POWER STEERING CONVERSION INTO LAND ROVER SERIES 2A, and 3
Our power steering conversion is quite unique, it is the only power steering conversion available that will give you 3 turns from lock to lock, not the usual 4 turns that manual and other power steering conversions steering have, we found that with 4 turns the steering was over powered and too light at speed, so with our unique steering system we have made the steering with more feel and slightly heavier. Land Rover models with power steering have 3 turns lock to lock.
We use the P38 Range Rover ZF power steering box, far more reliable than the Adwest box, this is fitted using our special mounting plates to be welded to the chassis, the steering box is then bolted on the outside of the chassis and therefore does not require the front chassis cross member or the front panel to be altered in any way. This allows Turbo intercooled Diesel engines being fitted so there is room for the intercooler, radiator and oil coolers etc. We use the Land Rover 90/110 steering column assembly and steering wheel for this conversion.
The customer will need to obtain the P38 steering box, the P38 universal joint coupling shaft, the power steering pipes, (petrol or Diesel it does not matter) the brown plastic reservoir and the mounting bracket. You will also require the power steering pipes from the engine that is being installed.
The customer will also need to obtain the steering column assembly and brackets from a Land Rover 90/110, complete with the steering wheel, (note there are 2 different splines on the steering columns so get the steering wheel to match) Whilst the series steering wheel may fit one of the columns the dish is too deep and will be too close to the driver, the Defender steering wheel is almost flat.
It is assumed the P.A.S conversion is being fitted at the same time as an engine conversion so the engine will have the power steering pump fitted, if using our 300TDI conversion please order the engine bay kit with power steering (the drive belts are different).
If You don’t have an engine fitted with a power steering pump then an electric one could be fitted. This is something we are currently developing and hope to have it available in the new year (Jan 22). Another option if it is a 2¼ petrol or diesel is to fit a 2.5 petrol or diesel bracket and pump along with the pulley required.
Series 2 (1958 –1961) models have the steering arms fitted on top if the swivel housings, these arms are quite weak and not up to power steering, However if you do want to fit the PAS kit ,we recommend fitting the Series 2a-S3 front axle, as these have the arms fitted underneath, they have stronger arms and 7/16” studs to swivel housings.
The inner wing will need altering to accommodate the steering box and shafts etc.
We recommend the swivel housings are in good condition and the swivel preload is set to the maximum the workshop manual states.
This conversion is suitable for Left Hand Drive models.
If the conversion is done neatly, the installation will look original and not like a conversion.
We are working in conjunction with Richards Chassis, so you can order a chassis from them with P38 power steering box mounting plate welded to the chassis before it is galvanised.
SUMMARY OF INSTALLATION
This conversion kit is to fit the P38 Range Rover power steering box to the chassis and drag link assembly to connect to the swivel housing steering arm, this is not a full power steering kit as the customer will need to supply their own major components, it is designed to be used with conversion engines that have power steering pumps fitted as standard.
You will need a steering column assembly and brackets from a Land Rover 90/110, complete with the steering wheel, (note there are 2 different splines on the steering columns so get the steering wheel to match) a P38 steering box, the universal joint coupling shaft, the power steering pipes, the brown plastic reservoir and the mounting bracket.
It is assumed the P.A.S conversion is being fitted at the same time as the engine conversion so the front of the bodywork has been removed.
Remove the original manual steering gear, including the drag link and relay from the chassis.
Clean up the chassis in the area the steering box mounting plate and gussets are to be welded.
Remove the original steering box mounting plate there are 3 x 5/16” bolts that fix this plate to the chassis. Measure 19” from the front bolt hole to the rear most mounting plate bolt hole centre line, clamp the plate in place, the plate should be vertical and equalise the distance between the chassis and the mounting plate bolt holes, on LWB models we would recommend placing the bolts from the back of the plate as the chassis is a different section to SWB models and the bolt head flats will need to be aligned with the chassis, tack weld the plate in place. Fit the gussets to the outer edge of the mounting plate tack these in place.
Check the dimensions and weld the plate and gussets in place leave out short sections of weld to allow the bolts head to fit correctly, weld in the plate and gussets, the welding must be of a very high standard and we recommend this be carried out by a competent welder, weld around the central hole to give extra strength. Clean up the welded area, paint with primer and black paint.
On the 90/110 steering column you will see a support bracket welded to upper part of the column, this will need removing, on Series 3 models there are two nutserts, fitted in the engine bay side of the bulkhead that the steering column support bracket is fitted to, the mounting bracket on the 90/110 column will fit to this, drill the bulkhead off the mounting bracket bolt holes then bolt up the mounting bracket. The bracket on the bottom bearing housing will fit the vertical section of the foot well, the foot well will need drilling for this. Mount the steering column, use a combination of Series 3 and 90/110 mountings to secure the steering column.
On Series 2-2a models, there are no nutserts in the bulkhead front face, there are 2 types of column supports, use the type that is fitted to the original vehicle, fit the bottom bearing mounting as per series 3 models.
Once the column and steering box is fitted, use the P38 steering shaft universal joint coupling shaft this will fit the column and steering box, adjust the position of the pinch bolts to suit and tighten up the pinch bolts.
The steering drag link will come supplied assembled, fit this to the steering box and the axle steering arm, the adjuster end goes to the steering box end, the track rod ends are standard S3 at the axle end and standard P38 at the steering box end.
As we are not fitting one specific engine we can only give general guidance on working out the hydraulic pipes, most of the Land Rover engines use 8mm main power steering pipe, the P38 used 10mm, fit the main power pipe to the box, and alter the pipe as required for you installation, fit the main power pipe from the pump, bend the pipes to align with each other. In a suitable location near the front cross member cut the pipes, fit the hydraulic compression fitting supplied.
Mount the reservoir in a suitable location to fit the feed pipe, use new return hose from pump to reservoir, STD oil resistant hose should be used for this, we recommend flushing the pipes before the pipes are connected to the pump and box.
The inner wing will need cutting around the steering box and the steering column, make up boxes to cover the steering box and column, see photos for suggestions, keep the steering box cover as small as possible so it does not foul the tyre on full lock when on full suspension articulation.
The upper steering column inside the vehicle has a longer inner shaft than the steering column you are replacing, the Series steering wheel is dished, the 90/110 steering wheels are flat so the rim is in the same position. The Series 3 column shrouds are to small to allow the indicator self -cancel lug to clear, a suggestion would be use the 90/110 shrouds and switches and alter the vehicle wiring as required.
Series 2A models a longer tube can be made up to allow the rubber indicator switch wheel to make contact.
When the system is connected up fill the reservoir with power steering fluid, Dextron 3 ATF should be used, turn the steering wheel from lock to lock a few times this will bleed the system, set up the steering box for straight ahead and adjust the drag link to get full lock to lock travel, road test, and check for leaks etc.
We recommend the swivel housings are in good condition and the swivel preload is set to the maximum the manual states.
This kit is suitable for Right Hand Drive Models and Left Hand Drive Models
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