$35 Electric Power Steering with Fail-Safe - No eBay module and no caster issues!!!

Discussion in 'Suspension, Steering and Chassis' started by waid302, Oct 19, 2016.

  1. waid302

    waid302 Member

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    It has been a while since I posted on this forum. I am not making or selling anything. I have posted this on couple of other forums and this is not for everyone.

    Some of you have manual steering and I though you might like to see how added electric assisted power steering in my 1964 Falcon. Some of you may have come across the Saturn Vue conversions but I think I have found even cheaper and better alternative with no caster issues!

    My testing shows that most Japanese branded cars and SUV with electric steering works in Fail-Safe mode if the control unit (ECU) is disconnected from CAN BUS. The effort in Fail-Safe mode feels just right like my 2013 Honda Civic. Not too much and not too little. Just like Hydraulic Steering, if the Electric Assisted Steering completely fails, the steering is back to completely manual mode maintaining car control.

    The biggest advantage of using EPS from Toyota, Nissan and Kia/Hyundai is that the EPS works in Fail-Safe. The ECU for the column is mounted remotely and cab be disconnected and removed. The EPS from Saturn Vue and Chevy Cobalt has the ECU that cannot be disconnected and must be de-soldered for remote mount. More importantly there is no Fail-Safe and a 3rd party eBay module is needed in order for it to work. Additionally , people have reported that with after market eBay module, the Saturn EPS does not self center the steering wheel coming out of a turn. You have to make constant corrections.

    Below is the list of Car that I know of that has Fail-Safe Electric Steering. Only 3 wire connection. Ignition On, Power and Ground to the Steering ECU. That's it !

    2004-2009 Toyota Prius
    2009-2013 Toyota Corolla
    2006-2011 Toyota Yaris - (With ABS)
    2007-2009 Nissan Versa
    2009-2012 Nissan Cube
    2012-2014 Kia Soul

    ECU Part Numbers:

    2004-2009 Toyota Prius 89650-47102
    2009-2013 Toyota Corolla 89650-02300
    2006-2011 Toyota Yaris - (With ABS) 89650-52120 / 52050
    2007-2009 Nissan Versa 28500-EM30A / 991-30303
    2009-2012 Nissan Cube 28500-1FC0B / JL501-000932
    2012-2014 Kia Soul B2563-99500 / 4PSG1312 / FPSG1312

    The output shaft on Toyota is little larger than the rest and therefore the Borgeson 312500, 11/16 36 X 3/4 smooth bore weldable coupling should fits nicely. This couple fits the others as well. The Kia EPS is the biggest and appears to be most heavy duty. The Prius & Corolla EPS are very easy to find at salvage yards so this is the best bet. I picked up these EPS for testing for $35 each at my local pic-a-part

    Note: As with any modification, there are risks. This post is intended to show how I did my modification. Use it at your own risk!

    Waid

    1 Corolla Prius.jpg

    2 Prius Yaris.jpg

    3 Prius Yaris.jpg

    4 Cube Versa.jpg

    5 Cube Versa.jpg

    6 Kia Soul.jpg

    7 ECU.jpg

    Saturn Vue 1.jpg

    Saturn Vue 2.JPG
     
    Last edited: Oct 21, 2016
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    • waid302

      waid302 Member

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      Wiring Diagrams. Only 3 wires are needed. Power, Ground and Ignition On

      2007 Yaris.jpg

      2008 Versa.jpg

      2009 Toyota Prius.jpg

      2010 Nissan Cube.jpg

      2014 Kia Soul.jpg
       
      Last edited: Oct 20, 2016
    • waid302

      waid302 Member

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      This is how I did my upper steering shaft and steering column.



      1 Upper Steering Shaft.jpg

      2 Upper Steering Shaft.jpg

      3 Upper Steering Column.jpg

      4 Upper Steering Column.jpg

      5 Upper Steering Column.jpg

      6 Upper Steering Column.jpg

      7 Back Bracket.jpg

      8 Prius Mounted.jpg

      9 Versa Mounted.jpg
       
    • waid302

      waid302 Member

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      This is how I dit the lower part of the column when I had the steering box.

      6 Steeringbox.jpg

      9 Final Assembly.jpg

      F49359517.jpg
       
    • waid302

      waid302 Member

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      For later cars with collapsible steering column

      Collapsible 2.jpg

      Collapsible 3.jpg

      Collapsible 4.jpg
       
    • waid302

      waid302 Member

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      This is how ended up with steering column

      1 Lower Shaft.jpg

      2 Lower Shaft.jpg

      3  Lower Shaft.jpg

      4 Complete.jpg

      5 Lower Bearing Support.jpg
       
    • waid302

      waid302 Member

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      YouTube Videos:

      DIY Electric Power Steering 1 - EPS with Fail Safe


      DIY Electric Power Steering 2 - Bench Test


      DIY Electric Power Steering 3 - Mounting Options


      DIY Electric Power Steering 4 - In Car Test
       
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      • waid302

        waid302 Member

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        In order to convert my hydraulic power steering rack to manual, I took the valve out, removed the sleeve and tack welded the input shaft to the pinion shaft.

        8 Rack.jpg

        9 Rack.jpg

        11 Rack.jpg
         
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        • DNasty777

          DNasty777 I Don't Even Drive It!

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          Thanks for posting this, this is some neat stuff!
           
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          • jos51700

            jos51700 Well-Known Member

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            Not my cup of tea in the least, but I'm glad somebody understands the value of DETAIL.
            Very well written, documented, and organized!
             
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            • YY1

              YY1 Well-Known Member

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              Very enterprising.
               
            • memike

              memike Super Moderator Staff Member FABO Gold Member

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              That is something very enterprising, thank you very much for the write up and doing a complete one with pictures @waid302 .
               
            • 89on35s

              89on35s Inferno Red Duster FABO Gold Member

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              I have to ask, Is that electric assist motor under the dash noisy at all?

              Cley
               
            • waid302

              waid302 Member

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              The motor is not noise at all. In fact, I don't hear at all. Almost all new small to medium cars has column electric power assisted steering. It uses a steel worm gear with very hard plastic gear that is very smooth. While sitting up, you can not see the motor.

              Electric assisted power steering is no different than hydraulic steering. If you lose electrical power, you still have control of the car - in manual. The beauty of this type of setup is that all is under the dash and noting obvious in the engine compartment. You can maintain every component of your old steering box, linkage, etc....

              Waid
               
            • 89on35s

              89on35s Inferno Red Duster FABO Gold Member

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              This is really interesting to me. Of all the units you have tested, and that you'd recommend using, which is the smallest in size?

              Cley
               
            • waid302

              waid302 Member

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              The Toyota Yaris is the smallest and the next size up is the newer Nissan Versa that I have not tested but will to bet that it will work in Fail-Safe as well. The problem is the smaller the EPS, the smaller the plastic driven gear and may not take the load of a bigger car. Worst case the gear breaks, you are back to manual steering.

              The best bet is the Prius and Corolla as they will be much easy to find.

              Waid
               
            • famous bob

              famous bob mopar misfit

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              you going in to production ?
               
            • JDMopar

              JDMopar Well-Known Member

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              Awesome research, and an even more awesome write up! The only downside I see to using EPS in an older car, is that it would not be able to be used with a column shifter. My wife has an 06 Saturn Vue, and the EPS is completely silent. Thanks again for the research and willingness to share it.
               
            • waid302

              waid302 Member

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              Yes you can use the EPS with column shift. See the link below!

              Electric Power Steering 56 Fairlane
               
            • waid302

              waid302 Member

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              I wish I could! Easier to get this at salvage yard for $35!
               
            • BV8NC

              BV8NC New Member

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              Terrific information! I've installed a Saturn Vue EPS in my MGB V8 and like it, except that the lack of self-centering does bother me. If I were to adapt a Toyota Corolla (or Prius) ECU to my Vue EPS, what wires would I splice from the Vue torque sensor? I would be correct in expecting that to give me the self-centering ? Thanks, Mike
               
            • waid302

              waid302 Member

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              The Corolla and Prius ECU will work but there is a little circuit board that you will need as well. This board is built in to the Saturn Vue ECU. The upper steering shaft is same on Saturn Vue and Toyota therefore it will easier to just swap the whole thing out.

              eps.jpg
               
            • BV8NC

              BV8NC New Member

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              Too bad, about the circuit board. The problem with swapping out the whole unit is that my upper and lower mounting points have been established by cutting and welding to integrate the Vue housing into the MGB column. Adapting to the Toyota housing would mean more cutting and welding. Also, it appears my local (Cape Fear) Pick-n-Pull is substantially more greedy than your local place; about two years ago they charged me $119.00 for the Saturn unit, so I'd expect a similar price for the Toyota unit. Still, great information and I appreciate your response to my question. Mike
               
            • dirty white boy

              dirty white boy 47 yr old Juvenal delinquent

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              witch donor columns would already have self centering in them??? considering this upgrade on several cars i have!
               
            • waid302

              waid302 Member

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              Tested one more EPS / ECU that works in fail-safe/limp home mode with fixed level of assist. 2008-2011 Scion XD

              2008-2011 Scion XD It's almost identical to Prius. The Prius, Yaris and Scion Xd ECU share same exact plug and works with each other.

              ECU Part Numbers that function in fail-safe / limp-home mode:

              2004-2009 Toyota Prius 89650-47102
              2009-2013 Toyota Corolla 89650-02300
              2006-2011 Toyota Yaris - (With ABS) 89650-52120 / 52050
              2006-2011 Toyota Yaris - (Non-ABS) 89650-52070 & 520140
              2007-2009 Nissan Versa 28500-EM30A / 991-30303
              2009-2012 Nissan Cube 28500-1FC0B / JL501-000932
              2012-2014 Kia Soul B2563-99500 / 4PSG1312 / FPSG1312
              2008-2011 Scion XD 89650-52A10
               
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