PAS Install

**BadCo.** · 23rd December 2014, 05:45 AM

Hey everyone,

Looking at doing my power steering install over the holidays so just wanted to make sure I have everything and that I'm good to go. Then I'll write it up with pictures in this thread.

Items I have are (all are pre loved):
4BE/D1 hydraulic pump, mounts to the timing case in place of the blank.
4 bolt Steering box from Discovery 1
Reservoir
Piping, everything that was in the disco
Engine oil on hand
PAS fluid

So, should I get the box reconditioned? I hear it is expensive, more then the box it self.

Should I be replacing O-rings or other parts on the pump? If so, part numbers? I called Isuzu and they have a overhaul kit that costs more then the pump and won't sell individually except for a upper seal!?

How am I going to reuse the old solid pipes from the disco? Can you just cut them and use fridgy pipe benders on them?

Any special tools required?

Anything else I have missed?

Sorry for all the questions, just want to make sure I have everything sussed before I start. I'll have a mechanic mate on hand hopefully, he owes me for his new lights in his garage haha. Once I have my power steering all figured out it will be Paultans turn next!

Cheers,

BadCo.

**Phil B** · 23rd December 2014, 06:08 AM

BadCo,

Cant help with advise I'm afraid but reading with interest.
Merry Christmas.
Phil.

LandroverScott · 23rd December 2014, 07:42 AM

Hi BadCo,

A new O ring on the pump would be wise, also a new tie rod on the pitman arm while it is apart. As far as servicing the box if it was okmwhen pulled out it should be fine. Was it from a D1 as the match the bolt holes in the chassis

Regards
Scott

**BadCo.** · 23rd December 2014, 08:00 AM

Originally Posted by Phil B

BadCo,

Cant help with advise I'm afraid but reading with interest.
Merry Christmas.
Phil.

No worries, I hope people thinking of doing this take something from my experience.

Originally Posted by LandroverScott

Hi BadCo,

A new O ring on the pump would be wise, also a new tie rod on the pitman arm while it is apart. As far as servicing the box if it was okmwhen pulled out it should be fine. Was it from a D1 as the match the bolt holes in the chassis

Regards
Scott

Hey Scott thanks for the reply. Do you know the part number or a specific description for the o-ring?

The box is from a D1, amended original post to reflect this.

Tie rod is a good idea, what about the cross rod ball joint too? Actually I think my cross rod is bent so will probably need a entire new one.

**usi** · 24th December 2014, 09:34 AM

Have a good look here.

It was my excuse for fitting power steering. Oh and it was about 1.5L of Power Steering Fluid from memory with the KLR supplied reservoir

**BadCo.** · 24th December 2014, 09:40 AM

What am I looking at there? Is that a crack?

**usi** · 24th December 2014, 10:01 AM

Sure is! It was almost the whole way through

**DWCamo** · 24th December 2014, 10:58 AM

Hi all,
I need to add a little power steering fluid to my reservoir. Anyone know what type I should use?

Brad at KLR installed the power steering unit in my Perentie (Carryall) earlier this year.

Cheers, DW
(48-350)

**isuzurover** · 24th December 2014, 11:06 AM

Since you have a disco box, the most important thing is making sure you have pullers that can get the drop arm off to swap over. This part is often a huge PITA.

You should also have:
Loctite retaining compound and a HUGE torque wrench to fit the 110 drop arm on the disco box.

Check the box for play. A good idea to replace the bottom seal at least while you have it out.

Is the reservoir a D1 plastic type? They are a million times better than the 110 metal type.

As for connections, measure up the distances, then take all the bits into the equivalent of ENZED or PIRTEK over there and get them to make up some flexible hoses. They will need to use the box ends from your lines, however the isuzu pump end fittings are standard so they should have them on the shelf.

**BadCo.** · 24th December 2014, 01:18 PM