F100 4x4 power steering conversion how to!

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69SCJ
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F100 4x4 power steering conversion how to!

Postby 69SCJ » Sat Jan 03, 2015 2:57 pm

Well I finally did it, and thought I'd post how I accomplished it so it would help others. First off I did my reading on here and other sites and decided to go with a 79 Bronco steering box with a later model 2 wheel drive worm gear/rack.
Check out these two links great info on this:
http://www.wcb4x4.com/tech/diyrockcrawler.shtml
http://www.fordification.com/tech/power ... 00-4WD.htm

Before I jump into how I accomplished this I have to say at first I just wanted to mount the 79 Bronco box near the trac bar bracket just like it is on the 78 and 79 full size Bronco, but it was so close to my oil filter that it would not make it possible to change the filter! My truck has a 390 with the oil filter adapter putting it in the horizontal position. Other combinations may allow the box to mount in this position, but it would not work for me. If you could mount the box in that position you would not have to trade the worm gear/rack.

Now on to how I did it:
1. I followed the directions in the WCB link above on swapping the worm gear/rack. No need for me to show any pics or go on about it as they a superb job in their link.
2. I cut out some of the inner fender to jockey around the box and figure out the best placement/angle. Notice I cut out way too much because I tried to fit it further back the first go ‘round!
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3. Next I placed the box in position using the existing rear most bottom bolt hole.
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4. To get the box to lay down in the front I realized I needed to cut some of the radiator support out, knock the body mount forward some, re-weld the joint, and shoot some paint for protection.
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I also had to grind a bit of the front of the steering box.
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5. Once I got the box at the angle I liked I used it as a template to drill a new forward most hole.
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6. At this point you should have two bolts to hold the box in place. While in place for the third hole I drilled a 27/64” hole thru the box, frame, and thru the plate that is on the inside of the frame. Next remove the box and drill the hole to 9/16” and tap the hole in the frame to receive the original bolt (1/2” – 13). I did this rather than use the existing hole in the box so I could bolt it to the plate inside the frame like it was from the factory (just in a new place). In these pics you can see the new bolt placement compared to the existing and the new tapped hole.
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7. Once the box was in I used the original Pitman arm and draglink. Surprisingly I did not even have to adjust anything! Steering wheel ended up dead level just as before. I don’t know if everyone will be as lucky as me. In the past my truck had some kind of power ram assist that was cobbled together to the manual box. Did that make my life easier? I don’t know!

8. Now that that was out of the way all I had to do was fashion some kind of steering shaft. It went surprisingly easy also. I used a combination of the two wheel drive box shaft and my original shaft. Basically I cut the 2wd shaft just below the rag joint and my original shaft far enough below the u-joint to insert into the 2wd shaft 2-14”. I did all of this for a measurement of 18-3/8” from center line of bolt to the flat part of the u-joint cup as shown. That was with the tulip coupler collapsed and the double D slip portion extended. You should do your own measuring to verify shaft length required.
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9. For some reason I had to use my original tulip joint to fit on the new steering box. To make it work on the new shaft I had to grin the pins down maybe a 1/16” each side.
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10. I welded all around where inserted and also did four 3/8” diameter rosette welds. Wallah…new shaft.
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And ready for paint:
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11. Connect hoses and bleed as described in the WCB link above.


I love my new power steering!!! It’s a joy to drive with 33’s!

Let me know if you have any questions,
Tyler
68 f100, 390, 4x4, NP435, LWB, 33/12.5/15's, power steering.... work in progress!!!

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Re: F100 4x4 power steering conversion how to!

Postby HIO Silver » Mon Jan 05, 2015 3:45 pm

Good job! We appreciate the pics and how-to write up! :thup:

Yessiree... when I bought my rig it had manual steering,a lil 13-inch steering wheel, and 35-inch tires. I hated driving it and swapped to the 78/79 PS steering system. It drives dreamy now.

On the oil filter interference issue, it can be overcome with a shorter, Fram PH16 (or equivalent) oil filter or a 90° housing from a later 4x4 equipped with an FE.
70 F100 LB 2WD, 360FE, E-Street EFI, TKO-500, 76K original miles.. follow my rebuild: The Lo-Buck Bumpside
71 F250 LB, 2WD, 360FE, T18, PS, PB, D60 with 4.11s
73 F100 SB 4WD, 390FE, NP435, +4 on 35s

01 Ferrari 360 Spider F1
01 F150 SuperCrew Lariat 4WD
01 PT Cruiser Limited (DD)
68 Mustang
65 Mustang

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Re: F100 4x4 power steering conversion how to!

Postby cep62 » Mon Jan 05, 2015 9:18 pm

Nice Job.

In regards to the oil filter.
The F E has a bolt on filter mount, you can switch it with one that points down.
The problem with that is, on a stock 4wd it hits the suspension.

The solution to either mount is a shorter filter Mustang II and some chryslers used them.

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Re: F100 4x4 power steering conversion how to!

Postby 69SCJ » Tue Jan 06, 2015 6:50 pm

HIO Silver wrote:Good job! We appreciate the pics and how-to write up! :thup:

Yessiree... when I bought my rig it had manual steering,a lil 13-inch steering wheel, and 35-inch tires. I hated driving it and swapped to the 78/79 PS steering system. It drives dreamy now.

On the oil filter interference issue, it can be overcome with a shorter, Fram PH16 (or equivalent) oil filter or a 90° housing from a later 4x4 equipped with an FE.


I have the 90 degree adapter, but it looks like the bottom of the oil filter would hit the axle housing when compressed. The short oil filter sounds like it would have done the trick either way.
Last edited by 69SCJ on Tue Jan 06, 2015 6:54 pm, edited 1 time in total.
68 f100, 390, 4x4, NP435, LWB, 33/12.5/15's, power steering.... work in progress!!!

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Re: F100 4x4 power steering conversion how to!

Postby 69SCJ » Tue Jan 06, 2015 6:54 pm

cep62 wrote:Nice Job.

In regards to the oil filter.
The F E has a bolt on filter mount, you can switch it with one that points down.
The problem with that is, on a stock 4wd it hits the suspension.

The solution to either mount is a shorter filter Mustang II and some chryslers used them.


Yea, wish I had known about the shorter filter. I actually thought....it sure would be nice if there was a short filter that worked, but did not know they made one! Seems like the whole mess would have been easier to do up next to the track bar. Anyhow, it's done now and I'm driving it a lot more because of it!
68 f100, 390, 4x4, NP435, LWB, 33/12.5/15's, power steering.... work in progress!!!

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Re: F100 4x4 power steering conversion how to!

Postby cep62 » Wed Jan 07, 2015 9:29 pm

69SCJ wrote:Anyhow, it's done now and I'm driving it


That's the most important part. :thup:

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Re: F100 4x4 power steering conversion how to!

Postby HIO Silver » Wed Jan 07, 2015 9:44 pm

cep62 wrote:
69SCJ wrote:Anyhow, it's done now and I'm driving it


That's the most important part. :thup:


2x... I used to absolutely dread driving it but I was well aware of the issue when I bought it. I can totally relate to SCJ's new-found elation. :thup:

.. and the tech tidbit is for "the next guy".
70 F100 LB 2WD, 360FE, E-Street EFI, TKO-500, 76K original miles.. follow my rebuild: The Lo-Buck Bumpside
71 F250 LB, 2WD, 360FE, T18, PS, PB, D60 with 4.11s
73 F100 SB 4WD, 390FE, NP435, +4 on 35s

01 Ferrari 360 Spider F1
01 F150 SuperCrew Lariat 4WD
01 PT Cruiser Limited (DD)
68 Mustang
65 Mustang

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Re: F100 4x4 power steering conversion how to!

Postby 69SCJ » Thu Jan 08, 2015 9:51 am

HIO Silver wrote:.. and the tech tidbit is for "the next guy".


Exactly, and much appreciated. That's why I love this site and classicbroncos.com. Lot of good people!
68 f100, 390, 4x4, NP435, LWB, 33/12.5/15's, power steering.... work in progress!!!

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Re: F100 4x4 power steering conversion how to!

Postby shybutpsycho » Mon Feb 01, 2016 4:53 pm

Similar to my conversion except I have L&L's fender well exit headers. I had to cut the steering column off at the fire wall & grind it into a "double D" shape. The it goes from a Borgeson joint to a collapsible shaft to a second Borgeson joint at the box. Had to slightly bend a header tube and used recessed tension screws on the joints, but walla! Power steering on a 69 F100 4x4 with fender well exit headers.

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Re: F100 4x4 power steering conversion how to!

Postby Socal F250 » Fri Sep 01, 2017 9:09 am

Do you have a rough cost on all the parts and pieces for the conversion?

Thanks!!
1971 F250 Explorer 4wd
2006 E350 Adventure Van 4wd

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Re: F100 4x4 power steering conversion how to!

Postby HIO Silver » Mon Sep 04, 2017 7:02 pm

I spent $353.....

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Re: F100 4x4 power steering conversion how to!

Postby Socal F250 » Mon Sep 04, 2017 7:16 pm

Great, thanks for the pricing info!!
1971 F250 Explorer 4wd
2006 E350 Adventure Van 4wd


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