Steering: Service and Repair

NOTE: When using a vise, do not overtighten it.

REMOVAL
1. Remove the engine under cover by removing the four bolts.
2. Remove the pitman arm by performing the following.
a. Remove the cotter pin and nut.





b. Using the 09611 - 22012 Special Service Tool (SST), disconnect the pitman arm from the relay rod assembly.
c. Remove the pitman arm set nut and spring washer.





d. Using the 09628 - 62011 SST, disconnect the pitman arm from the gear assembly.

3. Remove the steering damper with steering damper bracket by performing the following.
a. Remove the nut and 2 damper bracket set bolts.





b. Using the 09611 - 22012 SST, disconnect the damper with damper bracket from the relay rod assembly.

4. Remove the steering damper by performing the following.
a. Secure the damper bracket in a vise. Then remove the nut.





b. Using the 09610 - 55012 SST, remove the damper from the damper bracket.

5. Remove the relay rod assembly by performing the following.
a. Remove the cotter pin and nut.





b. Using the 09611 - 22012 SST, disconnect the relay rod assembly from the knuckle arm.

6. Remove the tie rod assembly by performing the following.
a. Remove the two cotter pins and nuts.





b. Using the 09611 - 22012 SST, disconnect the tie rod assembly from the RH and LH knuckle arms.

7. Loosen the tie rod end or relay rod end clamp and remove the tie rod end or relay rod end.

NOTE: When connecting the ball stud to the arm or rod, remove the grease on the joint surfaces.





INSTALLATION
1. Install the tie rod ends and the relay rod ends by performing the following.
a. Turn the tie rod ends or relay rod ends equal amounts into the rod tube. Tie rod assembly should be approximately 1,233 mm (48.54 inch). The relay rod assembly should be approximately 1,090 mm (42.91 inch).
b. The remaining length of threads on both tie rod ends or relay rod ends should be equal.
c. Temporarily tighten the tie rod end or relay rod end clamps.
2. Install the tie rod assembly by connecting the tie rod assembly to the RH and LH knuckle arms and tightening the nuts to 91 Nm (67 ft. lbs.). After tightening the nuts install two new cotter pins adjust the toe-in, then tighten the the clamp bolts and nuts to 37 Nm (27 ft. lbs.).
3. Install the relay rod assembly by connecting the relay rod assembly to the knuckle arm and then tightening the nut to 91 Nm (67 ft. lbs.). After tightening the nuts install two new cotter pins adjust the toe-in, then tighten the the clamp bolts and nuts to 37 Nm (27 ft. lbs.).
4. Install the steering damper by first securing the damper bracket in a vise then connecting the damper to the damper bracket. Tighten the nut to 74 Nm (54 ft. lbs.).
5. Install the steering damper with the steering damper bracket by performing the following.
a. Connect the damper with damper bracket to the relay rod assembly.
b. Tighten a new nut to 74 Nm (54 ft. lbs.) and the two damper bracket set bolts to 39 Nm (29 ft. lbs.).





6. Install the pitman arm by performing the following.
a. Align the alignment marks on the pitman arm and the cross shaft, and install the spring washer and set nut tightening them to 177 Nm (130 ft. lbs.).
b. Connect the pitman arm to the relay rod assembly and tighten the nut to 91 Nm (67 ft. lbs.).
c. Install a new cotter pin.
7. Install the engine under cover by tightening the four bolts.
8. Check the front wheel alignment.