Following Blaine's advice to use a 12 -AN pressure line, 8 -AN return lines, and single pass cooler, I also just finished up a PSC install. Although I ordered the SK250 kit, I didn't install the cylinder assist. After the install the steering was effortless and all my steering, clunks, groans, and weird noises were gone.
The only thing I needed extra was some additional 1/2" hose, for the cooler, and a -8 AN fitting for the reservoir. These were easily sourced from a local hydraulic hose shop. For me, the most difficult part of the job was:
1. Separating the steering rod from the sector shaft - a little pry bar and PB Blaster helped
2. Shortening the steering rod - drilling out the plastic pin and shortening the rod approximately 2"
3. Installing the 16" single pass cooler - I made a bracket out of aluminum and put it behind the "V" brace in the grill and sandwiched the "V" brace in between the cooler (on the front) and bracket (on the back).
The job was made much easier by removing the:
1. Fan
2. Fan shroud
3. Serpentine belt
4. Radiator bolts
5. Two top condenser bolts
6. Two top "V" brace bolts and
7. Driver side headlight bucket.
Items 4 -7 were needed so the radiator and condenser could be tipped back. This was the only way to get the 16" cooler through the headlight bucket and into position. Positioning of the reservoir was important also, because you need to keep the feed line to the pump as short as possible, without kinking the line.
Once I had everything done I double checked the fittings, filled the reservoir and primed the system by turning the pump by hand.
I'm sure Blaine will jump in if needed, but one of the most critical things to do is to ensure the wheels are straight and steering wheel locked in position when you take things apart. This will keep you from damaging the clock spring and set you up for using the reference markings provided by PSC on the steering box. The red marks need to be lined up to ensure the box is in the proper position for installation. I followed this and everything lined up perfectly.
Edit: I noticed Northridge has the SK250 kit 15% off now, at $1544, with free shipping. You do need to order the 16" cooler additionally though. Also, if you don't have one, you'll need a 33MM socket for the Pitman Arm nut.
