Questions on my Gen 2 steering box into Gen 1 SWB project problem

[KrzyDav]

The ole geezer is finally in motion. Got '94 SR box and lines and pump from the yard last spring. My rhumatizz let up so now I'm wrenchin.
I found out '94 pump is a one year pump. anybody need it?
I plugged the inlet / outlet hole by screwing in rubber corks to keep ATF in and grit out.
I used a fat rat tail file to slowly open up the top 2 bolt holes to meet hole on frame of SWB Gen 1.
Got her all cleaned up and painted.
Got her mounted,,,
then, Problem:
The steel lines have a completely different mating to box method.
On the '89 they are flared (like a brake line).
The '94 lines are straight tube into box with a flat forged area in steel tubing , and has a O ring on high pressure line. No o ring on low pressure line( or maybe it fell off in the salvage yard).
.
I called it a night. I think I'll have to use Gen 2 metal lines, but I'll probably have to have special hoses made to mate with Gen 1 pump. and probably special O rings for steel tubes.

I haven't heard of anyone having this problem with the fittings. Maybe it's an "'89 thing," as 90-90 had a Bigger Box on them  and maybe lines with the flat line fittings.

This geezers tired, I'll figure this out maybe tomorrow.

[ChargerX3]

In for how this turns out. I too have a 89 SWB monti as well as a 95SR parts truck.

[KrzyDav]

Looking a pictures of parts on Rockauto I can see that after '89 the line design changed, and from then on it requires O ring.
84-89-  SWB and LWB got the same box.
90 and 91 LWB got a beefier box (still not as big as Gen 2) and O ring lines.
I  got alittle work done today. Pulled steel lines off '89.
I'll install SR lines , , One good thing is '89 hose will connect to '94 steel line.
I don't know what kinds of O- rings to use....

[MudRaider]

Just take all your pieces to a hydraulic shop. Have the proper hose lengths figured out, and they can fit the ends in the hose and properly crimp a ferrule on there for you.

[KrzyDav]

Just took a test drive late last night.
No leaks and I figure I got all the air out of system. Just a few things to tighty  up.
The SR steel tubes bolted into Gen one without bending.
Slightly differnt curves in return pipe hose,,trimmed a few inchesoff and route will do for now. Eventually I'll by sttel/hosereturn line from Rockauto for a 91.
The Gen 2 high pressure steel line bolts just about perfect to Gen 1 pump hose. That line is probably still available from dealer (only) MB636510.
.
A tip for those doing this mod:
Mount box at 2 lower bolt holes.
I removed radiator to keep from risking damage,
( plus one box bolt won't pull out without lifting radiator anyway). I don't have AC to get in my way either.
With Radiator out you can run a big drill with a  25/64  bit to give a straighter shot on drill 2 top hole out.Then finish up with a fat rat tail file.
Shout out to Dan A for making me aware Gen 2 idler arm I was running did not match my Gen 1 pitman and was affecting my alignment during  on curves,,,my tires thank you.

[ChargerX3]

Thanks for sharing. Did you happen to take any pictures during the process?

[KrzyDav]

no,,,my camera died a while back. I am very computer chalenged. I could never get a photo up on the WIRE, can barelydo FB photos and not sure yet how to work this forum.
It was really fairly simple . My biggest worry was messing up the holes, liketaking too much metal . The metal was much softer and easier to work than I expected it to be. The rat tail file really worked well. I didn't realizethat the frame holes would act as a drill guide untill I got it bolted on.
I was unsure of the O rings on steel lines and took my time trying to figure out.
I have to take time be carefull on my truck as it is my only vehicle and I live in a rural area, I've screwed up and been stranded in the past.

[MudRaider]

A definite improvement, isn't it?

[KrzyDav]

I seem to have a little play,, or maybe  it is just more power. I think ratio is the same. I think I may need to turn the sloted bolt 1/2 turn. I'll wait untill it's  seals have soaked up some of its new ATF for awhile. Last time I adjusted my box it started leaking.
Yes this box is impressivly H.D. Even stock box is H.D. but I had to walk to town and buy 32 mm socket for the Pitman arm. I've never needed one that big before.
I'd like to get a 90-94  LS steering pump for it. There's some difference.

[KrzyDav]

Adjusted box. It only took 1/4 turn of sloted stud. It made a big difference.

[concealer404]

Adjusted box. It only took 1/4 turn of sloted stud. It made a big difference.

This adjustment is for "play?"  Like if the wheel is sloppy on-center?

[KrzyDav]

sorry for slow reply,
You should follow FSM. Your steering should only have 2" (check specs in FSM) free play. Mine has about 1/2" now. You should have front wheels off ground and engine off when you adjust. Don't over do it. Too tight and steering won't return like it should,,,which would not be safe.