4speedfunk
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This is way out there for most H3 guys but if you want to go solid axle, this thread shows you how to port a box for ram assist, and also touches on how to hook it up to the H3 chassis.
I prefer to use a Nissan Xterra steering box (also known as a "Delphi" box). These are very common, cheap, and fit the H3 very well. To hook it up you must get ask the appropriate adapters. I use JIC (-6 AN) hydraulic hoses and fittings. At the box you will need a 16mm female flare-to-6AN for the supply and a 14mm female flare-to-6AN for the return. You will also need a 16mm male o ring-to-6AN adapter for the supply line where it connects to the stock GM ps pump...
Porting for ram assist is optional and if you want to do this mod, you will need two 1/4"NPT-to-6AN fittings, and some caps...
Of course...you'll need a tap and a couple drills...
Start by stripping the internals and get the box down to a bare casting. I left the sector shaft bearings in place but you'll want to cover them to keep shavings out of them. I have shown the two tap points for the ports with some machine ink. Start by punching them and using a smaller but to drill a pilot hole...
Next, enlarge the hole to the proper size (7/16") and tap...
The side port is easy. The top port however requires some extreme care when drilling and tapping. The idea is to drill into a small horizontal passage inside the casting. I use a magnet to help corral the shavings...
When done...check to make sure you intersected the passage correctly. I inserted a small drill bit into the passage to show the intersection. Spend some time to de-burr the passages and make sure there are no obstructions...
Tap this hole and install the adapter fittings. If you use Teflon tape, be sure to pull off any residual tape so it won't break loose and get lodged inside the box...
Rinse and clean the box casting thoroughly...you cannot be too clean!
Now reassemble with a new seal kit...
Once done, you can grind the Nissan input shaft to accept the Hummer steering clamp, and also drill & ream the pitman arm for a GM 1-ton drag link end...
When it comes time to mount the box to the frame, make sure you install tube sleeves on the four mounting bolts. This will prevent you from crushing the frame rail when you tighten them. Also you should always plate the frame rails. They are very flemsy and designed to collapse in a collision...so they should be beefed up before doing any SAS mods.
I prefer to use a Nissan Xterra steering box (also known as a "Delphi" box). These are very common, cheap, and fit the H3 very well. To hook it up you must get ask the appropriate adapters. I use JIC (-6 AN) hydraulic hoses and fittings. At the box you will need a 16mm female flare-to-6AN for the supply and a 14mm female flare-to-6AN for the return. You will also need a 16mm male o ring-to-6AN adapter for the supply line where it connects to the stock GM ps pump...
Porting for ram assist is optional and if you want to do this mod, you will need two 1/4"NPT-to-6AN fittings, and some caps...
Of course...you'll need a tap and a couple drills...
Start by stripping the internals and get the box down to a bare casting. I left the sector shaft bearings in place but you'll want to cover them to keep shavings out of them. I have shown the two tap points for the ports with some machine ink. Start by punching them and using a smaller but to drill a pilot hole...
Next, enlarge the hole to the proper size (7/16") and tap...
The side port is easy. The top port however requires some extreme care when drilling and tapping. The idea is to drill into a small horizontal passage inside the casting. I use a magnet to help corral the shavings...
When done...check to make sure you intersected the passage correctly. I inserted a small drill bit into the passage to show the intersection. Spend some time to de-burr the passages and make sure there are no obstructions...
Tap this hole and install the adapter fittings. If you use Teflon tape, be sure to pull off any residual tape so it won't break loose and get lodged inside the box...
Rinse and clean the box casting thoroughly...you cannot be too clean!
Now reassemble with a new seal kit...
Once done, you can grind the Nissan input shaft to accept the Hummer steering clamp, and also drill & ream the pitman arm for a GM 1-ton drag link end...
When it comes time to mount the box to the frame, make sure you install tube sleeves on the four mounting bolts. This will prevent you from crushing the frame rail when you tighten them. Also you should always plate the frame rails. They are very flemsy and designed to collapse in a collision...so they should be beefed up before doing any SAS mods.
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