Removal and Installation

Steering Gearbox

REMOVAL
1. Set the vehicle on the lift.
2. Disconnect the battery ground terminal.
3. Loosen the front wheel nuts.
4. Lift the vehicle and remove the front wheels.
5. Remove the under cover.
6. Remove the sub frame.
7. Remove the front exhaust pipe assembly. (Non TURBO model)

WARNING: Be careful, exhaust pipe is hot.





8. Using a puller, remove the tie-rod end from the knuckle arm after pulling off cotter pin and removing castle nut.





9. Remove the jack-up plate and front stabilizer.





10. Remove the one pipe joint at the center of gearbox, and connect the vinyl hose to the pipe and joint. Discharge the fluid by turning steering wheel fully clockwise and counter clockwise. Discharge the fluid similarly from the other pipe.
11. Remove the universal joint.





12. Disconnect the pipes C and D from the pipe of gearbox.

CAUTION: Be careful not to damage these pipes.

NOTE: Disconnect the upper pipe D first, and lower pipe C second.





13. Remove the clamp bolts securing gearbox to the crossmember, and remove the gearbox.

INSTALLATION
1. Insert the gearbox into the crossmember, being careful not to damage gearbox boot.





2. Tighten the gearbox to the crossmember bracket via clamp with bolt to the specified torque.
Tightening torque: 59 Nm (6.0 kgf-cm, 43 ft. lbs.)
3. Install the four pipes on the gearbox.
1. Connect the pipes A and B to the four pipe joints of gearbox. Connect the upper pipe B first, and lower pipe A.
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)





2. Connect the pipes C and D to the gearbox. Connect the upper pipe D first, and lower pipe C second.
Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)
4. Install the universal joint.





5. Connect the tie-rod end and knuckle arm, and tighten with castle nut. Fit the cotter pin into the nut and bend the pin to lock.
Castle nut tightening torque:
Tighten to 27.0 Nm (2.75 kgf-m, 19.9 ft. lbs.), and tighten further within 60° until cotter pin hole is aligned with a slot in the nut.

CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.

6. Install the front stabilizer to vehicle.
7. Install the front exhaust pipe assembly.
8. Install the sub frame.
9. Align the center of roll connector.

CAUTION: Ensure that front wheels are set in straight forward direction.

10. Install the steering wheel.
11. Install the tires.
12. Tighten the wheel nuts to the specified torque.
Tightening torque: 90 Nm (9.1 kgf-m, 66 ft. lbs.)
13. Connect the ground terminal to battery.
14. Pour the fluid into the oil tank, and bleed air.
15. Check for fluid leaks.
16. Install the jack-up plate.
17. Lower the vehicle.
18. Check the fluid level in oil tank.





19. After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft. lbs.)

CAUTION: When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.