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Lick my balls
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Discussion Starter · #1 ·
So in reference to this thread, I've decided to finally get off my butte and install it already. Yesterday, after a few hours of OT I decided to do the install. I began by laying everything out on the floor.


After removing the air intake hoses from my way, and the Factory AC, I removed the factory power steering pump pulley to install the pulley that came with my pump. I had some problems installing the tool to remove the stock pulley and because it was so difficult to thread on, I assumed it was metric. Well just to let any of you who are planning on doing this...it is not metric I ended up buying a universal pulley removal kit for nothing, oh well now I can work on any make and model.
All you need, to be sure, is to spend a few bucks on a 3/8" UNC tap for a blind hole to chase the thread and clean up any crap that is in there. So here it is after I finally got it on.


Next, I had to move the AC tube from in front of my power steering filler neck, to the rear of the filler neck

You have to be careful, very careful you don't rupture the line.

Then I had to move or rather bend a power steering line out of the way. Once again, you have to be very careful you don't rupture the line. I bent it down and shoved the rubber line under the inner fender skirt. It doesn't show in this pic, but I got a length of heater hose, cut it length wise and wrapped the rubber part of the power steering line with the heater hose so that the inner wheel well doesn't wear through the line.



Next, I had to mount the bracket allowing me to mount the pump. One problem, the longer bolts, which were supplied, were too small in diameter and the holes in the bracket were drilled small to match the bolts. After some investigating, I came to the conclusion that the factory bolts were long enough (for now) and instead of the using the shims which came with the narrow bolts, I used 5 washers instead, per bolt.


I mounted the pump and was very happy with my progress.


I did, however, notice that I would have to make a bracket to keep my air filter and hoses up and out of the way. Not a big deal.


So now all I have to do is install the belt that goes from the pump to the new pulley I installed on the power steering pump. HMMMMMMMMMMM, something tells me this wont be happening right now.


I think I know why Dave sold this to me ( don't get defensive, or uppity Dave, I am not upset). Oh well, I'm a fabricator, I will make a new bracket just like the old one accept I will move the pump 1 3/8" back and then I will be back on track.


The part that confuses the hell out of me, is that stamped right on the bracket is patent pending with some #s to go with that and also stamped on there is the fact that it is for Broncos between 80 (I think) and 96.
So in the mean time I worked on the air tanks and got the location picked out and a bracket made up to mount the tanks to. I will post pics of that later, once the bracket is welded on the truck and the fittings I still need are figured out.
That's it for now, I hope this will be of some use to some of you out there.
 

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ate lug
88 + 96 broncos, 96 F250
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The clutch doesnt line up, cuz thats not the right clutch. York put a ton of different ones on, but the #1 most common was the Double-V pulley. Thats the one that every OBA kit currently on the market uses. If you cant find one in a yard, you can get a new one from Kilby.
 

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Lick my balls
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Discussion Starter · #3 ·
reptillikus said:
The clutch doesnt line up, cuz thats not the right clutch. York put a ton of different ones on, but the #1 most common was the Double-V pulley. Thats the one that every OBA kit currently on the market uses. If you cant find one in a yard, you can get a new one from Kilby.
I figured I can buy the right clutch pulley somewhere, but right now money is tight and I still have to buy miscellaneous parts to finish this job...plus I want to insure my 55 Buick for the summer. I will just make a new bracket for the pump. It looks to me like I can move the pump back the 1 3/8" and still be able to remove the power steering pump dip stick.
 

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Past Bronco Owner
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Why not weld a 2" x 1/4" (or whatever the thickness) plate to the front of the mount and redrill the holes?
 

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reptillikus said:
The clutch doesnt line up, cuz thats not the right clutch. York put a ton of different ones on, ...
Yup... My York's from a Freightliner, and when I got my brackets from Zebrafive, I wasn't able to use the adjuster bracket, because of the york pulley. Thankfully, I had enough foresight to get the adjuster bracket from the Freightliner, and after some shimming of everything, I was able to get it lined up


I like yours, better, tho... alot cleaner
 

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Lick my balls
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Discussion Starter · #6 ·
90Beater said:
Why not weld a 2" x 1/4" (or whatever the thickness) plate to the front of the mount and redrill the holes?
You mean splice a piece to the rear of the plate...I guess that would be easier than making a whole new bracket. I'm not even sure if we have any aluminum at the shop I work at. I know we have stainless and mild steel. If we have some 1/4" aluminum, I think I will go that route. Thanks for the suggestion.
 

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waltman said:
You mean splice a piece to the rear of the plate...I guess that would be easier than making a whole new bracket. I'm not even sure if we have any aluminum at the shop I work at. I know we have stainless and mild steel. If we have some 1/4" aluminum, I think I will go that route. Thanks for the suggestion.

I'm taking a second look at the bracket so I will try annd be more specific.

You want to butt join the 2" plate to the front of the bracket where it mounts to the AC. That will push the top part where the york mounts back.

That bracket looks like steel. Is it aluminum?

I guess you can add to the back of the top part but it looks like your clearances are tighter there.
 

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Lick my balls
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Discussion Starter · #8 ·
90Beater said:
I'm taking a second look at the bracket so I will try annd be more specific.

You want to butt join the 2" plate to the front of the bracket where it mounts to the AC. That will push the top part where the york mounts back.

That bracket looks like steel. Is it aluminum?

I guess you can add to the back of the top part but it looks like your clearances are tighter there.
If splicing a piece to the front of the AC side of the plate or the rear of the pump side of the plate will work, I will pick the easiest side. I was thinking too, that if there is no aluminum at my shop, I will just go and buy a length of 1 1/2" x 1/4" aluminum flatbar, can't be that much.

However a SAG upgrade, although it appeals to me, is not in the cards this year...they are all maxed right now. :toothless
 

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Lick my balls
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Discussion Starter · #9 ·
kf4amu said:
15 bucks man!!!
REALLY!?!?!!!?????? I thought this upgrade involved buying a new pump and whatnot and if I replaced the pump, than I would also have to replace the inlet and outlet lines while I'm there. But at the same time, my power steering system works just fine, so I'll save that job for a later date.

It turns out my shop doesn't deal in aluminum at all. But I remembered on the way home from work that a friend of mine builds aluminum boats and has lots of aluminum kicking around. I'm gonna have to see what he is up to.
 

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ate lug
88 + 96 broncos, 96 F250
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Just the hi-pressure line, the low pres. side is just rubber tube.
But, the pulley wont fit the Sag, so then you have to machine it, and then you have to shim the pump to get the pulley back in alignment, and then the york clutch goes out of alignment with that so you have to mod the york bracket again. also you need to space the bracket up off the a/c compressor just to clear the Sag's filler neck even though youll never get it open again with the bracket installed....
Its alot of work to get the York to work there, with a Sag installed.
 

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waltman said:
REALLY!?!?!!!?????? I thought this upgrade involved buying a new pump and whatnot and if I replaced the pump, than I would also have to replace the inlet and outlet lines while I'm there. But at the same time, my power steering system works just fine, so I'll save that job for a later date.
Waltman, just FYI, I got the pump and bracket from Wasney's for $25 (three years ago), the pressure hose was $28, and a longer belt was $20. I know a few guys that have just re-bent the original pressure hose, and I did have to re-bend the van one that I bought.
 

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Lick my balls
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Discussion Starter · #12 ·
reptillikus said:
Just the hi-pressure line, the low pres. side is just rubber tube.
But, the pulley wont fit the Sag, so then you have to machine it, and then you have to shim the pump to get the pulley back in alignment, and then the york clutch goes out of alignment with that so you have to mod the york bracket again. also you need to space the bracket up off the a/c compressor just to clear the Sag's filler neck even though youll never get it open again with the bracket installed....
Its alot of work to get the York to work there, with a Sag installed.
That right there sounds like more hasle than it's worth. I will consider this option when the factory pump either starts to make noise, or simply fails. In the mean time, I called my buddy, and he said he has some aluminum flatbar kicking around. So tomorrow, I will be splicing a piece to the york side of the bracket, since it is the shortest length and I think the best choice. I will then zip cut the excess aluminum off the front side. If all goes well, I will have the york up and running this weekend.
 

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Lick my balls
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Discussion Starter · #13 ·
bronco boy said:
Waltman, just FYI, I got the pump and bracket from Wasney's for $25 (three years ago), the pressure hose was $28, and a longer belt was $20. I know a few guys that have just re-bent the original pressure hose, and I did have to re-bend the van one that I bought.
that sounds reasonable. but like I said, I'll wait. As far as the pressure line goes, I already bent it to clear the york. Thanks though, when the time comes, I will give Wasney's a call.
 

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Try it now!!
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reptillikus said:
Just the hi-pressure line, the low pres. side is just rubber tube.
But, the pulley wont fit the Sag, so then you have to machine it, and then you have to shim the pump to get the pulley back in alignment, and then the york clutch goes out of alignment with that so you have to mod the york bracket again. also you need to space the bracket up off the a/c compressor just to clear the Sag's filler neck even though youll never get it open again with the bracket installed....
Its alot of work to get the York to work there, with a Sag installed.
I dont know why the York clutch would go out of alignment by going to a Sag. He's already modifying the bracket so a .5 inch spacer wouldnt be a big deal if he has a clearance problem.


Walt, I spent 15 bucks on the pump, bracket and high pressure line from the junkyard and it works fine for the last 3 years. On a wheelin trip the PS was cutting in and out toward the end of the day...I think it got really hot due to one of my e-fans not working, AC on, and it was hot all day.
 

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waltman, looking good. I have started on my broncoair kit install too. i bent the p/s pump line similar to yours, although i had to move some abs crap. the ac line is different. i put mine up kinda sketch-style...i will post a pic or two so yall can tell me if its no good or not. what i am really asking is how did you get that line bent so well with out breaking it?? mine was a bi#$c to bend so, like i said, its sketch.
 

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Lick my balls
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Discussion Starter · #17 ·
96broncoman said:
waltman, looking good. I have started on my broncoair kit install too. i bent the p/s pump line similar to yours, although i had to move some abs crap. the ac line is different. i put mine up kinda sketch-style...i will post a pic or two so yall can tell me if its no good or not. what i am really asking is how did you get that line bent so well with out breaking it?? mine was a bi#$c to bend so, like i said, its sketch.
I would like to say skill, but luck, I think played a bigger role. I fully expected the rebending to suddenly become easey.
My AC system is totaly empty so I wasn't too carefull about bending it out of the way, yet at the same time I was...you know what I mean? I had to bend it from the front of the pump neck to the back, and then I had to bend it up and back even more. I am truely surprised, and happy :chili: it did not break. Bottom line be very careful and do what bronco boy suggested.

So I just got back from my buddies place and he welded a piece of scrap aluminum to the one side. Tomorrow, I will cut the excess off the spliced piece, at the top and cut off part of the original plate at the bottom, clean up the weld and slot new holes. It doesn't look too pretty now but tommorow it will look as good as new.
 

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Lick my balls
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Discussion Starter · #18 ·
Here is the bracket after I trimmed it down and reslotted the holes using a wood router, of all things. I ended up drilling 3 holes at 7/16" per slot and then while applying very gentle pressure I slotted the aluminum plate. While slotting the third hole, th bit exploded, leaving me with less than half the bit to try and finish the last hole. I was able to join the holes on the last slot before it broke at the shank. I was able to finish off the last two slots with a file.

I should make this part very clear. Slotting the holes with a router is very dangerous and safety gear and extreme caution should be used.

anyways, here is the pic


and here it is mounted and painted


and as you can see, the pulley now lines up. :thumbup



I should add that I got very lucky. I was almost unable to put the fourth bolt in for the pump, due to the power steering pump neck being so close. I was able to pry the plastic neck over enough so that I was able to get a bolt in through the hole. The best part is that the dip stick for the power steering is accessable.


I bought a 7 gallon air tank for $42 on monday (after discovering the tank I was planning on using was rotted.) I will probably complete the job this weekend, if I am not working OT.
 

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jam0o0 said:
it is time for you to finish and update your thred. i wanna see how you get from the york fittings to the air line.
What's the big deal? He'll probably just use a barbed fitting. Or did I miss something? :confused:

And yes, it is time for him to finish and update this thread. :toothless
 
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