Steering Gear: Service and Repair

Gear





Special Tool(s)

Removal
1. Turn the wheel to the straight-ahead position and turn the ignition switch to the OFF position.
2. Remove the wheel and tire assemblies.
3. Remove the fluid cooler.





4. Remove the four air deflector retaining screws.





5. Pull downward on the air deflector to disengage the retaining pins.





6. Loosen the LH tie-rod end jam nut.





7. Remove and discard the cotter pins and nuts.

8. CAUTION: Do not damage the tie-rod boot when installing the special tool.

NOTE: Remove the adapter from the ball end of the special tool. Apply a small amount of grease to the tie-rod end stud and the ball of the special tool.





Using the special tool, separate the tie-rod ends from the wheel knuckles





9. Remove the LH tie-rod end.
^ Count and record the number of turns required to remove the tie-rod end.
10. Remove the front stabilizer bar.
^ Note or mark the driver side end of the sway bar for correct installation.

11. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered.





Remove the pinch bolt and detach the intermediate shaft from the gear.





12. Remove the nut and disconnect the lines.
13. Plug the ends of all fluid lines removed and ports in the steering gear to prevent entry of dirt.

14. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.





Remove the nuts.





15. Remove the stud bolts and washers.





16. Remove the steering gear to crossmember insulator bushings.





17. Rotate the steering gear control valve housing toward the front of the vehicle.
18. Turn the steering gear input shaft to the right until the stop is reached.





19. Move the steering gear as far to the RH side of the vehicle as possible.





20. Move the LH front wheel spindle tie-rod forward to clear the frame crossmember.





21. Remove the steering gear from the vehicle.

Installation





1. Using the special tool, install new seals on the power steering return hose and power steering pressure hose.

2. NOTE:
^ Make sure the steering gear input shaft is turned to the left until the stop is reached.
^ Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in tie-rod boots.

Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.

3. NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle.





Install the steering gear into the RH opening of the crossmember.





4. Move the steering gear as far to the RH side of the vehicle as possible.





5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position.
6. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously.





7. Rotate the steering gear control valve housing toward the rear of the vehicle.





8. Install the steering gear to crossmember insulator bushings as shown.
^ The large end of the metal sleeve must be positioned downward.
^ Check that the mounting surfaces on the crossmember are clean and free of foreign material.





9. Install the steering gear to crossmember washers and stud bolts.
^ The dished side of the washer faces downward.

10. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.





Install the nuts.





11. Install the lines and tighten the nut.

12. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered.





Connect the intermediate shaft to the steering gear input shaft. Install a new lower steering column pinch bolt.

13. Install the power steering fluid cooler.
14. Install the front stabilizer bar.
^ Orientate the front stabilizer bar as noted during removal.





15. Install the LH tie-rod end on the front wheel spindle tie-rod.
^ Rotate the tie-rod end the number of turns recorded during removal.





16. Position the tie-rod ends on the steering knuckles. Install the castellated nuts and new cotter pins.
^ Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals.





17. Tighten the tie-rod end jam nut.





18. Position the air deflector, and install the retaining screws.
19. Install the front wheel and tire assemblies.
20. Fill, purge and leak check the system.
21. Check and, if necessary, adjust the wheel alignment.