Rock-AssaultTM Steering Pump Kit Instructions

Paint power steering and reservoir brackets any color you wish.

Remove the stock power steering reservoir, pump, belt and hoses. Install new pump in to pump bracket.

 
Bolt new pump and bracket to stock idler pulley using provided hardware. Install new fan belt provided with kit. It will be necessary to retighten the fan belt after about 100 miles.

   
Install reservoir and bracket in the stock location. Reservoir bracket should line-up with at least 3 holes on the inner fender well on 1984-1995 4cyl Pick and 4Runner 4wd applications.
   
Mount cooler. This can be done one of two ways. You can mount the radiator with cable ties through the radiator using the parts provided in the kit. A second way is to create a frame in front of the radiator, then bolt the cooler to the frame work using the tabs mounted on the back of the cooler.

   
Install high pressure adapter fitting (provided) into steering box. The stock low pressure fitting will be reused. Connect lines as shown in the flow photo above. The black line is the high pressure hose. The blue lines are low pressure return lines. Note that the larger tube is used to connect the reservoir to the pump inlet. Do not use smaller 3/8" hose in this location as it will interfere with sufficient fluid.

Box Fittings
 

 
Fill power steering system with synthetic power steering fluid. We recommend Valvoline or Royal Purple synthetic fluid. When filling the reservoir, don't fill to the top, allow about 1/2" for fluid expansion due to heat.  Over filing reservoir will cause fluid to spill out of the reservoir once the fluid comes up to operating temperature. It will take some time to fully bleed the system the first time. We recommend that you run the motor for about 5 minutes at a time during the bleeding. Allow the oil to set until all the bubbles have separated out of the oil, then run the motor again for 5 minutes. Repeat procedure until oil runs without foam or bubbles.

   

These instructions are designed as a general installation guide. Installation of Trail-Gear Products requires specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 559-252-4950 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safely procedures.

Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Trail-Gear Inc are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warrantee. Modification of your vehicle may create dangerous conditions which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use.

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