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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 08, 2018 9:39 pm 
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Joined: Fri Mar 25, 2005 9:59 am
Posts: 2378
Location: Daleville, PA
The Cummins was drilled and tapped for 9/16” x 18 bolts. I had a hard time holding the bracket in place and trying to start the bolts so I wound up making (2) 9/16” studs that were about 1 1/2" long. I screwed these into the block and it made life a lot easier setting the bracket in place. So here is my first test fit...

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Once I was happy with the fit, I moved onto the piece that bolts off of the top of the air intake. For this I used a piece of 3/16” plate but wound up making it longer than the original piece. I decided to tie it into all (3) bolts on the intake instead of only (2)...

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Once that piece was done I decided to drill all the reservoir mounting holes in the 10” wide plate. I also drilled some 1/4" holes on the side of the plate so that I could use some line cushion clamps for the fuel shut off wire along with the Jake throttle switch wires...

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Then I moved onto the top angles for the bracket. I cut a total of (3) of these...

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And then welded them in place... I also radiused all the edges of the plate...

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And here was my last trial fit but this time with the top support bracket set in place...

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That’s it for now...

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 08, 2018 10:05 pm 
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Joined: Wed Nov 05, 2014 12:49 pm
Posts: 267
Location: Horseheads NY
Looks good Tom. You might want to think about using studs in the intake manifold to secure the brace. If you Loctite the stud in, then tighten with a nut, you will be less likely to strip out the threads in the aluminum manifold. When bolted, the bolts tended to pull out from vibration.


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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Wed Jan 10, 2018 5:02 pm 
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Joined: Fri Mar 25, 2005 9:59 am
Posts: 2378
Location: Daleville, PA
Thanks Stan, that’s good advice, I will replace the 3/8x16 bolts with studs... I didn’t realize the intake was aluminum at first.

When the mounting bracket was done I started working on the reservoir...

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Several coats of paint had it fairly well protected but there was some rust under the brackets...

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One thing I noticed is that the lid must have been leaking around the expansion fill plug. The used silicone on the top to try to seal it and some type of clear epoxy on the bottom...

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I wound up bead blasting the lid in the cabinet and then had a friend weld a bead around the bottom of the lid. Hopefully this will prevent any future leaks. One thing I did notice was that the lid on our 761 had a vent in it. This one didn’t and neither did the chrome one on my Dad’s 361...

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More to follow...

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Tom Millard
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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Wed Jan 10, 2018 5:03 pm 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
Another item I had to tackle was the location of the coolant filter. On this truck it was mounted to the top of the air intake with a re-purposed bracket (I don’t think it was originally a Cummins piece...)

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So I decided to modify the original bracket and weld it to a piece of flat stock. Then I could bolt this behind the reservoir bracket using the bolts that hold the reservoir on (if that makes any sense...) A future picture will help clear this up...

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Once I was done with all the brackets I decided to sandblast everything, starting with the reservoir...

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And here is what I wound up with when all the blasting was done...

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This takes us up to the week before Christmas. Right after I finished sandblasting the parts I dropped them off to get powder coated. As I mentioned before, there is a guy who does this locally who is reasonably priced and turns things around quickly.

That’s it for now...

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Wed Jan 10, 2018 5:33 pm 
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Joined: Fri Mar 25, 2005 9:59 am
Posts: 2378
Location: Daleville, PA
When I first started this conversion I ‘thought’ I had all the pieces and parts I needed... Well I was wrong! But fortunately, thanks to my all Brockway friends, I was able to get everything I needed...

The first issue I realized I had was not having the correct pump. I had asked this question in a separate post... My original oil pump did not have the provisions to mount the power steering pump. Fortunately Dave M was reading this post and called me to let me know he had the oil pump I needed.

So several weeks before the Holiday I spent a Saturday visiting friends in NY. First I stopped at Dave M’s in Delhi, checked out his great collection and picked up this oil pump. Ironically Dave also helped me out with the power steering pump for the 671 in my Dad’s 361.

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68_Brockway_0518

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The second problem I ran into was not having the correct steering arm for the 18k Rockwell axle we installed a few years back. The front axle did not come with a steering arm so Russ used one from a 12k axle. Although it fit, it did not fit well and had a little slop in it. I also knew it was important to get the right steering arm to maintain the correct steering geometry (ie Ackermann steering geometry). Brian Enck mentioned he had a parts truck with an 18k axle that originally had power steering.

So after finishing up visiting with Dave I went to Brian Enck’s in Otego. Equipped with some heavy duty tools and a set of torches, we proceeded to remove the steering arm from the front axle. Brian wears his hood up to protect his identity...

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I also had an issue with the pitman arms I had collected over the years. Once was too short...

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And the other had a ball that looked like it never saw a drop of grease in its life...

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Brian also had an extra pitman arm for me so I was able to come home with this...

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Last but not least I stopped at Paul Polizzi’s on my way home. I was able to check out his new V12 cabover with the custom dual stacks...

That’s it for now!

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Thu Jan 11, 2018 9:03 pm 
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Joined: Wed Jan 11, 2006 11:00 am
Posts: 816
Location: Unadilla,NY
Excellent work Tom as usual. I guess you and Mueller had a crystal ball. When i was taking off pittman arm for donor power steering box I so wanted to break out the torch and destroy that pittman arm. But I had the Mueller/Millard voice in my head "save everything". So it was good I did. You forgot to mention you took the una-bomber to brooks BBQ :)


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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 15, 2018 5:13 pm 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
You’re right Brian, our stop at Brooks for lunch was one of the highlights of the trip! And boy am I glad you didn’t ruin that pitman arm!!!

While the parts were out getting powder coated, I decided to work on the oil pump. I started with cleaning the heavy stuff out the outside of it first...

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Then I decided to take it apart to clean the inside as well...

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I also had a conversation with Stan A regarding the oil pump and he recommended removing and cleaning the pressure relief valve as well...

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When I was done cleaning everything I reassembled the pump and gave it a coat of Cummins beige. I found the gasket on eBay fairly cheap also...

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More to follow...

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 15, 2018 5:15 pm 
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Joined: Fri Mar 25, 2005 9:59 am
Posts: 2378
Location: Daleville, PA
Then I moved onto the power steering pump. The original pump I had was a Vickers V20F. For some reason the input splines were wore a bit so I decided to see about replacing the input shaft...

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At first I looked for a replacement shaft but realized they cost about $75 or so. Then with nothing more than luck I found a complete pump for sale on eBay that was rebuilt. Here why I say it was luck... They make about a thousand different variations of these pumps for every type of use. The one I needed was V20F 1P8P 38C 6F 11. I found this info from Eaton (Vickers) online and it explains how to break down the numbers...

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And the pump I found on eBay was the exact same number but 6E instead of 6F. In other words the only difference was that the it was rated at 6 gpm @ 1250psi instead of 6 gpm at 1500 psi. I was able to buy the pump for a little more than the cost of the replacement shaft (shipped!!!) so it was a great deal...

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Notice the arrows on the middle section of the pump. Stan A explained this was the direction of flow. Even if the new pump was backwards you can take it apart and flip it 180 degrees.

So now I decided to remove the pressure regulator valve from the old pump and put it in the new pump, in order to increase the pressure from 1250 to 1500. And it’s a good thing I did, I found out that the small spring within the valve was broke...

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In the previous pic you can also see 3 shims. I also disassembled the new pump and it only had 1 shim. According to the Vickers literature, you raise the pressure by adding shims and reduce the pressure by removing shims. I wound up using the new pump body along with the input shaft and used the original (3) shims to maintain 1500psi.

Here is a better pic of the old and new input shafts...

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Once I was done reassembling the pump I also gave it a coat of Cummins beige...

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That’s it for now!

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 15, 2018 9:46 pm 
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Joined: Wed Nov 05, 2014 12:49 pm
Posts: 267
Location: Horseheads NY
Tom you're doing great work as always. I know you have your pump all assembled and painted, but if you want to change the rebuilt pump to 8 GPM all you need to do is swap the vane cartridge between the two pumps. The housing castings are the same, the cartridge or "pumping chamber" is the difference. I doubt you will see any real change in performance at a lower GPM except that the steering lock to lock time, which is a full left turn to full right turn, will be slower. Remember the 1st rule of hydraulics, pressure does the work, gallons per minute is how Fast you do the work. There will be a benefit at a lower GPM. The system will be less likely to heat/foam and blow the fill plug out like the Sheppard systems are known to do on occasion. Remember to use 20W non-detergent motor oil for the fluid. It's getting hard to find sometimes, but that is what the system was designed for and performs the best with.


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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Tue Jan 16, 2018 7:25 am 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
Thanks Stan...

As far as I can tell both both pumps were rated at 6gpm. The original pump I got came off of a Brockway and was rated at 6gpm. The only difference between the two was the pressure rating. Were some other factory pumps rated at 8gpm?

Tom

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Tue Jan 16, 2018 12:02 pm 
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Joined: Wed Nov 05, 2014 12:49 pm
Posts: 267
Location: Horseheads NY
My mistake. I had thought that your original pump was 8 GPM and the rebuilt pump was 6 GPM. After rereading the text under the Vickers break down sheet, I see the only difference in your two pumps was the pressure setting. I remember there is a GPM difference on some of the Brockways using the Sheppard system, but I believe they are between the 200 series trucks with the small box and the 300/700/400 series with the 592 box. You should be good to go, and "Ole Shepp" is in good hands.


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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Thu Jan 18, 2018 6:51 pm 
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Joined: Tue May 16, 2017 8:04 pm
Posts: 49
Thanks Tom! I love your presentations, they are the best. Stan keeps us factory right.


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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Fri Jan 19, 2018 8:39 pm 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
Thanks Stan, you had me second guessing myself, I thought I missed something!

Thanks Second!

Once I was done with both the oil and power steering pumps, I decided to install both of them since I was still waiting on the parts from the powder coater. I started with removing the original oil pump (which of course didn’t have the provisions for the power steering pump...)

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And then I set and bolted the new one in place...

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Then I installed the coupler that connects the splined shaft of the oil pump to the splined shaft of the power steering pump, Cummins parts #199589...

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And then I set the power steering pump in place...

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But I did learn a few things... first, the 3/8” mounting bolt closest to the inside of the block is almost impossible to get started with your fingers. So I decided to replace the bolts with 3/8” studs. It was a lot easier to start the nut on the stud. Second, the 1 1/4" cast 90 degree fitting needs to be installed and tightened before the power steering pump is installed.

Once I was happy with the pumps I decided to replace the fuel line between the pump and the rear of the block. This line was replaced before but it wound up hitting the power steering reservoir bracket. You can see the old line here...

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I decided to bend a new one from 3/16” fuel line from Napa. I usually do pretty well bending these lines but for some reason I wound up doing this 3 times... In other words I take my time, measure everything twice, double check the direction of the bends etc, but hey, stuff happens.

I should also note that I had to remove the center section of the floor to get to the fittings at the rear of the block. Fortunately this section of floor was in great shape and all the bolts had Never Seez on them, so they came out easy. On my third try I wound up with this... also notice the bracket I made with a cushion clamp towards the rear of the block. I have a big cam 350 sitting in the garage and noticed all the supports for the fuel so I realized I really needed to add one here...

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In the meantime Russ came up to the garage to drink some coffee and visit, and see how things were going with Ole Shepp. Fortunately I received his seal of approval on the power steering upgrade :)

More to follow...

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Fri Jan 19, 2018 8:41 pm 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
There was one other thing I needed to do that I realized the summer before. For some reason there was no clutch switch installed for the engine brake. I did buy a switch for this but forgot I used it on the 155W for the 5.9 Cummins exhaust brake. I wound up ordering another one from PacBrake and it’s the exact same switch that Jacobs uses. Notice the diode on the switch that connects one terminal to ground. This is used to prevent the contacts from arcing within the switch...

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With the driver side fender off, this was the perfect time to install the switch. And it turns out the bracket that came with the switch worked out well also. It mounted the switch far enough off of the floor for the clutch pedal to activate it...

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By that time the powder coater texted me to let me know the parts were done so I went and picked everything up...

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And almost immediately I started to install everything, with the help of Maddie as well!!!

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Once the reservoir was mounted to the block I dug out the new filter I bought (from Amazon of all places... Fleetguard LF637 Power Steering Reservoir Filter) and the hardware for inside the reservoir...

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Once I installed the filter I made a new lanyard for the expansion plug using some stainless air craft cable I had that was left over from suspended light fixtures...

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And that’s about it for now...

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Tom Millard
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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Sat Jan 20, 2018 6:29 pm 
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Joined: Fri Apr 09, 2010 3:06 pm
Posts: 693
Location: ALEXANDER,NY
Thumbs up as always

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Sat Jan 20, 2018 9:04 pm 
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Joined: Wed Nov 05, 2014 12:49 pm
Posts: 267
Location: Horseheads NY
Great work as always Tom. I look forward to your posts. You need to check the orientation of the diode on the newly installed Jake switch if the truck is positive ground. Most switches that are NOS are meant for negative ground systems. All that needs to happen is flip the diode. You can check the stripe on the diode and compare it to the one on the fuel pump switch. One more gremlin to battle when you have positive ground trucks. The world switched to negative ground just about the time Brockway was building 700's.


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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 29, 2018 5:36 pm 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
Thanks Stan... you had me thinking about your positive ground question but luckily the truck is negative ground...

In addition to the power steering there were a handful of other items that I wanted to take care of. The was a long 1/4" rod that was used for the compression release. This rod now hit the bracket I made for the power steering reservoir. I had posted a question earlier about play in the linkage so I felt it would be a good time to correct everything. Here is a link to the original post...

viewtopic.php?f=2&t=5216

This is what I started with...

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After disassembling everything, this is what I wound up with...


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In the upper left hand corner of the pic you can see an NOS compression release bracket that Stan helped me out with (Thanks Stan!!!) You can also see a piece of 1 1/2” round stock. I decided to use this piece of round stock to replace the pieces that were originally installed when the jake was installed. I wound up turning this piece in the lathe to make my own extension...

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When I was done turning it in the lathe I drilled a hole in the middle to fit over the original piece and then drilled (2) 1/4" holes to accept roll pins (in lieu of bolts...)

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For comparison, this is what the factory install looked like...

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And here is what my extension looks like for the added height of the jake...

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More to follow...

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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 29, 2018 5:37 pm 
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Location: Daleville, PA
Someone has also welded an extension on the factory bracket the rod or cable would attach to, so I decided to cut that off since it wasn’t needed...

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I also decided to use a cable instead of the rod. I had a box full of older PTO cables and found one that was in tired shape. The first 4’ was in great shape but the last 3’ was wore through in a spot, etc. So I decided to use that cable. In order to use the cable, I turned a 5/16” bolt down in the lathe, drilled (2) holes in it, (1) for a cotter pin and (1) for the cable to pass through. And then I found (2) 5/16x18 nuts with washers attached to them...

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And this is what I wound up with...

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When I was done fabricating everything I gathered all the parts up and bead blasted them...

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At that time I also discovered that the original bracket was cracked and that was some of the reason for all of the play...

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I then assembled the new pieces using new 1/4" roll pins and painted everything...

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More to follow...

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Tom Millard
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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 29, 2018 5:38 pm 
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Joined: Fri Mar 25, 2005 9:59 am
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Location: Daleville, PA
While I was working on the compression release I decided to replace something else. The fan support bracket that is mounted directly underneath the compression release bracket had (3) separate spaces under each bolt to compensate to the jake height. I decided to remove these spacers and make (2) new ones...

This is what I started with...

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And these are what I made...

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And here they are installed...

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Well that’s it for now...

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Tom Millard
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 Post subject: Re: 68 Brockway - Power Steering Upgrade
PostPosted: Mon Jan 29, 2018 10:10 pm 
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Joined: Wed Nov 05, 2014 12:49 pm
Posts: 267
Location: Horseheads NY
Looks great Tom. Many of the compression releases used a cable to ease routing issues. Your plan to use an old PTO cable will work good but you may want to think about changing the handle. If you're planning on using the round knob in the cab it will be hard to grip. It takes quite a bit of force to pull the release into the actuated position. You might want to consider some type of a T handle. When you get it rigged you'll see what you need.


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