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Unread 03-09-2011, 07:24 PM   #1
littleblackXj
Registered User
1993 XJ Cherokee 
 
Join Date: Feb 2006
Location: Santa Rosa
Posts: 795
Default Cheap OTK Steering

This is going to be a short write up on how I did my OTK conversion.

Parts you will need:
Stock tapered inserts
Right hand drive drag link (if your jeep is a RHD you will need a LHD drag link)
Angle grinder or sawzaw
A 19mm and 15mm socket
Vice grips or large channel locks
A hammer, preferably a BFH
Seperating fork (you may not need it, but anticipate needing it)

First thing is first, get your front tires off the ground.


Now remove your steering linkages. The best way I found was to remove the tie rod from the drag link first, then the steering stabilizer. On the drag-link, you only need to pull it off from the knuckle and un-thread it out of the adjustment sleeve, there is no need to remove the TRE from the pitman arm. This part of the process is probably going to be the most difficult as the TRE do not like to come out. Fortunately for me I was able to get them all out with a couple good wacks with a hammer. You may have to use a seperating fork or another means as they can be very stubborn.

Once you have everything off you can begin work modifying the knuckle. If you are using the teraflex inserts like I am, the hole needs to be drilled out to 3/4". The best way to do this would be on a drill press, which would require you to remove the knuckle, but I was able to do it with a hand drill. Just make sure to get the holes perfectly vertical and centered.


Once the holes are drilled out, clean the surrounding area down to metal as you will need to weld onto it. Drop the insert into the hole, and weld it into place. Ensure the hole is cleaned of debris and metal shavings.


These welds are not crucial, but need to be strong enough to stay inplace if you were to take out the TRE in the future. I was using a fluxcore welder (I don't recommend it, use gas if you can), so i had some slag inside the hole. Make sure to grind down the welds as needed so the top of the insert is completely flat.


At this point, you can mock everything back together and see where there are clearance issues. The stock sway bar links were an issue for me, as well as the steering stabilizer hitting the draglink at full lock. This may not be an issue if your jeep is lifted higher though. I cut off the sway bar links and removed the steering stabilizer. The steering stablizer mount has to be relocated, or moved up higher. Also keep in mind that the tapered hole on the draglink will be backwards, and you will need to drill it out and put in another insert in the same way as the knuckle.

Once the clearance issues have been fixed, bolt everything back up.


You will need to recenter the steering wheel by adjusting the draglink, as well as an alignment as the tie rod adjustment will be off. You will also need to relocate the axle side trackbar up to keep the steering angles parallel so you won't have issues with bump-steer. I haven't had time to do this yet, but i'll be sure to post pictures when I do

__________________
1993 Jeep Cherokee
Rubicon Express 4.5" Lift
33" Wrangler Duratracs
30/44 4.88s Disks all around
Rear Detroit/Open front
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