Part # 2051614 – 1995-2004 Tacoma Rock Assault Power Steering Kit

To open a printable PDF version of this instruction CLICK HERE
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NOTE: This power steering upgrade kit only works after you have removed your rack and pinion steering system and have replaced with an 85-96 IFS steering box.

Tools Needed:

  • 3/8” Drive Ratchet w/ extension
  • Drill & 11/32” drill bit
  • ½”, ⅞”, 17mm, 18mm, 19mm Wrenches
  • 12mm, & 14mm Sockets
  • Crescent Wrench

Installation Notes:

    1. Read all instructions completely and carefully before you begin.

    2. Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Trail-Gear at (559) 252-4950.

    3. Park vehicle on a clean, dry, at, level surface and block the tires so the vehicle can not roll in either direction.


    Installation Instructions:

      1. Disconnect battery.

      2. Drain radiator.

      3. Grill must be removed at this point.

      4. Remove the lower fan shroud - 2 clips.

      5. Remove radiator.

      6. Remove belt.
    7. Remove ps pump and ps pump bracket.
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    8. Disconnect and plug vacuum ports.
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    9. Install new pump bracket.
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    10. Install new pump.
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    11. Using the reservoir bracket as a template, mark holes on fender and drill (11/32”) Note: The top of the bracket should be just above the fuse box.
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    12. Install reservoir.



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    13. Temporarily install suction line, and barbed fitting. Mark the hose to the proper length, and trim.
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    14. Apply light grease to barbed fitting and push hose over fitting.

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    15. Install new hose.

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    16. Install high pressure fitting onto the high pressure port on the steering box
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    17. Install high pressure hose.

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    18. Install cooler with round rubber spacers between the cooler and the A/C condenser .
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    19. Route the hoses through a hole in the radiator support.
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    20. Using hose clamps route steering box return line to top of cooler port and clamp.
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    21. Route lower hose to power steering reservoir

    22. Re-install belt.

    23. Re-install radiator and lower shroud.

    24. Re-install grill.

    25. Fill radiator.

    26. Fill the power steering system with synthetic power steering fluid. We recommend Royal Purple full synthetic fluid. When filling the reservoir, do not fill to the top, allow about 1/2" for fluid expansion due to heat. It will take some time to fully bleed the system the first time. With the vehicle on jack stands and tires completely off the ground, engine not running, turn the steering wheel from lock to lock several times and then refill the power steering reservoir with fluid. Note, this is done so that the power steering pump does not get started dry, which can cause damage to the pump. Now you’re ready to start the engine and turn the steering wheel from lock to lock, we recommend that you run the motor for about 5 minutes at a time during the bleeding. Allow the oil to set until all the bubbles have separated out of the oil, then run the motor again for 5 minutes. Repeat this procedure until the oil runs without foam or bubbles.