Project Samurai Power Steering - Trucks 4x4 @ Off-Road.com
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Project Samurai Power Steering

Source: Suzuki/Geo at Off-Road.com
The purpose of Project Samurai is to demonstrate the installation of bolt-on performance accessories. It will confirm that a very capable off-road vehicle can be built without having a degree in automotive technology. Most segments of this project can be completed using basic hand tools.

Project Samurai continues to become more trail-worthy every month. This month we will install power steering.

Previous articles can be viewed using links on the left side of this page.

If you are running larger tires or a locker up front, power steering is a must have accessory. Samurai owners no longer have to build their power steering from scratch. A bolt-in kit is available from Calmini, part number SS1580.

This kit can be installed in about fifteen steps. Please follow the complete instruction that are included with the kit. This article is not intended replace them.

In addition to Calmini's installation kit you will need the power steering pump, hoses and reservoir from a Geo Tracker or a Suzuki Sidekick.

Can't find the parts locally? Give Calmini a call. They have steering gear boxes in stock. For the hoses, pump and reservoir try Hawk Enterprises at 1 (888) SAMURAI.

Next Month
Next month: Steering Linkage Kit install.

Power Steeering Kit
Part Number SS1580

Tools and Parts:

  • Metric Hand Tools
  • Drill motor and bits
  • Pickle fork
  • Pump, reservoir and hoses
  • Steering box and Pitman arm

Parts included in kit:

  • 2 - 12 x 90mm bolts
  • 1 - 12 x 70mm bolt
  • 2 - 10 x 25mm bolts
  • 1 - 10 x 20mm bolt
  • 1 - 8 x 45mm bolt
  • 6 - 12mm nuts
  • 6 - ½" lock washers
  • 2 - 5/8 x 3/4 spacers
  • 1 - 5/8 x 1 1/8 spacer
  • 1 - 1¼ x 5/16 bolt
  • 1 - 5/16 nylock nut
  • 1 - ¼ x ¼
  • 1 - ¼ lock washers
  • 2 - 8 x 30mm bolts
  • 1 - frame adapter
  • 1 - pump adapter
  • 1 - U-joint
  • 1 - belt
  • 1 - pulley

Steering stablizer
Remove the stock steering stabilizer.

Radiator bolts
Remove the 4 radiator bolts.

Radiator removal
Pull the radiator out from the top.

psradbracket.jpg (19148 bytes)
Remove radiator supports from the frame.

Rag joint removal
Stock rag joint removal.

Steering shaft
Steering shaft also comes out. Now is a good time to center the steering wheel.

Steering shaft
Modify steering shaft to collapse. Drill out the two plastic pins and collapse the shaft. Heat may help this process. Do not hammer ends of the shaft.

psnewujoint.jpg (205637 bytes)
New U joint replaces rag joint.

Drag link
Drag link removal.

Pickle Fork
Ball joint removal. Sometimes you can leave the nut on loosely and tap it with a hammer and it will come loose.

Gearbox removal
Stock gear box removal (outside detail)

Stock gearbox
Stock gear box removal (inside detail)

Frame plate
New frame adapter plate hardware installation.

Frame plate installed
Install frame plate in the place of the stock gear box.

Donor box
Install donor gear box.

Do not remove pulley
Remove the small crank pulley bolts, leave the pulley in place.

New pulley
Install the new serpentine pulley over the stock pulley.

Pump engine plate
Install pump adapter plate to the engine.

Belts
Belt detail.

Steering shaft
Pump bracket & steering shaft install.

Drag link install
Connect drag link to Pitman arm.

Reservoir detail
Reservoir & pump installed.

Completed Kit
Completed Power Steering Kit.

Check all bolts and top off fluids. Cycle the completed steering conversion. Check for leaks and enjoy the newly installed power steering kit.

This kit is well engineered, both in quality and design. It is very easy to install and worth every bit of effort that goes into it. You will no longer suffer from tired arms at the end of the day at your favorite trail.

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Source: Suzuki/Geo at Off-Road.com,
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