Steering Gear: Service and Repair

NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear assembly must be replaced.

NOTE: Before proceeding with this procedure, review the SERVICE WARNINGS AND CAUTIONS found under Service Precautions.

REMOVAL

CAUTION: Positioning the steering column in the locked position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler.

1. Remove cap from power steering fluid reservoir.
2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.
3. With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position.






4. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler.
5. Raise vehicle on jack stands or centered on a frame contact type hoist.
6. Remove the front tires.






7. Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube connection. Remove the return hose from the metal tube of the power steering fluid return line. Then allow the remaining power steering fluid to drain from the system through the hose and metal tube.






8. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench.






9. Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or MB-991113.






10. Remove the 2 bolts and loosen the third attaching the antilock brakes Hydraulic Control Unit (HCU) to the front suspension cradle. Then rotate the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU.






11. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Then remove the cradle plate from the cradle.
12. If the vehicle is equipped with All-Wheel Drive, remove the power transfer unit. Refer to Transmission and Drivetrain.






13. Remove the bracket attaching the power steering fluid tubes to the front suspension cradle.






14. Using a 18 mm crowfoot, remove the power steering fluid pressure and return lines from the power steering gear.






15. Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle.

NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear.






16. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing with the knurled nut. Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler.
17. Separate the intermediate coupler from the shaft of the steering gear.
18. Remove the steering gear assembly from the front suspension cradle.

INSTALLATION
1. Install the steering gear up in the front suspension cradle, leaving room to install intermediate coupler.
2. Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear.






3. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut. Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler.
4. Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front suspension cradle mounting bolts and nuts.

CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important.

5. Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 Nm (135 ft. lbs.).
6. Attach the power steering fluid pressure and return lines to the proper fittings on the steering gear. Tighten the power steering fluid line tube nuts to a torque of 31 Nm (275 inch lbs.).






7. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.).
8. If the vehicle is equipped with All-Wheel-Drive, install the power transfer unit. Refer to Transmission and Drivetrain

CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important.

9. Install cradle plate on front suspension cradle and install the 10 cradle plate to cradle attaching bolts and nuts. Tighten all attaching bolts to a torque of 165 Nm (123 ft. lbs.).
10. Install the bracket attaching the power steering fluid tubes to the front suspension cradle.
11. Install the power steering fluid return hose on the steel tube at the front suspension cradle.
12. Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamp is installed on return tube past the upset bead on the tube. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.).

CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is required to prevent the power steering hoses from being overheated.

13. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position.
14. Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 129 Nm (95 ft. lbs.).
15. Lower the vehicle to a level were the interior of vehicle is accessible.
16. Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate coupler shaft is properly aligned with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.).
17. Perform the POWER STEERING PUMP INITIAL OPERATION service procedure found under Steering, Service and Repair, Service Procedures to properly fill and bleed the power steering system.
18. Inspect for leaks.
19. Adjust front toe.