Power steering install issues on my 1978 FJ40

[GA Architect]

Based on the two photos of similar power steering set-ups like yours, it appears their fan belf for the crank/alt/PS is on the outer pulley and your set-up may be on an inner pulley?

 

[Solace in Solitude]

My ALT-PS-CR is closest to radiator... But it looks like Mike's is too...

 

[78fj40mg]

Mike,

I have two belts - longer runs ALT-PS-CR. shorter runs WP-JimIdler-CR

I have an FJ60 PS pump and a reman FJ60 alternator (from Georg)

Two things... From your first picture... If you compare your's to mine...

1. My hose (from CDan) appears to be more a 90*x90* and the top leg looks longer than your's. The 90* out and 90* up on mine allows it to easily clear the belt. And the longer leg to the rad adds more cushion.

2. Could just be the picture, but your first picture looks like the PS pulley is back (out of line) of the ALT pulley by as much as half an inch. Is that true or just the picture angle?


Here's my hose/belt - compare it to your's

View attachment 1031081

Danny, your PS pump pulley alignment looks perfect!!!!! Thanks for the pic!!

My PS pulley/pump shaft is approximately 1.5 inches too short and as a result I have these problems. I've spent a lot of $$ on this mod so far and still doesn't work, I'm really perplexed with this PS pump install.

Georg keeps telling me that all the PS pump pulleys are misaligned, however, that's not the case. In fact he believes that my thermostat housing is the culprit, however I disagree because it doesn't change the fact that the PS pump pulley is still misaligned with the ALT pulley and CR pulley. What a tail spin!!

Would you mind measuring your PS pump shaft length so I can compare with mine?

Thanks!!!

 

[78fj40mg]

I think think this is a pure and simple comparison.

Here's @ErikinSC pulley alignment perfect!

Here's Danny's @pngunme pulley alignment perfect!

Here's my pulley alignment terrible!

 

[Solace in Solitude]

This is the best I can do... Hope it helps...

I bought a wider PS pulley from Georg. But, that was simply so I could run a wider belt.

Your PS Pump looks a little different from mine - is your's from an FJ60, like mine?

Here's the measurement from the front of the PS reservoir to the front of the pulley 2.5"

 

[Solace in Solitude]

Mike,

The more I compare your's, Erik's and mine, it looks like your PS Pump is actually mounted further back than ours... Is it possible to bring it forward to make up the difference you need?

In the three pictures, mine and Erik's PS Pump reservoir is about a third of the way into the rad hose .... Your PS pump reservoir almost aligns with the side of the rad hose.

Of course... It could be the pictures....

 

[78fj40mg]

Mike,

The more I compare your's, Erik's and mine, it looks like your PS Pump is actually mounted further back than ours... Is it possible to bring it forward to make up the difference you need?

In the three pictures, mine and Erik's PS Pump reservoir is about a third of the way into the rad hose .... Your PS pump reservoir almost aligns with the side of the rad hose.

Of course... It could be the pictures....

Hey Danny,

Thanks for the pics and the PS shaft measurements, I really appreciate your efforts!

I've exhausted all possibilities of correcting the alignment issue unless I find another PS pump pulley. I've removed the PS pump, brackets, etc. from my 40 for now.

As of this moment I don't know how I will proceed, maybe Georg will chime in with a remedial solution other than throwing more money at the problem by replacing other engine components when it's clearly the PS pump pulley alignment issue. Georg refuses to accept the fact that this is a pump pulley issue.


Have great weekend!

 

[roma042987]

Dude your pulley is on backwards!

 

[djcfj40]

Roma,
I believe you nailed it !!!!
I didn't see that until you mentioned it...
Now I'm really curious if this solves the mystery...
Good Job !!!

 

[78fj40mg]

Danny,

Here's a bench measurement of the PS pump and my suspicions are true, my pump shaft is a 0.25 inches shorter than yours.

Your pump shaft 1.75 inches

My pump shaft 1.50 inches

Pulley turned 180* 1.25 inches

updated pic

 

[Solace in Solitude]

Nor did I!!

Good eyes @roma042987 !!

Mike, as I said earlier... it looks like your PS Pump pulley is about 1/2" behind the track that Erik and I have with ours... that's what it looks like when I compare the pics. Turn your PS pulley around and see if it brings it forward enough to align it wit the ALT-CR. Hope it does!!

 

[Solace in Solitude]

Mike - can you see if you can get a clearer pic of the last pic, above? I can't make out the right edge of the pulley

 

[orangefj45]

Hey Danny,

Thanks for the pics and the PS shaft measurements, I really appreciate your efforts!

I've exhausted all possibilities of correcting the alignment issue unless I find another PS pump with a longer shaft. I've removed the PS pump, brackets, etc. from my 40, this has been a complete waste of money and time.

As of this moment I don't know how I will proceed, maybe Georg will chime in with a remedial solution other than throwing more money at the problem by replacing other engine components when it's clearly the PS pump alignment issue. Georg refuses to accept the fact that this is a pump issue.


Have great weekend!

Slow down a minute there .............

I think the first thing you should do is to remove the pulley and post pics of both sides. If you can measure the height in both positions that would help as well. I'll be happy to run to the shop tomorrow morning ( on my day off ) to grab another pulley from a 60 and take some measurements. If it's a pulley or pump issue, then you're guaranteed that I will send a replacement free of charge.
I have tried my best to help you out with your conversion every step of the way since you first contacted me. Be it via the board, messages or phone calls. So please consider what you post on here about how I conduct my business. If you're unhappy with any of the parts I supplied, then feel free to send them back for a 100% refund. My advice is and always has been free. I'm here to share information and help fellow cruiser heads with their projects. But I'm not here to have my reputation tainted ...........

Sincerely.

Georg @ Valley Hybrids

 

[GA Architect]

Mike,
Can you add some washers behind the pulley to bring it out? From this photo,

Looks like you may have a few washers between the nut and the pulley? Is there any more thread on the shaft outside the nut? If so, then maybe you can shim the pulley out?

 

[orangefj45]

Dude your pulley is on backwards!

That's the first thing I said when I saw the issue a few days ago.

It might just be an oddball pulley. Hopefully we'll figure this out shortly.

Georg @ Valley Hybrids

 

[orangefj45]

During our phone conversation yesterday you mentioned that there were only two bolts attaching the pump at the front to the factory bracket and no bolts in the rear. Were you able to confirm this?
It should have one bolt in the rear at roughly the 9 o'clock position.

Georg @ Valley Hybrids

 

[78fj40mg]

Mike - can you see if you can get a clearer pic of the last pic, above? I can't make out the right edge of the pulley

Danny I updated the pic. Thanks.

 

[78fj40mg]

During our phone conversation yesterday you mentioned that there were only two bolts attaching the pump at the front to the factory bracket and no bolts in the rear. Were you able to confirm this?
It should have one bolt in the rear at roughly the 9 o'clock position.

Georg @ Valley Hybrids

Georg, confirmed I had three bolts in.

 

[orangefj45]

Are the pump and pulley off the engine right now?

 

[78fj40mg]

That's the first thing I said when I saw the issue a few days ago.

It might just be an oddball pulley. Hopefully we'll figure this out shortly.

Georg @ Valley Hybrids

Georg, above you can see measurements with pulley turned 180* which is worst than before. The pulley has always been correctly installed.