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Discussion Starter #1
I knew that I wanted a welded front and that I wanted hydro assist. I didn't come up with anything new, just gathered info from other posts on this site and used a few different vendors.

First I followed Bronkzilla's drilling and tapping instructions here:

http://www.fullsizebronco.com/forum/showthread.php?t=10413

Ordered the same parts as derrick36 here:

http://fullsizebronco.com/forum/showthread.php?t=98041&highlight=hydro+assist

**Borrowed from Derrick's thread**

2x8 Surplus Center Ram - Chief Brand



Fittings for steering box



Fittings for Ram




90 Degree Swivel Fittings



Hydraulic Hoses



Caps just in case something goes wrong.



Here are the other items I ordered to complete my system.

Fabricated diff cover from Great Lake Offroad



Tabs from Offroad Overstock



1.5" OD Tubing clamp from Ballistic Fabrication



I extended my Saginaw pump reservoir really cheaply by clamping a radiator hose to the pump inlet. I had tried to be neat with a toyota PS reservoir, but the saginaw did not like the set up I had.

Here is the final set-up. Sorry for the dirty/oily pictures. I didn't have time to take pictures once I completed it because I was out the door for a wheeling trip.







It functions great at slow speeds but has a little lag at high speeds. I believe the lag at high speed is from the larger bore of the cylinder. If I had went with a smaller bore cylinder, I wouldn't have the lag. Just like everyone else, I can steer effortlessly with a welded front in a very high traction/bound up environment.

Also, be sure you have your steering box centered (adjust the drag link to center). I didn't think of this until I was going down the road with it. If you are off center, the ram will want to push the tie rod making you fight it all the time. This is a small pain, but large enough for me to center my box.

The combination of knuckle under steering, the Great Lake Offroad Diff cover, the 1.5" OD tie rod and the hydro cylinder make for a very tight fit. The tie rod is fractions of an inch off the diff cover and hydro cylinder at full lock, but everything clears.
 

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Discussion Starter #5
Yup, 2x8. All of the sizes and part numbers are in the threads I linked to, I might as well update the first post to include everything.

First post updated with links and parts. Like I said, I did not find these myself, I used the knowledge base of FSB.
 

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Discussion Starter #6
Another point to bring up. Before I ordered my diff cover, I talked with Sean at GLO about his covers. I originally wanted to add the 1/2" mid-plating option for additional strength and a sturdy mount for the cylinder, but with that cover, there would be no way I could have ran a 1.5" tie rod.

I asked Sean if he knew anyone running their covers without the mid-plating and using it for a hydro mount. He stated he has been running his that way for a long time with no problems. The only thing was that he was stretching the diff cover bolts and recommended to go to studs. He said once he switched to studs, he didn't have that problem anymore.

I have also been told that Dana 60's do not like to hold diff cover bolts, especially if you are hard on them - hitting them on rocks, mounting hydro cylinders to them. I cleaned out the bolt holes with Brake Cleaner and used red loctite on the bolts but they still managed to loosen up. For the time being I am going to move to a socket head cap screw (allen-head bolt) and see if that helps. If not, I will move to studs.
 

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1996 Bronco 5.0/E4OD/BW1356
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Airbags - you bastard :goodfinge Nice setup- I'll be using this as a guide.

So you welded one of those giant tabs on the top of the diff cover for the ram mount? Got a pic of that?
 

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Discussion Starter #9
The diff cover is 1/4" plate and the ring is 1/2". Great Lake Offroad did not see any problems with it and plus they have a lifetime warranty so I'm not too concerned. There are some very close tolerance bends in the cover and it looks to be machine welded (or a damn good welder). These two in combination provide a lot of strength.

Yes, the tab is welded to the outer ring on the diff cover. I'll see what kind of picture I can get in there.
 

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The diff cover is 1/4" plate and the ring is 1/2". Great Lake Offroad did not see any problems with it and plus they have a lifetime warranty so I'm not too concerned. There are some very close tolerance bends in the cover and it looks to be machine welded (or a damn good welder). These two in combination provide a lot of strength.

Yes, the tab is welded to the outer ring on the diff cover. I'll see what kind of picture I can get in there.
Thx - I know all about thier products, I'll have one on my D60 as well :thumbup

How much money do you think you have sunk into your hydro setup?
 

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Discussion Starter #11
I probably have close to $400 into the whole thing and that is including a "rebuilt" steering box off ebay. I already had the saginaw pump so I didn't include that. I'm counting everything I had to buy to go from my old setup this. I've bought all of these items over the course of a year so I didn't have to pay all at once.

Going from completely stock to this setup would get you into around $600 plus or minus.
 

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Discussion Starter #13
The stock pump wines with big tires on its own. I would say you should bump up to the saginaw purely for the better quality pump.

I will also be modding my saginaw pump for more flow to help on high speed stuff.
 

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So how did the whole thing turn out. I'm looking for similar write ups for hydro assist but with the TTB. I know that it' not exatcly what others would think about but I'm not going to give up on the IFS just yet.

Now when your talking about high speed, does that mean that your RPM's are high as well? Or just needing to turn the wheel at a moments notice.

Where did you get your pump from? I found about 10 of them in the bone yard today but all of them are from Chrysler's, would these work or would I have to modify the pulley some to get it to fit the pump?

Aside from the mods that were posted did you do anything else?
 

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Discussion Starter #19
I would not do hydro assist on the TTB with these parts.

I when I try to turn the wheel fast, RPM's do not matter. I end up fighting the system as the fluid return is not large enough in the stock box. I am working to correct that now. The pump is a pump from any late model E-series van and has been talked about a lot on here.
 

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Discussion Starter #20
I would not do hydro assist on the TTB with these parts.

I when I try to turn the wheel fast, RPM's do not matter. I end up fighting the system as the fluid return is not large enough in the stock box. I am working to correct that now. The pump is a pump from any late model E-series van and has been talked about a lot on here.
 
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