After some badgering from a handful customers, Wits' End is finally producing the Power Steering Cooler, Hose and Fittings Upgrade Kit. This is everything you need to replace the factory low pressure hoses you have been neglecting and replace the Land Cruiser's "paperclip" cooler with something with more oil capacity and heat transfer. All of the fittings and hoses are pre-assembled Push Lock fittings. The Derale cooler comes in raw aluminum but is anodized in type 2 black anodize to protect the aluminum from corrosion (and make it look cool). Everything is already cut to fit. The only thing you need to do is drill and tap four holes onto the same cross member your old paperclip cooler was on.
NOTE: This kit does NOT include the HIGH pressure power steering hose.
• 14" Derale dual pass cooler, anodized in black
• (2) 1/4NPT to AN-6 fittings
• (3) AN-6 90deg to 3/8" nipple
• (2) 3/8" lengths of Made in USA Continental oil cooler hoses
• (1) AN-6 to 17mm pipe adapter
• (3) OEM clamps: 90467-16008 and 90467-21005
• Drill and tap for the mounting screws
• (4) stainless metric mounting screws
• First decide if you are doing the pressure hose at this time or not. The pressure hose is about $300 from Toyota or about $30 from various aftermarket sources. Doing this hose at the same time as the rest of the kit does makes things smoother. The instructions follow the assumption that you are indeed changing the pressure hose.
• The next step in this mod is to drain your power steering system of fluid. The easiest way to undo the bottom of the smaller resevoir hoses and have a bucket ready to catch the fluid. The reservoir will drain. Then you can remove the bottom of the larger reservoir hose and drain out that. From there you can remove both return hoses completely.
• There are two bolts holding down the paperclip cooler that are above the front crossmember, under the radiator, that need to be removed in order to start removing the paperclip.
• There is a bracket on the driver's side inner frame that is the junction point of the low and high pressure hoses. Remove the 12mm bolt and the main bracket and high pressure how can now go to the next step of removal.
• On the steering gearbox you have an 16mm and 17mm threaded port. These are sized on the box so that you really can't make a mistake. Go ahead and remove both of these fittings using a flare nut wrench. Access to these is challenging but going in from the wheel well helps.
• The paperclip can be removed without taking out the radiator but it does take some finagling.
• Removing the banjo bolt on the pump side of the high pressure hose is a pain in the ass. Be sure to hold the nut on the pump still and you work getting the banjo bolt out. Its a bear. Be sure to remove the two copper gaskets when the hose and banjo bolt come out.
• At this point you should have removed the small and large hoses and clamps from the reservoir, the high pressure hose and the paperclip.
• Now you can move on to the install by just hand threading in the 1/4NPT to 6AN flare fittings into the black anodized Derale cooler. DO NOT TIGHTEN.
• Take the two 90º ends of the hoses and fish them thru the driver's side hole in the front cross-member until they are poking out thru where the cooler will be mounted.
• Place the cooler onto the cross-member to where the fittings are facing the hole where the two hose 90º are facing. Go ahead and thread the 90s onto the flare fittings on the cooler. The orientation doesn't matter.
• Get the cooler positioned so that the two hoses are dead center to the cross-member hole. Once that is decided, go ahead and mark the two REAR mounting holes. NOTE: center the mark as best you can since you will be drilling and tapping those holes.
• Now that you have the two rear holes marked, go ahead and unscrew both the 90s and the 1/4NPT fittings from the cooler.
• Line up the marks from the rear up again and now mark the two front holes.
• Start by drilling out the two rear holes first by using the supplied drill bit, then trap the holes using the supplied tap. Use cutting oil.
• Once trapped and deburred, test fit the mounting for the cooler and use the supplied bolts. Once you have the two rear bolts in hand tight, note the marks on the front two mounting holes. Are they still good where marked or should it be adjusted?
• Once confirmed, drill and then tap the two front holes.
• Using teflon tape on ONLY the NPT ports (never the flare side of the fitting), thread in and tighten the 1/4NPT to flare fittings. To not over-tighten.
• The cooler is now ready to be mounted using the supplied bolts.
• You can now attach both hoses with the 90º fittings but hand tighten for the moment.
• This is the best time to not only install the pressure hose from the gear box to the power steering pump, but its also a good time to thread in the supplied 16mm to 6AN steel adapter fitting into the other hole in the gear box. Tighten down both the pressure hose and fitting into the gear box.
• Place a new copper washer under the banjo fitting onto both sides of the pressure hose before running the banjo bolt thru. then tighten the banjo bolt and hose per the FSM torque spec.
• Going back to the hoses from the cooler, route the hoses from the cross-member, to the frame bracket and behind the mounting bracket of the pressure hose. Using the stock holding bracket from the paperclip could be possible but I didn't see the need for it and it can be difficult to make it work. Your call.
• The hose with the 90º fitting now goes onto the steel fitting you previously tightened down into the gear box.
• The longer hose without a fitting now gets a small supplied clamp before it is pushed onto the small tube of the reservoir.
• The 12" long 5/8" hose gets the two larger supplied clamps and goes from the pump to the large port of the reservoir.
• Now verify ALL of the connections and fittings are tight and fill the reservoir with the power steering fluid of your choice.
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My LX450 had a broken paperclip, and a hacked together fix from the previous owner. Looking for parts I stumbled upon this kit and purchased right away! Installed last week, and everything couldn't have been easier. I took a ton of photos so I could share my easy install with fellow LC owners and those looking to pick up this kit! Only advice I would add would be to triple check your mounting holes as outlined in the instructions. Make sure you tighten the connections before you mark and drill holes so once everything is installed and tight, it lines up properly. Very solid kit, and great buying experience!