ok - the PSC Big Bore JK steering gearbox is bolted in place. Since I didn't have a gearbox to begin with (well I did but it was for a right-hand-drive so that wouldn't help anyway) I opted to take the large volume of online advice and got the PSC Big Bore gearbox...and yeah BIG it is. To give some perspective here's a couple pics -

This is the Big Bore gearbox compared to the stock unit -


This is the sector shaft compared to a 1-ton Chevy TRE - big stuff indeed -


The nut is effing huge -


Anyway, the big Magnum 360 between the fenders made things a bit tight, but even so thankfully the only place where there was a clearance issue was between the steering pump (Grand Cherokee placement) and the top of the box. In order to get it to clear I had to French the mount into the frame about 3/8", which worked great, and to make plenty of room for the ram-assist lines I modified the d-side engine mount frame plates.

Cut into the frame to make room for the new mount -
Before -


After -


Welded 1"x .5" id DOM tubes to the back side of the main mount plate, made respective holes on the opposite side of the frame, and glued it all in solid


easier to see what I had to do to french the mount into the frame when it was in primer -


The mount had to be moved forward about an inch for clearance, which worked great, and just filled in the remaining holes. Note, this was originally a right-hand drive and fortunately I didn't have to contend with the OE anti-compression tubes presently on the pass-side -


and painted, even used proper conical lock washers (didn't want standard split lock washers to spit themselves out during the constant side-to-side stresses, torqued to the OE-spec 87 lbs -








Got 7/8x3/4 right and left-hand heims and have the tie rod in place right where the old setup was, all of which is very nicely protected by the full-hydro mount truss, which I left in place -


Used multiple tape measures to center the steering, and measure the tie rod length including a very slight toe-in -




Picked up a nice 7* reamer and drilled the pass-side high-steer arm for a TRE to connect the crossover drag link to the huge Big Bore pitman arm -


The JK Big Bore pitman arm is a BIG honkin' unit (apparently same-same as an '09 Dodge, in case anyone wants a drop pitman arm, FYI). And when 'straight' the Big Bore pitman arm was unusually off-center (to the d-side) relative to the chassis (stock JK setup I presume), but I wanted mine centered so I carved out one of the splines to locate the arm a couple slots to the center -


Drag link, 1.75x8 ram, fittings, and hoses are next up to be finished. Progress

 

The threads on both of the 7/8-18 threaded inserts for the crossover drag link were jammed up, but yesterday ShazAmazon delivered both of the right and left-hand taps same-day, got the threads cleaned up, and this morning got the 1-ton TREs installed at both ends, and got the drag link installed. Then removed both front coils and flexed everything out to see how good my eyeball math is on what will hit or not, and the only mods I had to do were to put a small bend in the drag link and trim the front truss a small bit for the minimal clearance needed - everything flexes out nicely 👍 .

I'm going to drill/tap the Reid knuckles and thread in some steering bump stops, and then next up is to find a good home for the 1.75x8 ram that arrives today. Then to connect the plumbing, reinstall everything, and party on.

No idea if having 17 degrees of flex is 'good' or not, but it's what this Jeep ended up, and considering it's just a simple lifted stock-style suspension it's plenty good enough for me -

 

ok the conversion back to ram-assisted steering is almost complete. The gearbox, pitman arm, drag link, tie rod, and ram are in place. Hoses and column linkage are next, then I'll fill it back up with Prestone. These pics are at nearly full drop -









the cover plate makes an excellent mounting platform for the ram -

 

Plumbing, column and such are all connected and ready to fill -

It gets cramped at max squish but it all fits and functions -





I also wanted a bit more front compression travel before hitting the bumps so I pulled the DV8 bump stops apart and machined a 1.5" longer internal sleeve so it now has 1" of travel vs the 2.5" it came with - should work great -

 

a'rite - after 3-1/2 weeks the conversion to ram-assisted steering is complete, updated bump stops and coils are back in place, weight is on the wheels, system is bled out, and everything appears to be behaving nicely. Couldn't get the drag link exaaaactly parallel to the track bar but they're pretty close - hopefully it will steer confidently at speed. Once I get the radiator back in I can fire it all up and see how it performs...

 

horray! Fired it up and everything is working great - steering actually seems faster lock to lock than it did with full-hydro, smooth, no bubbles, fluid is crystal clear, drives really dern'd well down the street. More fine-tuning to come, but I'm really happy with the system, and it definitely feels way more awesomer .

- Sam

 

...tossed Kilroy in Liberty Trail this weekend - part of the Independence Trail system in nearby Penrose, CO, and the beastie did great. Liberty is a solid 7 - pretty much a ravine full of big rocks and ledges, a real workout for any machine. The new steering setup is much better than the full hydro setup - I don't think it's any more powerful, but the 'feedback' in the wheel is SO much better - much more to my liking. Live and learn.

And yah I am VERY happy I chose to keep the full hydro front truss - it is an outstanding shield for the tie rod, and it got plenty of 'use' on this trail.

The fan tickled the fan shroud a couple times, so this morning I pulled it out and opened it up another 1/4 inch, which should do the trick. Also the radiator fan just isn't creating the airflow necessary to keep the engine at/near 180*, so I'm looking at alternatives...which might have to be an electric setup...which I don't really want - I like the 'mechanical' setup...but apparently it just isn't enough to keep up, so there's that to ponder.

Otherwise it's getting closer and closer to being fully 'done' mechanically, and hopefully I'll be able to start on the finish work - lights, HVAC, paint, etc.

I haveta say...I am really...really liking this machine.

Couple pics from the trail. Not quiiiite all the way stretched out but close -







couple pics of the trail itself - pretty much just like this the whole way -

 

picked up some heavy duty spiral wrap loom for the ram lines, fabbed my own aluminum rear quarter panel armor and got it bolted up, got the rear winch installed and ready to use, and hitting a trail tomorrow -







relocated the winch controller plug to 'here' -




took the soft top off for the run tomorrow...

 

it's not very exciting, but here's a video from Liberty crawling out the gatekeeper -
https://imgur.com/65fS78S

 

went to my favorite local trail this past weekend - Chinaman Gulch, and here's some vids to show some of the harder lines -
The "Rockpile" -
https://imgur.com/65fS78S

"Whale Tail" -
https://imgur.com/0yDcIK8

"The Wall" -
https://imgur.com/24GHg8s

"V-notch" -
https://imgur.com/ldgYhFy