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Home/ Registry/ Ford/ Bronco/ 1992–1996/ “Big '92”/ Saginaw Powersteering Pump Rebuild & Swap supermotors.net/registry/2896/18217

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Saginaw Powersteering Pump Rebuild & Swap

From 1992 Ford Bronco “Big '92” — documented by Jeremy Millrood.

74 photos 1 video
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1992 Ford Bronco - Saginaw powersteering pump out of a '91 Ford van, much better than the stock pump the Broncos came with. I'll cover the installation of the… 1992 Ford Bronco - Powersteering pump rebuild kit ordered from Advance, cost $15 bucks. 1992 Ford Bronco - Used a pulley puller to separate the pump from the bracket. You'll need to do this for the rebuild. 1992 Ford Bronco - Now I put it in a vise to remove the high pressure fitting and the other retaining bolt for the resevoir. The high pressure fitting takes a… 1992 Ford Bronco - Top bolt removed. 1992 Ford Bronco - High pressure fitting removed this is the flow valve behind it, flow valve should always be replaced. There is a seal on the high pressure… 1992 Ford Bronco - With the bolts removed from the resevoir and the unit in the vise, take a soft rubber mallet and hit the resevoir. The can should come righ… 1992 Ford Bronco - This is what it will look like once the can has been removed. 1992 Ford Bronco - In this pic you can see three of the seals that will be replaced. 1992 Ford Bronco - In this pic you can see the retaining ring for the pump plate. This has to be removed. The is a small hole on the outside of the pump big e… 1992 Ford Bronco - Here the retaining ring is about to come out. Be careful as there is a spring behind this that will cause the plate to shoot out if you're… 1992 Ford Bronco - With the retaining clip off the plate will not come out. 1992 Ford Bronco - This is the spring behind the retaining plate. 1992 Ford Bronco - I now removed the two other seals with my pick. 1992 Ford Bronco - Close-up of a disassembled power steering pump, showing its internal mechanisms and metal housing. 1992 Ford Bronco - Flip the unit over and hit the shaft with a rubber mallet or hammer. Use something to protect the shaft from damage and small block of wood… 1992 Ford Bronco - I wound up putting it back in the vise and using a small socket to get the shaft the rest of the way out. 1992 Ford Bronco - The internals of the pump coming out. 1992 Ford Bronco - These parts will all come out before you complete remove the shaft from the pump. Make sure you don't lose any of the small flat pieces, th… 1992 Ford Bronco - Here's the shaft assembly completely removed. 1992 Ford Bronco - The inside of the pump housing with everything removed. 1992 Ford Bronco - The shaft had some scoring on it, so I used some fine grit sand paper and smoothed it out. 1992 Ford Bronco - Remove the two large o-rings from inside of he pump. It was a little tricky getting the new ones to fit. 1992 Ford Bronco - Removing the shaft seal was a pain, I wound up using a small chisel and then pried it up. 1992 Ford Bronco - Jumping ahead, b/c the shaft seal was not wanting to come out I put the large o-ring on the case, this is the one that seals the resevoir t… 1992 Ford Bronco - Finally got the old seal out, and installed the new one. I used a socket the same size as the seal and gently tapped it in. 1992 Ford Bronco - Installing the new inner o-rings. 1992 Ford Bronco - Reinstalling the shaft. I used a rubber mallet to tap it down, it went in pretty easily. It was at this point, I realized I had forgotten t… 1992 Ford Bronco - Put all of the vanes back in their respective slots and put the inner part of the pump back over it. There were two metal rods that came ou… 1992 Ford Bronco - Install the next part, again it can only go in one way so be patient. Once you get it right it will drop right in. 1992 Ford Bronco - New seals for the fittings installed. 1992 Ford Bronco - I used my u-joint press to push the plate down so I could get the retaining ring on, the pressure from the spring behind it makes it imposs… 1992 Ford Bronco - Cleaned up the resevoir. It was covered in grease as most salvage yard parts are. 1992 Ford Bronco - The resevoir for my pump on had the two holes, some have a 3rd hole. Make sure the high pressure fitting hole and the other bolt hole are b… 1992 Ford Bronco - After lubing the o-ring on the pump with some powersteering fluid. Lightly tap the resevoir on with a rubber mallet. (Note, the resevoir wi… 1992 Ford Bronco - Reinsert the spring. 1992 Ford Bronco - Reinsert the flow valve. It has been said you shouldn't reuse the flow valve. I cleaned mine of with carb cleaner and it was good to go. 1992 Ford Bronco - Put the high pressure fitting bolt in. Again this uses a 1 inch wrench. 1992 Ford Bronco - Put the top retaining bolt in and tighten it down this bolt is very short so be careful when tightening. I used an 18 mm closed end wrench… 1992 Ford Bronco - And the pump is rebuilt. 1992 Ford Bronco - A power steering pump is shown on a workbench with various automotive fluids and tools in the background. 1992 Ford Bronco - Here the pump is reinstalled in the bracket, almost ready to put in the Bronco. Just need to put the pulley back on. 1992 Ford Bronco - The pulley has been put back on and the pump is ready to be installed. 1992 Ford Bronco - To install the pump, remove the tubes from the airbox to the throttle body, this will allow access to the top A/C compressor. 1992 Ford Bronco - The A/C is now accessable. 1992 Ford Bronco - Remove the serpentine belt. 1992 Ford Bronco - Unplug the A/C harness, and move it out of the way, you don't want to risk ripping it off. 1992 Ford Bronco - Start to remove the A/C bolts. 1992 Ford Bronco - Once all of the bolts are removed use a bungee cord to hold the compressor out of the way. The bracket is now easily accessable. 1992 Ford Bronco - Next I'll remove the high pressure line from the pump and then the gear box. My old C2 pump was really beat up. The plastic pulley was even… 1992 Ford Bronco - Close-up view of metal lines connected to a power steering pump assembly. 1992 Ford Bronco - It's a tight fit, but you'll be able to get a wrench in there to take the pressure fitting off. 1992 Ford Bronco - Close-up view of the power steering pump assembly, showing hoses and electrical wiring. 1992 Ford Bronco - The pressure fitting removed from the pump. At this point, don't forget to remove the return line otherwise you'll have a difficult time ta… 1992 Ford Bronco - Now you can remove the bolts from the pump bracket, there are 3 bolts and one nut. 1992 Ford Bronco - The bracket w/pump will lift right out. 1992 Ford Bronco - So here they are side by side, the most noticeable difference is the C2 resevoir is much smaller than the Saginaw, and it's also made of pl… 1992 Ford Bronco - Here you can see the difference in the diameter of the compressor bolts. The one on the right works with the Saginaw bracket. 1992 Ford Bronco - I located a bit that would allow me to ream the holes out to the appropriate size. Basically I just matched the diameter of the bolts with… 1992 Ford Bronco - These aluminum shavings will go everywhere so be careful you don't get them into your airbox or throttle body. 1992 Ford Bronco - Mount the high pressure hose. I reused my old hose, but had to use a tube bender to get the correct bend in it. This is not very difficult,… 1992 Ford Bronco - Here you can see the bend I put in the tube, the allows you to get around the return line. 1992 Ford Bronco - Now the bracket goes back in. 1992 Ford Bronco - Reinstall the bolts on the front of the bracket. 1992 Ford Bronco - The pumps in the return line is attached. 1992 Ford Bronco - Here is a better angle of the bend I put in the high pressure hose to make it fit at the gear box. Make sure the fitting threads properly i… 1992 Ford Bronco - Put the A/C compressor back on. 1992 Ford Bronco - Reinstall the serpentine belt. I put the stock one on but it felt to tight so I stepped up one size. Don't forget to add powersteering flui… 1992 Ford Bronco - This is the model serp belt I used, works perfectly. with a 302 and the sag swap. 1992 Ford Bronco - Here it the pump working. Dollar for dollar, this was one of the best mods I have done. The pump doesn't whine and it turns the tires effor…Video 1992 Ford Bronco - Power steering lines and assorted tools are laid out on a workbench. 1992 Ford Bronco - This is the hose from an early '90s Ford van, NAPA part 7-1483, the routing is a little unusual, but it works and all of the connections bo… 1992 Ford Bronco - Close-up view of a vehicle's power steering pump and associated hoses, showing mechanical components and fluid lines. 1992 Ford Bronco - Close-up view of a power steering pump with attached metal lines. 1992 Ford Bronco - This is the correct belt for a sag swap on a 351W with the smog pump deleted.