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We have had problems with synthetic fluids, royal purple in specific, it tends to thin out too much when hot and you loose assist due to fluid pushing past piston seals. We always recommend a standard GM power steering fluid such as AC Delco 10-5073.
Keep it to pre-1974 to have the key way style pump shaft and SAE mounting holes. 1975 is press on shaft with SAE threads, 1976 and later are all press-on with metric threads.
I don't think this will work as it was not just a pitman arm diameter change but a linkage change, one has ball stud up and the other ball stud down. I do see this item listed on eBay that claims it can fix this issue but do not have any first hand experience with it...
For a Dodge Charger you would want to use our box part #800126 which has the 1-1/8" diameter pitman shaft to match your pitman arm. The 1971 pitman arm would be 1-1/8" as well. The diameter was not changed to 1-1/4" until 1973.
160-180 would be a normal up to temp operating temperature for a power steering system, over 220 gets to be problematic. Heat is generated when the fluid is compressed / pressurized. In this particular application the need for a cooler arises due to the very short fluid circuit and the heat...
There is no major issue running the power steering through the trans cooler, of course make sure it is plumbed in the return line of the power steering system, benefit is increased fluid capacity as well as fluid cooling which will provide a consistent temperature resulting in a consistent...
The 4.5 degree angle is intentional and necessary. With the much smaller distance from the center-line of the input to the center-line of the pitman shaft when compared to the stock box the angle is necessary to have the input shaft of the steering box point toward the steering column.
Saginaw pumps pre-1974 were all key-way pulley shaft with SAE threads, 74-79 used press-fit shaft with SAE threads, 80 and up used press on shaft with metric threads. SAE thread size 3/8-16 Metric thread size is M10X1.5
As the manufacturer we do not compete with our dealers on price. You can check with Bergman Autocraft, Classic Industries, Year One and POL which are all sponsors of this site.
You should place the cooler in an area where it will be away form engine / exhaust heat and get some decent airflow. In front of or behind the radiator will work. Feel free to create a thread for all to track any questions and answers that may arise.
While I don't know the reasoning behind the change it was year based for the B-Body cars, Pre-73 running the smaller 1-1/8" shaft and 73 and later running the larger 1-1/4" shaft. That being said, the C body cars did use the larger shaft Pre-73
Our box is smaller and lighter than the factory unit the weight of our box is 26.46 pounds. Box will fit directly to your stock pitman arm. There is no need to drop the pressure of your pump to run our box. Dimensions of our box can be viewed here...
The hydroboost set up does increase the length of lines and time it takes for the fluid to get back to the pump and can aid in cooling the fluid however a cooler is always a good idea as reduced temperatures increase the life of all components involved in the system.