Install day arrived (that means I had a day off from work) and I headed up to Troy's shop to do the work. We had previously discussed his welding the extra connector to the reservoir. If I found the appropriate fitting and made the new hole, he would fire up the new Lincoln and make it happen.
I needed to mock up the reservoir mounting location so I could determine the appropriate spot for the reservoir's new fitting. It didn't take long to disconnect the PS lines from the existing pump and remove it from the stock mounting bracket. (For more step-by-step details on doing the pump removal, check out this PS pump replacement write-up.)
I had asked Sean about running a stock or undersized pulley on his pump. He told me that I could use either one. I have a PSC undersized pulley but you can not mount the pulley onto the pump and then bolt the pump in place. The smaller diameter pulley does not allow the holes in the pulley to line up properly with the pump's three mounting bolts. I took the easier route and opted for using my stock pulley.
Before I could mount the pump to the bracket, I decided to remove the threads from a pair of the mounting tabs. The center section was tapped and the bolt size/pitch matched the stock mounting bolts....but I could see no reason for them so out they came. A 5/16" drill bit made short work of them. With the threads out of the way, I slipped the pump into the mounting bracket and used a single bolt to temporarily hold it in place while I got the reservoir ready to mount.
As I write this, I realize I missed taking a close-up picture of the mounting bracket while I was making it. This bracket was made from some 1.5" wide steel flat stock, about 1/8" thick. I cut a piece that was the same length as the aluminum reservoir bracket. The reservoir bracket has four 5/16" holes in it. I transferred the hole pattern to the flat stock and punched out the holes. The steel bracket was then bolted to the aluminum reservoir.
With a flapper disc attached to a 4" angle grinder, I removed the paint from the driver's side grill support rod, near the vicinity of the power steering pump. I temporarily removed the radiator overflow bottle and the TJ's windshield washer reservoir. I needed some space and these were in the way as I tried to position things, measure for hose length, etc. As I found what I thought was a suitable route for the hose connections, I would slip the washer reservoir into place to ensure I had proper clearance. Satisfied that I found a suitable location for the reservoir, I marked the spot on the reservoir where the hole would be drilled for the AN fitting.
Before I could drill the hole in the reservoir, I needed to open it up and temporarily remove the filter. I did not want the filings from the drill getting into it. I removed the nut at the top of the baffle plate, which also serves as the top of the reservoir. With a bit of effort, the top was pulled out of the reservoir. The rubber o-ring, as seen in the above pic, keeps it snuggly in place.
You can see the filter in this pic. It is held in position with an aluminum filter retainer and another nut on the threaded rod. I removed the nut, the retainer, and finally the filter.
With the filter out of the way, it would be easy enough to clean the filings out of the reservoir after I finished drilling the hole. After making a small pilot hole in the reservoir, I finished the job with a step drill bit. They work great for this kind of task when you need a hole about 3/4" in diameter.
I handed the gutted reservoir, with a fresh hole in it, over to Troy. A couple of minutes later, I had one very hot reservoir with a brand new -6 male AN fitting welding into place. Thanks Troy!
When the reservoir had cooled, I installed the filter, put the top back on the unit, and slipped it back into the aluminum mounting bracket. I bolted the aluminum bracket to the steel bracket with 4 mounting bolts. I then clamped the steel bracket onto the grill support rod with a Vise Grips. After rechecking the location one more time (I wanted to make sure it would clear everything), I tacked it in place with the welder. After another check to make sure I could route the hoses in the manner I wanted, I welded the bracket to the support rod. (Did I mention this is one of those measure 3 times, weld once kind of steps?)
Here is a pic I snapped after the install was done. You can see the mounting bolts on the aluminum reservoir bracket. As I said previously, it is bolted to the steel bracket that I welded to the support rod.
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