Img_0032.jpg
1709 hits | 62.22 KB | Posted: 5/24/04
Saginaw powersteering pump out of a '91 Ford van, much better than the stock pump the Broncos came w...

Dcp01229.jpg
1416 hits | 66.69 KB | Posted: 5/27/04
Powersteering pump rebuild kit ordered from Advance, cost $15 bucks.

Dcp01230.jpg
1322 hits | 79.52 KB | Posted: 5/27/04
Used a pulley puller to separate the pump from the bracket. You'll need to do this for the rebuild.

Dcp01232.jpg
1302 hits | 84.99 KB | Posted: 5/27/04
Now I put it in a vise to remove the high pressure fitting and the other retaining bolt for the rese...

Dcp01233.jpg
1228 hits | 86.33 KB | Posted: 5/27/04
Top bolt removed.

Dcp01234.jpg
1278 hits | 72.44 KB | Posted: 5/27/04
High pressure fitting removed this is the flow valve behind it, flow valve should always be replaced...

Dcp01235.jpg
1228 hits | 84.96 KB | Posted: 5/27/04
With the bolts removed from the resevoir and the unit in the vise, take a soft rubber mallet and hit...

Dcp01231.jpg
1121 hits | 86.89 KB | Posted: 5/27/04
This is what it will look like once the can has been removed.

sag1.jpg
1153 hits | 61.17 KB | Posted: 5/27/04
In this pic you can see three of the seals that will be replaced.

sag1.jpg
1088 hits | 65.28 KB | Posted: 5/27/04
In this pic you can see the retaining ring for the pump plate. This has to be removed. The is a smal...

Dcp01242.jpg
1150 hits | 61.52 KB | Posted: 5/27/04
Here the retaining ring is about to come out. Be careful as there is a spring behind this that will ...

Dcp01245.jpg
1101 hits | 80.27 KB | Posted: 5/27/04
With the retaining clip off the plate will not come out.

Dcp01246.jpg
1121 hits | 84.09 KB | Posted: 5/27/04
This is the spring behind the retaining plate.

Dcp01243.jpg
1152 hits | 63.74 KB | Posted: 5/27/04
I now removed the two other seals with my pick.

Dcp01244.jpg
1039 hits | 72.88 KB | Posted: 5/27/04

Dcp01248.jpg
1190 hits | 86.45 KB | Posted: 5/27/04
Flip the unit over and hit the shaft with a rubber mallet or hammer. Use something to protect the sh...

Dcp01250.jpg
1135 hits | 93.98 KB | Posted: 5/27/04
I wound up putting it back in the vise and using a small socket to get the shaft the rest of the way...

Dcp01251.jpg
1254 hits | 78.9 KB | Posted: 5/27/04
The internals of the pump coming out.

Dcp01249.jpg
1037 hits | 88.26 KB | Posted: 5/27/04
These parts will all come out before you complete remove the shaft from the pump. Make sure you don'...

Dcp01252.jpg
1077 hits | 82.76 KB | Posted: 5/27/04
Here's the shaft assembly completely removed.

Dcp01253.jpg
1067 hits | 62.75 KB | Posted: 5/27/04
The inside of the pump housing with everything removed.

Dcp01254.jpg
1069 hits | 77.79 KB | Posted: 5/27/04
The shaft had some scoring on it, so I used some fine grit sand paper and smoothed it out.

Dcp01255.jpg
1047 hits | 65.78 KB | Posted: 5/27/04
Remove the two large o-rings from inside of he pump. It was a little tricky getting the new ones to ...

Dcp01256.jpg
1020 hits | 86.38 KB | Posted: 5/27/04
Removing the shaft seal was a pain, I wound up using a small chisel and then pried it up.

Dcp01257.jpg
985 hits | 93.54 KB | Posted: 5/27/04
Jumping ahead, b/c the shaft seal was not wanting to come out I put the large o-ring on the case, th...

Dcp01258.jpg
976 hits | 91.16 KB | Posted: 5/27/04
Finally got the old seal out, and installed the new one. I used a socket the same size as the seal a...

Dcp01259.jpg
999 hits | 73.13 KB | Posted: 5/27/04
Installing the new inner o-rings.

Dcp01260.jpg
1006 hits | 78.61 KB | Posted: 5/27/04
Reinstalling the shaft. I used a rubber mallet to tap it down, it went in pretty easily. It was at t...

Dcp01261.jpg
940 hits | 64.85 KB | Posted: 5/27/04
Put all of the vanes back in their respective slots and put the inner part of the pump back over it....

Dcp01262.jpg
1046 hits | 74.3 KB | Posted: 5/27/04
Install the next part, again it can only go in one way so be patient. Once you get it right it will ...

Dcp01263.jpg
917 hits | 73.99 KB | Posted: 5/27/04
New seals for the fittings installed.

Dcp01264.jpg
940 hits | 76.43 KB | Posted: 5/27/04
I used my u-joint press to push the plate down so I could get the retaining ring on, the pressure fr...

Dcp01265.jpg
999 hits | 68.31 KB | Posted: 5/28/04
Cleaned up the resevoir. It was covered in grease as most salvage yard parts are.

Dcp01266.jpg
1068 hits | 68.04 KB | Posted: 5/28/04
The resevoir for my pump on had the two holes, some have a 3rd hole. Make sure the high pressure fit...

Dcp01267.jpg
1099 hits | 74.41 KB | Posted: 5/28/04
After lubing the o-ring on the pump with some powersteering fluid. Lightly tap the resevoir on with ...

Dcp01268.jpg
1012 hits | 67.07 KB | Posted: 5/28/04
Reinsert the spring.

Dcp01269.jpg
1004 hits | 62.19 KB | Posted: 5/28/04
Reinsert the flow valve. It has been said you shouldn't reuse the flow valve. I cleaned mine of with...

Dcp01270.jpg
1104 hits | 76.46 KB | Posted: 5/28/04
Put the high pressure fitting bolt in. Again this uses a 1 inch wrench.

Dcp01271.jpg
971 hits | 66.05 KB | Posted: 5/28/04
Put the top retaining bolt in and tighten it down this bolt is very short so be careful when tighten...

Dcp01274.jpg
1014 hits | 87.35 KB | Posted: 5/28/04
And the pump is rebuilt.

Dcp01275.jpg
889 hits | 82.2 KB | Posted: 5/28/04

Dcp01276.jpg
1086 hits | 84.03 KB | Posted: 5/28/04
Here the pump is reinstalled in the bracket, almost ready to put in the Bronco. Just need to put the...

Dcp01277.jpg
1077 hits | 74.95 KB | Posted: 5/28/04
The pulley has been put back on and the pump is ready to be installed.

Dcp01278.jpg
1122 hits | 72.22 KB | Posted: 6/1/04
To install the pump, remove the tubes from the airbox to the throttle body, this will allow access t...

Dcp01279.jpg
1040 hits | 73.67 KB | Posted: 6/1/04
The A/C is now accessable.

Dcp01281.jpg
996 hits | 64.54 KB | Posted: 6/1/04
Remove the serpentine belt.

Dcp01283.jpg
1026 hits | 76.5 KB | Posted: 6/1/04
Unplug the A/C harness, and move it out of the way, you don't want to risk ripping it off.

Dcp01284.jpg
1002 hits | 71.66 KB | Posted: 6/1/04
Start to remove the A/C bolts.

Dcp01285.jpg
1074 hits | 76.75 KB | Posted: 6/1/04
Once all of the bolts are removed use a bungee cord to hold the compressor out of the way. The brack...

Dcp01288.jpg
1006 hits | 74.12 KB | Posted: 6/1/04
Next I'll remove the high pressure line from the pump and then the gear box. My old C2 pump was real...

Dcp01290.jpg
958 hits | 68.36 KB | Posted: 6/1/04

Dcp01291.jpg
1064 hits | 79.64 KB | Posted: 6/1/04
It's a tight fit, but you'll be able to get a wrench in there to take the pressure fitting off.

Dcp01292.jpg
1048 hits | 76.96 KB | Posted: 6/1/04

Dcp01293.jpg
1074 hits | 87.26 KB | Posted: 6/1/04
The pressure fitting removed from the pump. At this point, don't forget to remove the return line ot...

Dcp01294.jpg
1034 hits | 72.06 KB | Posted: 6/1/04
Now you can remove the bolts from the pump bracket, there are 3 bolts and one nut.

Dcp01295.jpg
1052 hits | 107.05 KB | Posted: 6/1/04
The bracket w/pump will lift right out.

Dcp01297.jpg
1076 hits | 79.68 KB | Posted: 6/1/04
So here they are side by side, the most noticeable difference is the C2 resevoir is much smaller tha...

Dcp01302.jpg
1129 hits | 88.54 KB | Posted: 6/1/04
Here you can see the difference in the diameter of the compressor bolts. The one on the right works ...

Dcp01300.jpg
1107 hits | 77.65 KB | Posted: 6/1/04
I located a bit that would allow me to ream the holes out to the appropriate size. Basically I just ...

Dcp01301.jpg
1104 hits | 79.66 KB | Posted: 6/1/04
These aluminum shavings will go everywhere so be careful you don't get them into your airbox or thro...

Dcp01303.jpg
1131 hits | 90.53 KB | Posted: 6/1/04
Mount the high pressure hose. I reused my old hose, but had to use a tube bender to get the correct ...

Dcp01304.jpg
1114 hits | 86.75 KB | Posted: 6/1/04
Here you can see the bend I put in the tube, the allows you to get around the return line.

Dcp01305.jpg
1075 hits | 97.07 KB | Posted: 6/1/04
Now the bracket goes back in.

Dcp01306.jpg
1074 hits | 77.53 KB | Posted: 6/1/04
Reinstall the bolts on the front of the bracket.

Dcp01308.jpg
1024 hits | 80.77 KB | Posted: 6/1/04
The pumps in the return line is attached.

Dcp01311.jpg
1070 hits | 74.32 KB | Posted: 6/1/04
Here is a better angle of the bend I put in the high pressure hose to make it fit at the gear box. M...

Dcp01312.jpg
1075 hits | 81.68 KB | Posted: 6/1/04
Put the A/C compressor back on.

Dcp01313.jpg
1183 hits | 80.19 KB | Posted: 6/1/04
Reinstall the serpentine belt. I put the stock one on but it felt to tight so I stepped up one size....

Dcp01314.jpg
1013 hits | 77.33 KB | Posted: 6/1/04
This is the model serp belt I used, works perfectly. with a 302 and the sag swap.

Mvi_0067.avi
1350 hits | 6.72 MB | Posted: 6/1/04
Here it the pump working. Dollar for dollar, this was one of the best mods I have done. The pump doe...

IMG_5658.JPG
659 hits | 62.34 KB | Posted: 1/4/12

20140423_193735.jpg
479 hits | 70.47 KB | Posted: 4/24/14
This is the hose from an early '90s Ford van, NAPA part 7-1483, the routing is a little unusual, but...

20140423_193741.jpg
396 hits | 70.2 KB | Posted: 4/24/14

20140423_193755.jpg
418 hits | 68.07 KB | Posted: 4/24/14

20140606_095348.jpg
451 hits | 65.16 KB | Posted: 6/6/14
This is the correct belt for a sag swap on a 351W with the smog pump deleted.