don't know if that was necessary.


step 5 - move the a/c compressor to the side and remove the pump and bracket


step 6 - remove the return hose


step 7 - install new pump and bracket. i removed the accessory stud off the back and replaced it with a standard bolt m10-1.5 x 20mm.
also, i'll add that i did not have to drill out the a/c compressor. the sag pump i got came with the small bolts. it may be because it was off a new van, although i didn't think to see what year it actually was.



step 8 - install the steering gear. if yours came with a pitman arm attached already, you're in luck! mark where it is facing so you can put your pitman arm on it facing the same direction. that will make it easy to keep your steering wheel right where it needs to be.
to remove the pitman arm off the van gear, i had to do a relief cut in the back of the pitman arm before i could get it free. i used a cutoff wheel for that.

here is the first pressure hose



also, the 1st pressure hose is already installed. i didn't like the routing towards the fan and under the pump. it was trying to get too close to the fan blades for my liking.


here you can see it routing under the pump. and it's pretty crowded under there with the return hose, the filter, and the pressure hose.


from underneath



and this is the filter




**note** this is the junkyard pump and modified hose. at this point, i installed the return hose w/o modification just to see how it all sounded. it sounded god awful. the pump was bad. i bought a reman from oreilly with a lifetime warranty, price matched to autozone. installed it, and back in business.

also at this point, i decided to have a completely custom hose made. and since i was going back to the hose shop, i had them modify my return hose in hopes that i could avoid cutting it. well, i kept bending and bending but get fed up with it, so i cut it anyway.

this is the final version of the return hose


you can see they welded on a new end to go to the AN fitting.


this went into the steering gear



step 9 - install new custom hoses










and from the bottom. the return hose doesn't really bend that much, it's an odd angle.


step 10 - install serpentine belt

step 11 - reconnect steering shaft

step 12 - i disconnected the inner tie rod and drag link. then i attached the pitman arm to the steering gear. then the drag link. then the inner tie rod. i had my wife sit in the driver seat and turn the steering wheel as needed to make connecting them a piece of cake.

step 13 - fill up the pump

step 14 - connect the air box to the engine, cross your fingers, and start it up. go through the normal bleeding process.

after thoughts
i considered getting a motorcraft remanufactured 2-bolt (factory) steering gear. they're "only" $190 from rock auto. plus the forum 5% discount negates shipping. i wanted to avoid the custom hose. but i thought about how long a pressure hose should really last and i decided it would be worth it to get a steering gear that is simply a better design than the factory 2-bolt. i am glad i did it. it's not as quiet as everyone made me hope it would be, but maybe my factory pump just wasn't as loud as some? i'm not sure. but the slop is all gone from the steering and i couldn't be happier.

rough pricing:
steering gear - junk yard - $40
pump/bracket/pulley - junk yard - $40
reman pump - oreilly - $40
1st pressure hose - rock auto - $10 + $18 at hose shop
return hose + fitting + custom pressure hose $55 at hose shop
belt - ebay $13
filter - amazon $15
trans fluid - $20 / gallon at autozone. i used maybe a 1qt? not sure.

it's fun to do bad things

my "build" thread
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post #2 of 20 (permalink) Old 05-09-2016, 11:59 AM
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Nice write up. My 300 is starting to make some noise so this is on my mind. Unfortunately I've got too many other projects and not enough time.
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post #3 of 20 (permalink) Old 05-18-2016, 02:53 PM
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If its all good with Dash_Cam I would like to share how I am doing the high pressure side for my 4 bolt box and sag pump setup. I dont have it installed yet but have some pics of it setup on the bench.

High pressure hose, -6an x 24" w/ 90 & straight, Fragola part# FRAHSE3090-06-ST-24

High pressure fitting to steering box, 1/2"-20 o-ring to -6an, Russel part# 648010

Sag pump high pressure fitting, M16x1.5 oring to -6an, Russell part# 648060



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post #4 of 20 (permalink) Old 05-18-2016, 03:15 PM
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Nice work Dash! Do you run bigger tires than stock?
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My Build Thread - http://www.fullsizebronco.com/forum/...d.php?t=191067
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post #5 of 20 (permalink) Old 05-18-2016, 05:17 PM Thread Starter
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Quote:
Originally Posted by Alwaysdirty View Post
If its all good with Dash_Cam I would like to share how I am doing the high pressure side for my 4 bolt box and sag pump setup. I dont have it installed yet but have some pics of it setup on the bench.

High pressure hose, -6an x 24" w/ 90 & straight, Fragola part# FRAHSE3090-06-ST-24

High pressure fitting to steering box, 1/2"-20 o-ring to -6an, Russel part# 648010

Sag pump high pressure fitting, M16x1.5 oring to -6an, Russell part# 648060
looks good, but will you double check your p/n for the hose? i can't find that number anywhere, including the fragola catalog.

and what do you have going on for the return hose?


Quote:
Originally Posted by jowens1126 View Post
Nice work Dash! Do you run bigger tires than stock?
thanks.

i only run 31" tires right now, may do 33" in the future. my reasoning for the saginaw pump was that i was hoping it would be quieter than my factory pump. it is "meh" quieter. and i did the 4-bolt over a reman motorcraft 2-bolt was that a reman 2-bolt is still the same design that is proven to wear out with relative quickness. the risk/reward is strictly in the custom hose. however, i decided that it just wasn't really likely to fail.


as an overall thread update, i've discovered my truck pulls to the right. i'm going to install my new ball joints, my leveling springs, and camber/caster bushing then take it in for an alignment. hopefully after that i can close the book on the front suspension and steering for a while.

it's fun to do bad things

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post #6 of 20 (permalink) Old 05-18-2016, 05:49 PM
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Quote:
Originally Posted by dash_cam View Post
looks good, but will you double check your p/n for the hose? i can't find that number anywhere, including the fragola catalog.
I came up with 372024 on page 48 of their catalog.

Is -6 big enough?
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post #7 of 20 (permalink) Old 05-18-2016, 08:15 PM
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my sag pump is dead quiet. I also have a red head 2 bolt gear. Ive been very happy with it. Like you though, my steering has no slop, but it seems like my front end is about worn out now, and I need to totally rebuild it from scratch. Thats going to be one hell of an expensive job, even if I do alot of the work.
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My Build Thread - http://www.fullsizebronco.com/forum/...d.php?t=191067
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post #8 of 20 (permalink) Old 05-19-2016, 01:03 AM
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Quote:
Originally Posted by dash_cam View Post
looks good, but will you double check your p/n for the hose? i can't find that number anywhere, including the fragola catalog.

and what do you have going on for the return hose
Heres the Amazon link Amazon.com: Fragola -6 AN Straight x 90 Degree PTFE Hose Assembly, Steel Nut, 24" Long: Automotive

For the return hose I am just using the factory 4 bolt steering box fitting and 90, cutting it right at the tubing flare transition to rubber and sliding new hose over it with a clamp. I am also using the same Wix filter and a new cooler mounted in front of the radiator. It will be all regular rubber hose for the return side.
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post #9 of 20 (permalink) Old 05-19-2016, 01:14 AM
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Quote:
Originally Posted by Hillbilly Heaven View Post
Is -6 big enough?

I was concerned about that as well. The inside diameter looks to be very close to the factory tubing and is larger than the passageway of the steering box port. So I went with it.
The next size up -8, I think is like .5" inside diameter and seems to big with the factory line at around 3/8" like -6, although I don't know the exact inside diameter of the factory line at the moment.
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SAS coming one of these days...
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post #10 of 20 (permalink) Old 05-19-2016, 06:04 AM
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Ahh ok that explains the discrepancy in the part numbers.

The number you referenced is an Item Number they used for Amazon. Even though it worked for you something is weird as they list the actual part number as 372024 further on down in the technical description of the part.

Yoy are correct about your AN sizes. A dash 6 is 3/8" Tube size whbich is also the same as the hose I.D,

A dash 8 is 1/2" Tube size and hose I.D.

Remember hard tube is measured by the O.D. and hose is measured by the I.D.
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post #11 of 20 (permalink) Old 05-19-2016, 07:17 AM Thread Starter
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My custom hose is 3/8" hose, so you should be good

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post #12 of 20 (permalink) Old 01-19-2017, 09:04 PM
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great write up. i read your build thread and this. my 96 that i just got sounds identical to the issues you had. I am tempted to do what you did. Unfortunately, we do not have pick n pulls up here, and the full service yards charge a ton. If you ever go back to the yard, let me know, i may be interested in paying you for some parts for me
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post #13 of 20 (permalink) Old 01-19-2017, 10:08 PM Thread Starter
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Quote:
Originally Posted by ThomasStemmle View Post
great write up. i read your build thread and this. my 96 that i just got sounds identical to the issues you had. I am tempted to do what you did. Unfortunately, we do not have pick n pulls up here, and the full service yards charge a ton. If you ever go back to the yard, let me know, i may be interested in paying you for some parts for me
PM sent.

and thanks for the feedback! i'm glad i could be of help.

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post #14 of 20 (permalink) Old 02-10-2017, 11:15 AM
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Great write up!

For anyone interested, I am taking on this 4 Bolt swap myself and was able to source the right adapters instead of having a custom hose made.
Here is a breakdown of the 6 fittings I ordered (total cost was about $50):

stock Pressure Hose (has -8 AN male fitting at steering gear end)
-ICT Billet #AN894-08-06B (-8 AN female to -6 AN male reducer)
-Russell #640040 (-6 AN female to -6 AN female 45deg coupler)
-Russell #648010 (-6 AN male to X 20 O-ring male)

4 Bolt steering gear (has X 20 O-ring port)

stock Return Hose (has -10 AN male fitting at steering gear end)
-Maxon F45001 (-10 AN female to -6 AN male reducer)
-Russell #640040 (-6 AN female to -6 AN female 45deg coupler, ^ same as pressure side)
-Russell #648030 (-6 AN male to 5/8 X 18 O-ring male)

4 Bolt steering gear (has 5/8 X 18 O-ring)

The steering gear I ordered is Cardone #27-7623

^ I HAVE FOUND ISSUE WITH THIS SET UP, PLEASE SEE NEW SET UP BELOW
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post #15 of 20 (permalink) Old 02-22-2017, 02:42 PM
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Quote:
Originally Posted by 5billiondead View Post
Great write up!

For anyone interested, I am taking on this 4 Bolt swap myself and was able to source the right adapters instead of having a custom hose made.
Here is a breakdown of the 6 fittings I ordered (total cost was about $50):

stock Pressure Hose (has -8 AN male fitting at steering gear end)
-ICT Billet #AN894-08-06B (-8 AN female to -6 AN male reducer)
-Russell #640040 (-6 AN female to -6 AN female 45deg coupler)
-Russell #648010 (-6 AN male to X 20 O-ring male)

4 Bolt steering gear (has X 20 O-ring port)

stock Return Hose (has -10 AN male fitting at steering gear end)
-Maxon F45001 (-10 AN female to -6 AN male reducer)
-Russell #640040 (-6 AN female to -6 AN female 45deg coupler, ^ same as pressure side)
-Russell #648030 (-6 AN male to 5/8 X 18 O-ring male)

4 Bolt steering gear (has 5/8 X 18 O-ring)

The steering gear I ordered is Cardone #27-7623
Is this for a sag or stock pump setup?

94' 302, e4od, 1356m, Manual hubs 33x12.5 tires. Fiberworx 4.5 inch flared fiberglass fenders/bedsides. Sag pump/4blt steering box swap in progress
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Matching set
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post #16 of 20 (permalink) Old 02-22-2017, 05:13 PM
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this is what i said in the other threads about this. what i would do is reuse the saginaw hose. cut the middle of the metal line on the gearbox side of it. buy a Superduty hose, and do the same. buy a couple of inverted flare nuts and inverted flare coupling of correct size. flare the ends of each metal tube and coupling them together. no need to adapt to AN fittings or run a custom hose. all you have to do is cut and flare the new and old hose jsut like if it were a big brake line or a tranny cooler line. any auto parts store should have those fittings and coupling for use for tranny cooler tubes. easy as pie
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-----96 5.0 E4OD--------------88 5.8 C6--------------96 5.8 E4OD------
---------KIA-------------------Mud/Trail---------------Daily Driver------
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post #17 of 20 (permalink) Old 02-22-2017, 06:06 PM
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Definetely more than one way to skin a cat on this. I would like to add that the setup I posted earlier in this thread and has about 500 miles on it in my truck now and has been working great. Didn't cost much and was super easy to install.

Quote:
Originally Posted by Alwaysdirty View Post
If its all good with Dash_Cam I would like to share how I am doing the high pressure side for my 4 bolt box and sag pump setup. I dont have it installed yet but have some pics of it setup on the bench.

High pressure hose, -6an x 24" w/ 90 & straight, Fragola part# FRAHSE3090-06-ST-24

High pressure fitting to steering box, 1/2"-20 o-ring to -6an, Russel part# 648010

Sag pump high pressure fitting, M16x1.5 oring to -6an, Russell part# 648060



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1995 Bronco, 351w, Hill Killer E4OD, 4.10's, 2" lift and 33's
SAS coming one of these days...
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post #18 of 20 (permalink) Old 02-23-2017, 07:25 AM
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Quote:
Originally Posted by Teal94 View Post
Is this for a sag or stock pump setup?
Saginaw. However, I have decided against using a bunch of adapters because I realized that the stock hoses have a flared end, which will probably leak when mated to a AN female fitting.

Instead I am replacing both the pressure hose AND installing an aftermarket cooler using this set up:

Steering Gear, Cardone #27-7623
Saginaw pump pressure fitting, Russell #648060
Pressure Hose, Fragola #372024
Steering Cooler, Hayden Automotive #1010 (comes with rubber hose + hose clamps)
Steering Gear pressure fitting, Russell #648030
Steering Gear return fitting, Russell #648010
Steering Gear return fitting adapter, Earl's #700167 (-6AN to 3/8 barb, adapts return fitting ^ to rubber hose)

Here is my build thread with pics showing the set up (post #88):
5billiondead's 94 EB build (2nd bronco)

Last edited by 5billiondead; 03-06-2017 at 08:04 AM. Reason: updated
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post #19 of 20 (permalink) Old 03-09-2017, 12:37 PM
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I found this while trying to research this swap. Can anyone confirm that Saginaw made all of the 4 bolt boxes?



Also, found this neat video explaining how it work:

AeXj35aOK7k
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post #20 of 20 (permalink) Old 03-09-2017, 03:31 PM Thread Starter
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Quote:
Originally Posted by 5billiondead View Post
I found this while trying to research this swap. Can anyone confirm that Saginaw made all of the 4 bolt boxes?
I can't confirm it, but that was what i found as well.
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