Removal and Installation
Steering Gearbox RemovalSpecial Tools Required
Ball joint remover, 28 mm 07MAC-SL00200
Note these items during removal:
^ Using solvent and a brush, wash any oil and dirt off the valve body unit, its lines, and the end of the gearbox. Blow dry with compressed air.
^ Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.
1. Raise the front of vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheels.
3. Remove the steering wheel.
4. Remove the driver's dashboard lower cover and under cover.
5. Remove the steering joint bolts, and disconnect the steering joint by moving the steering joint (A) toward the column.
6. Remove the cotter pin (A) from the tie-rod ball joint nut (B), and loosen the nut.
7. Separate the tie-rod ball joint and damper steering arm using the special tool. Repeat on the other side of the vehicle.
8. Remove the P/S heat baffle plate (A).
9. Remove the engine wire harness clamp and clip (A) from the two mounting brackets.
10. Loosen the adjustable hose clamp (A) and disconnect the return hose (B)
11. Loosen the 14 mm flare nut (c) and disconnect the feed line (D).
12. Open the hose holders (A) on the return hose, and remove the return hose clamp bolt (B).
13. Disconnect the power steering pressure switch connector (A).
14. Remove the feed line (B) on the P/S line mounting bracket (C), and move it aside.
15. Remove the body stiffener (A).
16. Remove the two 10 mm flange bolts (A) and washers (B) from the left side of gearbox.
17. Remove the 10 mm flange bolt (A) and nut (B) from the right side of gearbox, and remove the mounting bracket (C).
18. Lower the steering gearbox, and rotate it so the pinion shaft points upward, and remove the mounting cushion (D).
19. Remove the pinion shaft grommet (A) from the top of the valve body unit.
20. Carefully move the steering gearbox and tie-rods as an assembly toward the driver's side until the pinion shaft (A) clears the wheelwell opening (B) on the frame.
21. Remove the steering gearbox (A) through the wheelwell opening on the driver's side. Be careful not to damage the hoses, lines, and wire harnesses.
22. Remove the P/S line mounting bracket (A).
Steering Gearbox Installation
1. Install the P/S line mounting bracket (A).
2. Pass the cylinder of the steering gearbox (A) together with the tie-rods (B) through the wheelwell opening on the driver's side.
3. Carefully move the steering gearbox toward the passenger's side until the pinion shaft (A) clears the wheelwell opening (B) on the frame. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position.
NOTE: Make sure the power steering return hose is routed between the gearbox and right tie-rod.
4. Install the pinion shaft grommet (A).
5. Insert the pinion shaft up through the bulkhead, and place the steering gearbox on the mounting brackets. Be sure that the pinion shaft grommet is in place securely.
6. Loosely install the two 10 mm flange bolts (A) and washers (B) on the left side of the gearbox.
7. Install the mounting cushion (A) on the right side of the gearbox. Position the cutout (B) on the mounting cushion as shown.
8. Install the mounting bracket (c) over the mounting cushion.
9. Install the 10 mm flange bolt and nut loosely first, then torque the flange bolt and nut alternately in two or more steps.
10. Tighten the left side flange bolts to the specified torque value.
11. Install the body stiffener (A).
12. Loosely connect the 14 mm flare nut (A) to the valve body unit, and install the feed line (B) on the P/S line mounting bracket (C). Connect the power steering pressure switch connector (D).
13. Connect the return hose (A) to the return line joint (B) securely. Install the return hose clamp (C) on the steering gearbox.
14. Install the return hose on the hose holders (D) securely.
15. Tighten the 14 mm flare nut (A) to specified torque and the adjustable hose clamp (B).
16. Reinstall the engine wire harness clamp and clip (A) to the mounting brackets.
17. Install the P/S heat baffle plate (A).
18. Clean off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the damper steering arms. Install the 12 mm nut (B), and tighten it to the specified torque.
19. Install a new cotter pin (c), and bend it as shown (D) or (E).
20. Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:
^ Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft).
^ Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove (F) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft.
^ Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. Tighten the lower joint bolt to specified torque.
21. Install the driver's dashboard under cover.
22. Install the front wheel, then set the wheels in the straight ahead position.
23. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about two and a half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.
24. Fill the system with power steering fluid, and bleed air from the system.
25. After installation, perform the following checks.
^ Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks.
^ Perform the front toe inspection.
^ Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/ pinion shaft serrations, then adjust the front toe by turning the tie-rods, if necessary.