Jeremy Millrood > 1992 Ford Bronco > open folder Saginaw Powersteering Pump Rebuild & Swap

Saginaw powersteering pump out of a '91 Ford van, much better than the stock pump the Broncos came w...
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Powersteering pump rebuild kit ordered from Advance, cost $15 bucks.
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Used a pulley puller to separate the pump from the bracket. You'll need to do this for the rebuild.
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Now I put it in a vise to remove the high pressure fitting and the other retaining bolt for the rese...
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Top bolt removed.
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High pressure fitting removed this is the flow valve behind it, flow valve should always be replaced...
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With the bolts removed from the resevoir and the unit in the vise, take a soft rubber mallet and hit...
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This is what it will look like once the can has been removed.
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In this pic you can see three of the seals that will be replaced.
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In this pic you can see the retaining ring for the pump plate. This has to be removed. The is a smal...
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Here the retaining ring is about to come out. Be careful as there is a spring behind this that will ...
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With the retaining clip off the plate will not come out.
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This is the spring behind the retaining plate.
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I now removed the two other seals with my pick.
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Flip the unit over and hit the shaft with a rubber mallet or hammer. Use something to protect the sh...
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I wound up putting it back in the vise and using a small socket to get the shaft the rest of the way...
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The internals of the pump coming out.
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These parts will all come out before you complete remove the shaft from the pump. Make sure you don'...
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Here's the shaft assembly completely removed.
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The inside of the pump housing with everything removed.
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The shaft had some scoring on it, so I used some fine grit sand paper and smoothed it out.
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Remove the two large o-rings from inside of he pump. It was a little tricky getting the new ones to ...
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Removing the shaft seal was a pain, I wound up using a small chisel and then pried it up.
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Jumping ahead, b/c the shaft seal was not wanting to come out I put the large o-ring on the case, th...
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Finally got the old seal out, and installed the new one. I used a socket the same size as the seal a...
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Installing the new inner o-rings.
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Reinstalling the shaft. I used a rubber mallet to tap it down, it went in pretty easily. It was at t...
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Put all of the vanes back in their respective slots and put the inner part of the pump back over it....
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Install the next part, again it can only go in one way so be patient. Once you get it right it will ...
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New seals for the fittings installed.
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I used my u-joint press to push the plate down so I could get the retaining ring on, the pressure fr...
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Cleaned up the resevoir. It was covered in grease as most salvage yard parts are.
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The resevoir for my pump on had the two holes, some have a 3rd hole. Make sure the high pressure fit...
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After lubing the o-ring on the pump with some powersteering fluid. Lightly tap the resevoir on with ...
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Reinsert the spring.
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Reinsert the flow valve. It has been said you shouldn't reuse the flow valve. I cleaned mine of with...
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Put the high pressure fitting bolt in. Again this uses a 1 inch wrench.
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Put the top retaining bolt in and tighten it down this bolt is very short so be careful when tighten...
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And the pump is rebuilt.
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Here the pump is reinstalled in the bracket, almost ready to put in the Bronco. Just need to put the...
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The pulley has been put back on and the pump is ready to be installed.
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To install the pump, remove the tubes from the airbox to the throttle body, this will allow access t...
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The A/C is now accessable.
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Remove the serpentine belt.
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Unplug the A/C harness, and move it out of the way, you don't want to risk ripping it off.
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Start to remove the A/C bolts.
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Once all of the bolts are removed use a bungee cord to hold the compressor out of the way. The brack...
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Next I'll remove the high pressure line from the pump and then the gear box. My old C2 pump was real...
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It's a tight fit, but you'll be able to get a wrench in there to take the pressure fitting off.
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The pressure fitting removed from the pump. At this point, don't forget to remove the return line ot...
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Now you can remove the bolts from the pump bracket, there are 3 bolts and one nut.
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The bracket w/pump will lift right out.
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So here they are side by side, the most noticeable difference is the C2 resevoir is much smaller tha...
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Here you can see the difference in the diameter of the compressor bolts. The one on the right works ...
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I located a bit that would allow me to ream the holes out to the appropriate size. Basically I just ...
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These aluminum shavings will go everywhere so be careful you don't get them into your airbox or thro...
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Mount the high pressure hose. I reused my old hose, but had to use a tube bender to get the correct ...
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Here you can see the bend I put in the tube, the allows you to get around the return line.
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Now the bracket goes back in.
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Reinstall the bolts on the front of the bracket.
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The pumps in the return line is attached.
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Here is a better angle of the bend I put in the high pressure hose to make it fit at the gear box. M...
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Put the A/C compressor back on.
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Reinstall the serpentine belt. I put the stock one on but it felt to tight so I stepped up one size....
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This is the model serp belt I used, works perfectly. with a 302 and the sag swap.
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Here it the pump working. Dollar for dollar, this was one of the best mods I have done. The pump doe...
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This is the hose from an early '90s Ford van, NAPA part 7-1483, the routing is a little unusual, but...
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This is the correct belt for a sag swap on a 351W with the smog pump deleted.
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