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Does anyone have a link for a "how to" instruction sheet on adding an e81 power steering setup to a brumby ?

EDIT: I have now had the full conversion and have edited the list below

And Yes I've searched and googled.

I have a 1990 brumby and two EA81 P/S equipped donors parts cars.

You need AT LEAST


1) the PS steering rack, boots and ends etc

2) the larger support bracket ( see below) or here http://www.ausubaru.com.au/showthread.php?t=25836

3) the 4 bolt plate attached under the engine crossmember that enclosed the rack On the non-ps car this plate will have 2 bolts and two spot welds. It will need to have its two spot welds drilled out so it can be removed to fit the thicker PS rack. On the donor car this plate will have 4 bolts, and it can be reused on the receiving car.

4) the PS pump, with front and rear brackets and lines

5) the P/S pulley

6) The longer belt

7) the different thermostat housing that's longer to clear the P/S pump.

8 ) longer radiator/thermostat hose for new PS thermostat housing.

9) the smaller universal joint that connects the rack to the steering column




OPTIONAL dependent upon the receiving car.

A) the whole engine cross member (including removable skid plate) - as some cross members would not take the rack's "U" bracket due to the width of the bolt holes being different.

B) A triple engine crankshaft pulley - if your engine only has a single or a double.

C) If you have a crankshaft fan, this is a good time to replace it with one or two thermo fans. If you have A/C you already have one fan. If you don't have A/C you can install both the A/C fan and another elec fan. Some MYs had electric fans without A/C being installed. see here Alloy radiator install

D) check the drivers side head for the threaded holes the pump bracket needs to locate into. These can be drilled and tapped if necessary.

E) If your car is lifted you will need to extend the steering shaft Uni joint to an appropriate length. There are several ways of doing this, depending upon the height of the lift.

PS bracket on left - standard on right

henpecked wrote:
I gather I need

1) the whole engine cross member (including removable skid plate)
2) the PS steering rack
3) the PS pump/brackets and lines
4) the P/S pulley
5) the triple pulley for the crankshaft (Brumby already has elec fan)
6) the different thermostat housing that's longer to clear the P/S pump.
7) the smaller universal joint that connects the rack to the steering column
Ps
what am I missing ?

any particular parts I should look at replacing while I'm at it ? bushes etc

all advice greatly appreciated
thanks

1) don't need whole engine crossmember, drill spot welds on your jack plate and replace with a bolt arrangement.
2-7) all correct.

Missing: a six pack to enjoy once the job is done

Cheers

Bennie

You may find the blind holes & threads aren't in the Cylinder head bosses where the big boomerang arm bolts on...

You shouldn't need the whole crossmember, just drill out the spot welds and replace with bolts as mentioned above. But I have heard not all crossmembers can accept a P/S rack. Dunno which years/models this is specific too though.

Silverbullet wrote:You shouldn't need the whole crossmember, just drill out the spot welds and replace with bolts

Thats all I did to my brumby to install my PS rack, as for the rest I don't know as I used EJ parts due to my EJ motor.

I did have to shim the front of the rack to stop the steering arm from fouling the boot of the CV but once again this was due to having an EJ gearbox.

TOONGA

Missing a belt of course and also a longer radiator hose.
Is you car lifted? You will need to combine 2 steering unis into one, if it is.
Mine is an AUG 1990 Aggy Brumby and after hours of degreasing, rubbing back and painting and then fitting, I found I HAD to change the engine x-member.
For some reason they narrowed the 2 mounting boss' where the U bracket bolts into. (come to think of it you will need the U bracket from the donor car too)
Also check the drivers side head for the threaded holes the pump bracket needs to locate into. These can be drilled and tapped if necessary.
Cheers
John

Pictures of the system (did I miss anything?)





From left to right : PS pump with boomerang shaped bracket, steering rack, crank to PS pulley to pump cable, screw-screw hose, water pump (extra long) hose, small bracket that covers part of PS rack from bottom of car (2 bolts), 3-pulley crank and crank bolt, screw-tube hose, square bracket that covers part of PS rack from bottom of car (4 bolts), water pump housing, tub of icecream (full o'bolts), steering column flexible joint, and PS rack bracket.

Looks good, the only thing I can see you haven't mentioned is that you may need to check condition of the rubber mount blocks for the rack.

Replace them if missing or cracked. Add : don't forget the heat shield too ... !

The icecream for after installed ... ?

Cheers, Bantum ...

Yeah mate that looks like all of it!

Was it really that clean or have you given it a scrub already?

Cheers

Bennie

>Was it really that clean or have you given it a scrub already?

It was a real mess, I have cleaned it up a fair bit but will leave the rest to the new owner (a USMB guy based in Guam). Total price from PAP today for the system - $35 (and $10 of that was the crank pulley!). Half price on anything starting with "S" this week

>don't forget the heat shield too ... !

Where was that ? Near the CV ?

This might help locate things :



Excuse the American system, just flip it over for Oz ...

The item 15 ( Protector or Heat shield ) I believe goes over rack boot where exhaust runs ...

Cheers, Bantum ...

It's in the pics Bantum, he's got it there!

Cheers

Bennie

dfoyl wrote: ... Don't forget the heat shield too ... !

Where was that ? Near the CV ?

Yep dfoyl was asking so ...

P.S. - If anyone has the correct diagram for an Australian one, might be bit more helpful ...

Cheers, Bantum ...

Ok, so the little thin gauge sheet *is* the heat shield. I thought I was missing a part.

Now the big question is, can the rack be pulled apart and put back together for a LHD car ?

dfoyl wrote:Ok, so the little thin gauge sheet *is* the heat shield. I thought I was missing a part.

Now the big question is, can the rack be pulled apart and put back together for a LHD car ?

Not sure what you mean, if you are talking about serviceability on the P/S racks then yes they can be pulled apart completely for repairs etc. You wouldn't be able to pull apart one and convert it to the other side if that's what you were asking...

I have the correct RHD diagram in my FSM at home...too bad that is 9000 miles away at present They are essentially the same but the hard lines on the P/S rack are different obviously.

You can't make a RHD rack into a LHD rack, the casing for the input shaft is different - they're a mirror image left and right.

You shipping this off to the US? Why don't they just get one over there, there would be loads more units available over there!!!

Cheers

Bennie

Technically, shipping it to Guam which is closer to us than the US mainland. The guy I'm helping isn't exactly over-run with fellow US guys willing to ship outside the 50 states, so I've been sending him whatever I can find (he is stuck with some of the LHD parts, and it looks like the rack will be one of them)...

Ah fair enough!

Good to hear you're looking out for a fellow subi nut in a different location!

Cheers

Bennie