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View Full Version : Waggy Box Swap in a ZJ



97trxuszj
11-19-2005, 03:40 AM
what lines do I need to bolt in my waggy box my ZJ lines don't match???

chopshop
11-19-2005, 04:20 AM
wierd. i broke my stock box yesterday, and i have a j20 box kickin around waiting to go in, i woke up in the middle of the nite tonight and was like "arrrg! what about the lines!!!!" haha. i just came in from the garage in my pj's........

got this from this site: 79 earlier have flared fittings, 80 up have o-rings.

so you need the o-ring style. you could get a hydraulic shop to make you adaper lines for a reasonable cost. bring 'em your stock lines and wag box.

luckily my j20 is o-ring, cause i got it off a half crushed rig that i had no idea what year it was.

Kraqa
11-19-2005, 06:55 PM
most hydro shops wont build lines for steerign setups. If they will they charge you an arm and a leg. i got a 3/8" coupler (about 3$ frm the hydro shop) and a 79 waggy High Pressure hoze. Then i chopped the pump fitting off the stock line keepign enough so that i can use the coupler. then chopped the pump fittign of the waggy line. Then i coupled the stock pump fittign onto the waggy ling and bolted it right up.

The remaining pump side of the waggy line bolts right up to the low pressure lien on the box. then i used the stock return line and a hoze clamp.

sounds confusing but it took abotu 10 min. super easy.

ATL ZJ
11-19-2005, 07:04 PM
Just how much pressure does the high pressure line hold? Summit sells flexible line in the length of your choice with whatever ends you need that is good to 1000psi.

Kraqa
11-19-2005, 07:39 PM
ower stearing is around 1800 PSI i beleive. Someone correct me if i'm wrong.

ogdak
11-20-2005, 02:54 PM
According to the 1994 ZJ FSM,
The steering pump relief pressure is between 1350 and 1450 psi.

97trxuszj
11-20-2005, 05:22 PM
so kraqa can you take pictures? I need to solve this imediatley. any other options?

nathaniel
11-20-2005, 08:46 PM
exchange for correct box?



so kraqa can you take pictures? I need to solve this imediatley. any other options?

97trxuszj
11-20-2005, 09:32 PM
got it from a bone yard for 35 bucks

Kraqa
11-21-2005, 05:35 PM
i'l take pics tonight if i remember.

97trxuszj
11-21-2005, 05:56 PM
thnx

Kraqa
11-25-2005, 05:23 PM
sorry dude my comp has been fucked latly. I havn't been able to get on in a while. here are the pics

http://img.photobucket.com/albums/v280/Kraqa/power00001.jpg

the hoze is the 79 waggy high pressure hoze. the fitting is the stock one. you can see the coupling in the middle.

97trxuszj
11-26-2005, 04:06 PM
and thats the only line you had to change? was the othe rline ok being stock? let me know. also, the hrd line in the pic is a ZJ the soft line is a waggy line does it bolt up to our PS pump? and also did you have to cut the stock ZJ line and re flare it or how dd u use the comp. fitting

Kraqa
11-26-2005, 06:25 PM
the end i cut off the waggy line is used for the low pressure fitting on the box. The low pressure line could be a garden hoze if you want, there is hardly any return pressure.

everythign from the left og the coupling is stock ZJ lines everythign frm the right is a stock waggy line. its pritty clear what you have to cut then you get the new waggy line and ZJ together.

The fittign i used was a 3/8" coupling for hydrolic lines. its rated for 3000 PSI max. you do not require any flaring tool. there is a crush sleeve in both ends. so cut your hard line, deburr it then just slide it into the coupling. turn the coupling nut 1-1/4 turns and leave it. then slide your other end in the coupling, tighten that side 1-1/4 turns. super easy.

i used a felt to mark there i started turning, then i knew exactly 1-1/4 turns. the local hydro shop will be able to explain to you how to use the coupler. They will not modify the line for you because of the liability, some shops wont even touch stearing lines. But this is perfictly safe, if done correctly.

Kraqa
11-26-2005, 06:26 PM
oh and in the pic, that is the PS pump side of the hoze.

97trxuszj
11-26-2005, 08:38 PM
ok my problem is that my zj lines won't bolt onto my pump, so to mke my PS box work I would have to use waggy fittings and hard lines and connect those to my stock PS pump lines is that what you did? all I really need to do is go get waggy PS lines and cut off the hard line portion then connect my PS pump lines to that via a coupler on the HP side the then LP side I will just slide my old hard line out then the waggy line in and reposition the hose clamp . is that right

Kraqa
11-26-2005, 08:40 PM
call my cell. 778-808-2173

Swamp boy
11-26-2005, 11:20 PM
I have a buddy that works at a Speed shop ... They make custom lines... (Brake lines and whatever...All Aeroquip stuff... )

Anyway.. He said he could make any line I needed when I asked him about this before... His prices are beyond reasonable as well.. Like I said in the brake line post from before... He made my two fronts 24" and my rear line 37" and Charged me about $80 If I remember correctly.. Whatever it was ... It was very good deal...

And.. He can do your line in Pimptastic braided steel stuff... :mrgreen:

Swamp boy
11-26-2005, 11:36 PM
Quick question.. Does anyone know if the ZJ line will work on a Durango box.. I think I can get one for a very good price.. (IE Free..)

So.. There you have it.. Will I need a new line or will mine fit or do I need to wait til I get it and find out for myself..

StinkoMan20X6_
11-27-2005, 02:00 AM
I've heard that durango boxes work fine. I tried to get an 80's and up box and they were all 3 bolt and had the same part number as the ZJ pump. Which years are 4 bolt?

Swamp boy
11-27-2005, 03:04 PM
I heard 98-99 ..But I dont know for sure..

JeepinHank
11-28-2005, 11:22 AM
I too believe the Durango boxes will swap right in. You'll need to get an earlier model box. I know they made the switch over to rack in pinion somewhere around 2000.

rob92xj
12-15-2005, 03:05 PM
You would need a 98-99 Durango box the lines are the same ZJ to Durango(DN) the pumps are relatively the same. 00 and later Durango's have Crack and Pinion steering. I'm working on getting a Durango box for my XJ. Stinkoman and JeepinHank I found a salvage yard for Jeeps and Dodge trucks in SC throught the Dodge truck club I have joined.

Jim311
12-16-2005, 01:48 AM
Is it a bad idea to buy a reman box from the parts store for a late 90's Durango?

Kraqa
12-16-2005, 11:22 PM
Reman'ed ones can be prone to failer under high stress. I mean there great for the street but you just seem to see them fail on the trail.

97trxuszj
12-27-2005, 06:26 PM
ok so 80+ waggy boxes bolt right in with our PS lines?

Kraqa
12-27-2005, 08:46 PM
yes