Second Generation Power Steering Cooler How To

All second generation S-Series trucks came with a power steering cooler as a standard feature. This is a good addition to any steering system especially if you are an auto crosser or if your power steering pump also powers a hydraulic brake booster. Unfortunately none of the first generation S-Series trucks ever came with a cooler from the factory. But luckily it is not hard to add one.

The first thing you need to do with your new cooler when you get it home is clean it and paint it to prevent any rust. Once you are done with that then you need to flatten out the mounting tabs by placing them on a flat surface like an anvil or even a bench top and flatten them out with a hammer. This will make the tabs long enough to reach across the first generation radiator support and also make it mount flush. You will also need to cut off all the excess steel line. The bends that fit the second generation truck will not work with the first generation design. You can add your rubber lines at this point if you wish. Remember since you cut off the barbs that were on the old lines it is always a good idea to use two clamps on a line without a barb, just incase. One clamp would probably work since there is very little pressure in this side of the system. You will also need to spread the steel lines apart just enough to get both pieces of rubber hose onto the steel lines.

To be able to install the cooler you are going to have to remove your grill and front bumper. Remove the grill before the bumper it makes accessing the bumper bolts much easier.

To bolt on the cooler you will need one 6mm bolt and one sheet metal screw. On the top of the radiator support remove the plastic clip that holds the hood release cable. Bolt the threaded side of the cooler mount to the radiator support with the 6mm bolt. Next line up the cooler so it sits properly on the radiator support and lines up with everything else. Then drill a small pilot hole in the bottom of the radiator support and then use a self tapping sheet metal screw to secure the bottom of the cooler mount.

Once you get everything installed you can attach your lines. Feed the lines through the large hole in the lower drivers side of the radiator support. Protect the lines with some sort of cover. Your lines must attach to the low pressure RETURN SIDE of the power steering system. You can identify it in an instant because the hoses are secured with hose clamps. You can also opt to install a power steering fluid filter (AC Delco # PF883) this will keep the fluid clean for years to come. Remember you will need to top up the fluid before you drive.