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Tools Needed:
- 3/8” Drive Ratchet w/ extension
- Metric Socket Set
- Metric Wrench Set
- Screwdrivers - Flat/Philips
- Crescent Wrench
- Drill & 3/4” Uni-bit
- 15/16” Wrench
- Hose Cutter
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.
NOTE: Never use ATF uid, or a semi-synthetic blend. This will void the warranty. Ok to use standard power steering uid or a full synthetic. Royal Purple fully synthetic power steering uid recommended.
- 1. Remove the battery.
2. Remove Air Box, Disconnecting vacuum lines, and
electrical connections as needed
- 3. Remove marker lights and grill.
3. Continued
4. Drain radiator, disconnect hoses, remove lower fan
shroud, and remove radiator.
5. Remove power steering pump retaining main bolt for later
use.
6. Fasten Tension Bracket to PS Pump using 5/16 x 2 ¾”
bolt, 8mm bolt, and washers. Install New Power Steering
pump using retained main bolt and spacer.
6. Continued - Install New Power Steering pump using retained main
bolt and spacer.
7. Fasten reservoir to bracket, and support bracket with
3/8” nuts and bolts
8. Temporarily install air box making sure reservoir location
is clear of air tube. Mark hole locations, and drill through
inner fender with 8mm drill bit.
9. Fasten to inner fender with 3 8mm bolts and nuts.
10. Connect 90°JIC tting to Super ex hose, and attach to
bottom of reservoir. Connect #10 Barbed tting to
pump. Mark Super ex hose and trim to desired length
and connect to barbed tting.
11. Fasten Cooler to radiator, and cut holes through fan
shroud in line with cooler connection points. NOTE:
Hoses shown for illustration purposes only.
12. Temporarily install radiator. Connect return line (#6 hose
with 90° tting) to reservoir and run hose to lower cooler
connection point through lower hole in fan shroud. Mark
hose and cut to necessary length. Remove radiator, and
connect hoses to cooler with hose clamps.
- 13. Install radiator and connect upper return hose to the
steering box with hole clamps and lower return hose to
reservoir.
14. Re-assemble remaining components in reverse order. Fill the
15. 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 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.
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