Notice: We request that you don't just set up a new account at this time if you are a previous user.
If you used to be one of our moderators, please feel free to reach out to Chris via the facebook Outerlimits4x4 group and he will get you set back up with access should he need you.
Recovery:If you cannot access your old email address and don't remember your password, please click here to log a change of email address so you can do a password reset.

60series steering upgrade on the 40

Tech Talk for Cruiser owners.

Moderators: toaddog, Elmo, DUDELUX

Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

RAY185 wrote:Andy, what brand steering dampener do you want? I can get you Monroe or Maxitrac unless you were thinking something else.

These guys are good for high pressure hoses, they'll come to you and make one to suit.

http://www.mobileautohoses.com.au/

Ring them for a price.
I was going to get one from the wreckers initially along with a high pressure line from a 60, again from the wreckers..

i figure i've paid $250 for the bits for the conversion so I'll make sure I can get all the bits I can for the $$

I'll keep the hose dude in mind.. i doubt they'd come out on sunday or mondays eh..

worst case i was going to pay enzed a visit on nudgee road tomorrow after I visit you..

I dummied up all the steering shafts and pleased to report all the bits fit..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Resident Terrorist
Posts: 4278
Joined: Fri May 21, 2004 9:37 am
Location: Driving Barnsey's mum to bingo

Post by RAY185 »

Yeah not sure about saturdays but definately not this monday (pub hol). Enzed would be good but keep in mind I think there is a need for a right angle fitting at the pump end, can't remember why.... I think the 60 hose comes out straight? I did the hose last after everything was mounted so the hose went exactly where I wanted.

Image

If you can get a decent dampener from the wreckers go for gold but don't pay too much, $75-$80 gets you a new one.
Posts: 6029
Joined: Tue Dec 24, 2002 9:34 pm
Location: South Australia

Post by bad_religion_au »

i used the 60 dampener bracket no issue.

when i was running the 2f, i used the 60 series lines no worries, although i had to get creative to use up all the line. now i'm going ford motor, i'm going to get a proper one made up
Spit my last breath
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

any idea if the fittings are the same at both ends for the high pressure line?? I brought the 60 box with me to take to Enzed so I can ensure the right sized fittings are purchased.

I guess being a high pressure line there will be the need to crimp it..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 2588
Joined: Mon Apr 19, 2004 10:45 pm
Location: Hobart Tas

Post by Reddo »

very good, very good. Not intertested in running a heavy RTC dampener?
such as a tuff dogg??
Nice gq swb ute chop with a huffer for the good times
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

Reddo wrote:very good, very good. Not intertested in running a heavy RTC dampener?
such as a tuff dogg??
hey Reddo,

not yet.. my steering pump needs a reco and I figure its just added expense at the moment and fatigue on the pump if i go that way right now. If i find the bigger bore 60 or 75 dampener isn't providing much dampening i might move up to that..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

just chased up the wreckers and they have got a chassis bracket + dampener from a 60 at no extra charge!

i'll get the missus to pick it up on saturday mornin.. :)

last thing to get is the high pressure hoses...
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 6029
Joined: Tue Dec 24, 2002 9:34 pm
Location: South Australia

Post by bad_religion_au »

shorty_f0rty wrote:any idea if the fittings are the same at both ends for the high pressure line?? I brought the 60 box with me to take to Enzed so I can ensure the right sized fittings are purchased.

I guess being a high pressure line there will be the need to crimp it..
pretty sure they are... i'll check mine when i get home if you like.

heavy duty return to centre dampeners are just a bandaid to disquise issues with your steering geometry. i'd much rather be able to feel when something wasn't up to speed
Spit my last breath
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

bad_religion_au wrote:
shorty_f0rty wrote:any idea if the fittings are the same at both ends for the high pressure line?? I brought the 60 box with me to take to Enzed so I can ensure the right sized fittings are purchased.

I guess being a high pressure line there will be the need to crimp it..
pretty sure they are... i'll check mine when i get home if you like.

heavy duty return to centre dampeners are just a bandaid to disquise issues with your steering geometry. i'd much rather be able to feel when something wasn't up to speed
No need thanks Adam,

Ray lent me a power steer pump to take to enzed.. $120 later and the high pressure line is sorted..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

bad_religion_au wrote:yep, should work a treat, that's the way i did mine. don't forget that if it's too long, you can shorten it by drilling out the plastic bung and "tapping" the shaft with a hammer because they are collapseable columns.
well.. i have just dummied up things today. I think the intermedia shaft will be too long.. on it there are two divots where I think its holding the part that slides.. Adam is this what you mean to drill out? (its probly a 2-3mm hole).. did you do anything to the shaft after you made it fit to length? to stop it sliding unexpectedly?

The 55 steering column shaft goes in sweet.. i used the outer column from the 55 so it kinda sits flush with the firewall. although it pushes the steering wheel into the cab by about 20-30mm. you dont notice it too much sitting at the wheel.
Image

I was hoping this would help in relation to the length of the intermediate shaft. i think the 80 cushion joint adds considerable length to the rod.. if it was just a single uni it would be a bit shorter and maybe the intermidiate shaft wouldn't need shortening

Image

The steering arms went on ok (with a little work) without having to pull down the hubs/knuckles all the way.. this was good as I wasn't really looking forward to the extra work there.. (thanks for your pointers with that Ray).
Image

there is considerably more meat on the 75 steering arms eh.. good to see
Image

managed to get the old TRE's off the Tie rod and drag link from the wreckers after a bit of work.. new TRE's are in place but I need to put anti-sieze on the threads and thought I might put some anti rust stuff down the guts of the steering rods.
Image

mocked up where the box goes without doing any work on the shock tower.. this is tomorrows job (grinding, cutting, mounting box)..
Image

glad to finally see all the old steering gear out for good!
Image

thanks for everyones help so far.. so far its been a relatively straight forward mod with no major issues.
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 6029
Joined: Tue Dec 24, 2002 9:34 pm
Location: South Australia

Post by bad_religion_au »

yep those two divots are probably the pins that hold the collapseable column in place.

as the column has a well greased slip joint already, and the collapseable section is quite... stiff... to slide in and out (i needed a sledgy to persuade it), the slip joint moves before the collapseable section will.

just remember to protect the splines if your going to hit the end of the column! i almost stuffed mine because i wasn't thinking.
Spit my last breath
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

cheers adam.. i was going to drill those out and maybe reposition the shaft to the correct lenght and redrill some new hole, place some rivit pins through it to hold it and stop it from moving..


i noticed with the 62 box that the pitman arm is quite low.. how much room do others have from their pitman arm to the top of th leave spring.. wouldnt this affect the spring compression? i htink I have roughly 90mm between bottom of drag link to top of spring and there is about 110-120mm between bumpstop and top of axel..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 6029
Joined: Tue Dec 24, 2002 9:34 pm
Location: South Australia

Post by bad_religion_au »

shorty_f0rty wrote:cheers adam.. i was going to drill those out and maybe reposition the shaft to the correct lenght and redrill some new hole, place some rivit pins through it to hold it and stop it from moving..


i noticed with the 62 box that the pitman arm is quite low.. how much room do others have from their pitman arm to the top of th leave spring.. wouldnt this affect the spring compression? i htink I have roughly 90mm between bottom of drag link to top of spring and there is about 110-120mm between bumpstop and top of axel..
i know some people have had issues, others haven't. i honestly don't think mine hits, but i haven't flexed it up in ages. i know Pcman's hit on his 40 when he did it the first time.

if it's an issue, a pitman arm off of a 75 series is flat from memory, or add bigger bumpstops, it's only 20mm up travel your losing.

also it's a bit hard to tell in the pic, but the one where you've clamped the box onto the chassis, it looks like you could rotate it (front up, back down) a tad so the pitman arm is raised a little, and still have it clear the chassis.
Spit my last breath
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

hmm.. yep i've tried to position the box so its runs as close to the chassis as possible..

a pic full lock left:
Image

a pic full lock to the right:
Image

the tie rod probably clears the pumpkin by about 10mm at full lock right

front on shot
Image
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 6029
Joined: Tue Dec 24, 2002 9:34 pm
Location: South Australia

Post by bad_religion_au »

ah yep, it's a bit clearer with those pics. not the room i thought there was.
Spit my last breath
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

yeh its all good.. I've mounted the box so if a 75 pitman arm is needed it would still clear..

had a few interuptions today which was a PITA and I only got half a day spent on it..

managed to get a few holes and backing plate drilled tonight..

got the ford shock towers too (THANKS TWISTY & BOOF!) so they are going on tomorrow too

I wanted to flip my rear hangers but I'll have to see how I go for time..

I didnt get to modify the intermediate shaft yet. maaan i'm glad tomorrow is a public holiday!
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 1516
Joined: Wed Mar 10, 2004 3:36 pm
Location: melbourne australia

Post by pcman »

you gain about 20mm extra using a 75 series arm

i had to do this on mine as i didnt mount the box correctly and didnt have enough clearance
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

hey pcman.. thanks for the heads up.. we'll see how it goes once its all flexed up.. I was thinking if i go back to slightly shorter shackles than the distance on compression will be less.. but we'll see..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Resident Terrorist
Posts: 4278
Joined: Fri May 21, 2004 9:37 am
Location: Driving Barnsey's mum to bingo

Post by RAY185 »

That pitman arm looks a bit lower than my 60 arm from the pic (and my memory). I'll have a look at mine tomorrow as it might be somewhere in between the full drop of that 62 arm and the flat 75 arm. Looking good though Andy. :armsup:
Posts: 2588
Joined: Mon Apr 19, 2004 10:45 pm
Location: Hobart Tas

Post by Reddo »

RAY185 wrote:That pitman arm looks a bit lower than my 60 arm from the pic (and my memory). I'll have a look at mine tomorrow as it might be somewhere in between the full drop of that 62 arm and the flat 75 arm. Looking good though Andy. :armsup:

thats correct ray. the 60 arm dose not come down that far. That arm is a lot lower than mine. You couldnt get away with that box if you went SOA, and ran flatter packs. Will a 60 arm fit that box?

But like you said, its a matter of working with what you have, and that will work fine.

Are you placing some crush tube in that chassie?
Nice gq swb ute chop with a huffer for the good times
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

yep reddo thats the plan.. i'll run with it and see how it goes..

well the drilling of the backing plate and the chassis was a major PITA.. i spent most of today drilling 2 12mm holes.. after they were done i discoverd two captured nuts on the otherside of the chassis next to where the bolts for the box go through..

anyway..

intermediate shaft mounted and tight
box mounted with crush tubes and backing plate
tie rod, drag link and steering dampener on
dampener bracket is on the chassis

still left to do..

mount 1 ford shock tower (I wont have time to do the other today)
remount fender
bleed brakes
bleed power steer
test drive
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

yay .. .all done!

need some more power steering fluid.. but there is enough there to make the power steer work..

need to get used to the new position of the steering wheel and find somewhere for the water overflow for the radiator.. can i run with out this for a day??

I'll get some completed pix up in the morning.. too dark now and i'm stuffed..
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Resident Terrorist
Posts: 4278
Joined: Fri May 21, 2004 9:37 am
Location: Driving Barnsey's mum to bingo

Post by RAY185 »

Sweet Andy, if you don't have any cooling issues it won't worry it to not have the overflow bottle there for a day. So what do you think of it over the standard POS 40 p/s?
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

well.. I had some trouble finding some power steering fluid last night.. only got enough in there to JUST register on the dipstick. this allowed for a bit of power assist but not much..

to be perfectly honest I think the 40 p/s was a bit lighter.. but it could be due to the fluid needing to be bleed.

I just have to drive it more to find out.. the box is a bit more touchier.. ie, you dont have to turn the steering wheel as much to change direction.

there are still a few things to sort out until its all done
- shorter bolts for the box
- flip the chassis bracket for the dampener
- maybe find a flatter pitman arm
- fix leaking power steer pump

I noticed when i topped up the fluid the stuff that was in there was full of bubbles.. probly not a good sign but i dont think its anything to do with the box, more likely the pump.

Image

you can kinda see the angle of the dampener.. i dont think its right.. flipping the bracket around should fix this.

Image


only got time to put one shock tower on.. i'll do the other on the weekend.
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 2254
Joined: Tue Dec 10, 2002 5:09 pm
Location: Sydney

Post by jessie928 »

shorty_f0rty wrote:well.. I had some trouble finding some power steering fluid last night.. only got enough in there to JUST register on the dipstick. this allowed for a bit of power assist but not much..

to be perfectly honest I think the 40 p/s was a bit lighter.. but it could be due to the fluid needing to be bleed.

I just have to drive it more to find out.. the box is a bit more touchier.. ie, you dont have to turn the steering wheel as much to change direction.

there are still a few things to sort out until its all done
- shorter bolts for the box
- flip the chassis bracket for the dampener
- maybe find a flatter pitman arm
- fix leaking power steer pump

I noticed when i topped up the fluid the stuff that was in there was full of bubbles.. probly not a good sign but i dont think its anything to do with the box, more likely the pump.



you can kinda see the angle of the dampener.. i dont think its right.. flipping the bracket around should fix this.




only got time to put one shock tower on.. i'll do the other on the weekend.
hi mate
sounds like your pump is still cavitating, it will take a while before all your bubbles are out and the power assist works properly. It will get lighter.

Jes
ATTACH BROKEN TOYOTA HERE--->
DUCATI <-----Worlds best warning label
Posts: 15549
Joined: Tue Oct 22, 2002 9:23 am
Location: Your Mummas House!

Post by bj on roids »

you ran crush spacers in the chassis right?

It is very common for the bolts holding your box to come loose, if you dont brace the chassis... check them often
hands and mums dont count!!!
Posts: 2765
Joined: Wed Jan 14, 2004 10:32 pm
Location: somewhere out there

Post by shorty_f0rty »

bj on roids wrote:you ran crush spacers in the chassis right?

It is very common for the bolts holding your box to come loose, if you dont brace the chassis... check them often
yep.. m12 high tensile bolts with spring washers and nyloc nuts with crush tubes in the chassis and a 6mm backing plate.. i will keep a close eye on them.. i guess i should have used some locktite on em eh?
Built, not bought!
'84 BJ42 - sold! :(
'79 Coiled and turbo diesel'd FJ55
Posts: 15549
Joined: Tue Oct 22, 2002 9:23 am
Location: Your Mummas House!

Post by bj on roids »

shorty_f0rty wrote:
bj on roids wrote:you ran crush spacers in the chassis right?

It is very common for the bolts holding your box to come loose, if you dont brace the chassis... check them often
yep.. m12 high tensile bolts with spring washers and nyloc nuts with crush tubes in the chassis and a 6mm backing plate.. i will keep a close eye on them.. i guess i should have used some locktite on em eh?
nah, they'll be right, you can get some movement down the chassis there is all
hands and mums dont count!!!
Posts: 2588
Joined: Mon Apr 19, 2004 10:45 pm
Location: Hobart Tas

Post by Reddo »

like any pump, you will need to bleed the system. so remember to jack the whole front end up, and rotate the wheel from lock to lock (slowly - like when your pulling into maccers and pimping). those air bubbles are just that, air.

The 40 box will be ligher, however, powersteering, is just an assistant, and when you want to steer out of that rut, bank, curb, it will help you out.
Nice gq swb ute chop with a huffer for the good times
Posts: 34
Joined: Sun May 06, 2007 7:24 am
Location: Maitland NSW

Post by Muz103 »

Hi Guys,

I'm following this closely cause I'm about to do the same to my 40 in a month or two ... starting to source parts in the next few weeks etc...
TWISTY wrote: thing I hate about my setup is the 75 series column, would have modified the stock one or used a 55 series one if I did it again.
Out of curiosity... what is it about the 75 column that you don't like?
Cheers

Muzza
Post Reply

Who is online

Users browsing this forum: No registered users and 7 guests