FJ80 Power Steering Pump & Gearbox Rebuild

[Cruiser Jimmy]

With the box off, you can get some grip around the pitman arm.

Notes:
There are match marks on the Pitman Arm and the Shaft. When reassembling match the marks back up. The marks are on both sides of the pitman arm and the shaft.

There are match marks of the u-joint and the steering shaft also. Make sure those match back up too.

 

[OGBeno]

Lookin tough Jimmy....

Ya wanna come over for the 4th to help me with mine??



Thanks.

This should go directly to the FAQ section.

-o-

 

[Cruiser Jimmy]

Next,
Remove the end cover by taking the 4 bolts out, taking the adjusting nut off and turning the adjusting screw to retract the end cover.
Next,
Take the shaft out.
Note the shafts teeth position in relation to the body. The teeth are on an elipse around the shaft. If the teeth are not centered when coming out of the body, the teeth will engage the body and scare the surface. There is an o-ring around the top of the end plate. If the body surface is scared you'll add extra expense to have this repaired.

Pic 3 shows a mark on the oppisite end of the shaft to reference with. The mark will be horizontal with the frame mounting portion of the body.

 

[Cruiser Jimmy]

Nice write up Jimmy.

As always, I follow your lead!

Just as long as you don't follow my line

 

[Cruiser Jimmy]

Hey,

Why not a video? Hee hee.....!

Ali

I've got a betamax camera. I can add some '70 tracks in the background.

 

[Cruiser Jimmy]

Next, use a 10mm allen to remove the plunger guide nut, spring, o-ring and plunger guide.

 

[Cruiser Jimmy]

Worm gear valve body

Okay, pay attention to this part.

The steering shaft end/valve body needs to be removed very carefully. Turn the steering shaft end so to draw out the assembly. The piston valve and the shaft housing should come out together. There are several BB's inside the assy which are a medium that connects the piston and the shaft assy.

All the o-rings can be replaced with these two units still continued.

If they're separated, you'll have to figure out how to put it back together. (Like I did )

With the assy out and in a vise, check the ball clearance with the dial indicator. Max clearance is 0.15mm.

 

[Cruiser Jimmy]

With everything disassembled start replacing all the o-rings and seals, etc.

Reassembly is pretty easy:

Install the worm gear valve body, replace the plunger nut assy. Align the worm gear so that it's center to the body of the housing body.
Install the steering shaft with the teeth aligned with the teeth of the piston body.

 

[lowtideride]

I just rebuilt my Gear Box last night after taping it for Hydro Assist. I am a little ticked off at FSM for not going into detail on replacing the worm shafts seals, the ones I was really after. The FSM manual just tells you not to take it apart. If I would not have been pressed for time I would have.

I had the piston off before by mistake and had to reload it with ball bearings...Not all the difficult and rather neat how it works...agian it also NOT explained in the FSM. I hoping the worm shaft does not leak because it is the one oil seal I did not get to replace. (where the sector shaft connects to it). These seals were present in the re-build kit from Toyota but agian where not even in the exploded view of the Gear Box of the FSM....

Also...Ill add some tips. It is a good Idea to use the piston ring clamp on the teflon seal on the piston. Becuase the sharp wall of the box will cut it if the seal is not compressed. Make sure you follow the steps in order for the seals on the bottom of the box....Becuase they go on in a different order than they come off.

Aside from that.. Have Fun

P.S. Jim how are the box and pump doing? any leaks? I have to rebuild a P.S. Pump in our 80 in the next comming months...

Thanks for the write up.

 

[Cruiser Jimmy]

No leaks for the pump or box. Just a little bit around the 'off the shelf' hose (low side) that I used, more like it's sweating that leaking. I guess the 3 stright weeks of <32º might be a factor.

Ride on. . . .

 

[nat88toy]

thread resurrection... hey care to elaborate in how the heck you got the balls bearing back in im haveing one hell of a time with this thing


ehh i got them in what a pita

 

[BenMara]

there are match marks on the pitman arm and shaft? hmm im gona have to line mine thats y the wheel is off and PO tried to reposition steering wheel and pit man arm

 

[sledge916]

thread resurrection... hey care to elaborate in how the heck you got the balls bearing back in im haveing one hell of a time with this thing


ehh i got them in what a pita

I would like to know too how the heck the balls go back in, also the seals on the bottom of the box seems to be a pain too, the thick o-ring teflon ring metal washer and oil seal, their has to be a trick for this

Sethro

 

[lxed]

crying....

I'm blowing PS fluid everywhere....put off for a year now. I sure hope its not the gear box....waaaaa.
Any suggestions on where to buy my rebuild kit??

 

[landtoy80]

My input shaft is leaking. The FSM doesn't show any seal for the shaft. Is there a seal or O-ring in there? How do you replace it?

 

[landtoy80]

Does the rebuild kit come with the input shaft seal?

Cruiserdan can get you the parts (assuming the lit has the seal). But unless someone has done a write up on how to replace the seal, you are on your own. Its not in the FSM and the seal is not shown in FSM. The balls are not in the FSM either, so its going to be hit or miss if you can get it back together. If you screw up there is no data on how to get it back together.

 

[72rockcruiser]

So, after seeing the insides of this pump, does anyone have any ides where to start modifying one of these pumps if you wanted to increase the pressure output of the pump?

I bought a new pump, and want to mess with this old one, see if I can increase the flow, help turn these big ol swampers.

 

[96r50]

Talk to scotia: https://forum.ih8mud.com/80-series-tech/409610-power-steering-r-d.html

 

[72rockcruiser]

*edit* I need to spend some more time reading that thread. I think it may have the answers I need.

Thanks!!

 

[84stockcrawl]

thanks for the photos! I was trying to get my pully off because the key on the shaft was broken and gone, so the pully was just spinning. Thanks to the pictures i spend hours trying to get to the shaft from the backside of the pump( still installed). NO parts 80 series out here. I had to salvage the $200 pully!!! Wifes happy (it is our family rig) now I get to go buy my old 4runner back!