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Old 03-23-2016, 12:33 AM
Thread Starter
Join Date: Mar 2016
Location: South-Central KY
Posts: 220
Something for the 2.5 guys

I've been having a few issues with the stock power steering reservoir on my '97 Wrangler SE. I fixed that today using a power steering pump from a '97 up 4.0 pump from an XJ. I did a lot of research and came up with a few vague references of possible interchangeability, but overall pretty inconclusive. I completed this in around an hour, maybe slightly less. Aside from this being a standard part replacement here are a few modifications you must do.

- vacuum canister - This will hit the top part of the P/S reservoir. You can loosen the band clamp around it and slide it up some. There is a location tab (1/4"ish triangular shaped) on the bracket at the bottom, fender side of the canister. You need to take a pair of Vise-Grips and bend this down parallel to the canister. This will allow you to slide the canister away from the pump and retighten the band clamp. I had enough play in the vacuum lines to not get any kinks or interferences.

- reservoir return hose - This will not be long enough. It's not pressurized, so just use an appropriate size/material hose cut to length with a spring or worm gear clamp.

- feed line - The issue here is that with the stock shape of the hardline portion on the pump end. It will hit the 4.0 reservoir. I took two pairs of Vise-Grips. I placed one on each horizontal portion of the hardline and was able to twist it 20* (guesstimation). This was enough to not fatigue/crack/kink the hardline. Play with the amount in slow increments to fit your application.

- feed hardline sensor - With the new hardline placement the wiring will be too short to reach this. Simply extend the wires using your preferred method.

Aside from those issues it's all typical replacement procedure. You may ask why. One is less areas to leak. The 4.0 has one o-ring between the pump and reservoir. The 2.5 has a length of hose with a barb and clamp at each end. This setup is also much cleaner and out of the way. I'm in the middle and an E-fan swap and now I also don't have to worry about finding a mounting point for the reservoir.

I can get some pics tomorrow, though I'm not sure it's really needed. I'll also be glad to answer any questions.

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Old 03-23-2016, 06:53 AM   #2
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Join Date: Feb 2012
Location: Brookings, Oregon
Posts: 3,146
Not to mention the 2.5 reservoir has become scarce as hens teeth.
1999 Wrangler Chili Pepper Red

If you come to a fork in the road take it.
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