Power Steering Kit Installation

If you are running larger tires or a locker up front, power steering is a must have accessory. In addition to the installation kit you will need the power steering pump, hoses and reservoir from a Geo Tracker or a Suzuki Sidekick. Can't find the parts locally give Calmini a call at 1 800 345 3305. They have steering gear boxes in stock. For the hoses, pump and reservoir try  Hawk Enterprises at 1 888 SAMURAI.

Power Steeering Kit
Calmini Part Number SS1580

Tools and Parts:

  • Metric Hand Tools
  • Drill motor and bits
  • Pickle fork
  • Pump, reservoir and hoses
  • Steering box and pitman arm

Parts included in kit:

  • 2 - 12 x 90mm bolts
  • 1 - 12 x 70mm bolt
  • 2 - 10 x 25mm bolts
  • 1 - 10 x 20mm bolt
  • 1 - 8 x 45mm bolt
  • 6 - 12mm nuts
  • 6 - 1/2" lock washers
  • 2 - 5/8 x 3/4 spacers
  • 1 - 5/8 x 1 1/8 spacer
  • 1 - 1 1/4 x 5/16 bolt
  • 1 - 5/16 Nylock nut
  • 1 - 1/4 x 3/4
  • 1 - 1/4 lock washers
  • 2 - 8 x 30mm bolts
  • 1 - frame adapter
  • 1 - pump adapter
  • 1 - U -joint
  • 1 - belt
  • 1 - pulley

Steering stablizer Remove the stock steering stabilizer.

Radiator bolts Remove the 4 radiator bolts.

Radiator removal Pull the radiator out from the top.

psradbracket.jpg (19148 bytes) Remove radiator supports from the frame.

Rag joint removal Stock rag joint removal.

Steering shaft Steering shaft also comes out. now is a good time to center the steering wheel.

Steering shaft Modify steering shaft to collapse. Drill out the two plastic pins and collapse the shaft. Heat may help this process. Do not hammer ends of the shaft.

psnewujoint.jpg (205637 bytes) New U joint replaces rag joint.

Drag link Drag link removal.

Pickle Fork Ball joint removal. Sometimes you can leave the nut on loosely and tap it with a hammer and it will come loose.

Gearbox removal Stock gear box removal (outside detail)

Stock gearbox Stock gear box removal (inside detail)

Frame plate New frame adapter plate hardware installation.

Frame plate installed Install frame plate in the place of the stock gear box.

Donor box Install donor gear box.

Do not remove pulley Remove the small crank pulley bolts, leave the pulley in place.

New pulley Install the new serpentine pulley over the stock pulley.

Pump engine plate Install pump adapter plate to the engine.

Belts Belt detail.

Steering shaft Pump bracket & steering shaft install.

Drag link install Connect drag link to pitman arm.

Reservoir detail Reservoir & pump installed.

Completed Kit Completed Power Steering Kit.

Check all bolts and top off fluids. Cycle the completed steering conversion. Check for leaks and enjoy the newly installed power steering kit.

08/23/10 14:04




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