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.
- Make sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.
1. Drain the power steering fluid.
2. Raise the front of vehicle, and support it with safety stands in the proper locations.
3. Remove the front wheels.
4. Remove the steering wheel.
5. Remove the steering joint cover A.
6. Remove the steering joint bolt (A), and disconnect the steering joint by moving the steering joint (B) toward the column. Hold the slider shaft (C) on the column with a piece of wire (D) between the joint yoke (E) on the slider shaft to the joint yoke on the upper shaft.
7. Remove the center guide (A), and discard it.
8. Remove the steering joint cover B. Be careful not to damage the mating surface on the joint cover B and pinion shaft grommet. Replace the cover seal (C) if necessary.
9. Remove and discard the cotter pin (A) from the tie-rod ball joint nut (B), then loosen the nut.
10. Separate the tie-rod ball joint and knuckle using the special tool.
11. Remove the P/S heat baffle plate (A).
12. Remove the feed line holder mounting bolt (A) on the front suspension subframe.
13. Remove the feed line holder mounting bolt (B) and return hose (C) from the gearbox mounting bracket (D).
14. Place several shop towels under the line connections, and cover the gearbox mounting part to protect it from the power steering fluid. Loosen the flare nut (A), and disconnect the feed line (B).
15. Loosen the flare nut (C), and disconnect the return line (D).
16. After disconnecting the lines, plug or seal them with a piece of tape or equivalent to prevent foreign materials from entering.
NOTE: Do not loosen the cylinder line A and B between the valve body unit and the cylinder.
17. Remove the front suspension subframe left mid mount (A).
18. Remove the steering gearbox mounting bolts on the left gearbox mount, and remove the steering stiffener plate (A).
19. Remove the two flange bolts from the right side of the gearbox, then remove the gearbox mounting bracket (A) and cushion (B).
20. Move the steering gearbox toward the front, and remove the pinion shaft grommet (A) from the top of the valve body unit.
21. Apply vinyl tape (B) to the splines on the pinion shaft.
22. Apply vinyl tape or equivalent material (A) to the brake lines to protect them from the pinion shaft.
23. Move the steering gearbox to the driver's side, and rotate it so the pinion shaft points toward the front of the vehicle.
24. Carefully move the steering gearbox as an assembly toward the driver's side of the vehicle until the pinion shaft clears the wheelwell opening. Be careful not to damage the brake lines with the pinion shaft.
25. Remove the steering gearbox through the wheelwell opening on the driver's side.
26. After removing the steering gearbox, make sure that no power steering fluid gets on the gearbox mount cushions, gearbox housing, surface of the subframe and stiffener. Wipe off any spilled fluid at once.
Steering Gearbox Installation
1. Before installing the steering gearbox, make sure that no power steering fluid is on the mating surface of the gearbox and a front suspension subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove the power steering fluid from the mount cushions and bolt holes.
2. Apply a mild soap and water solution to both side of the mount cushion mating surfaces (A).
3. Pass the cylinder of the steering gearbox (B) through the wheelwell opening on the driver's side.
4. Carefully move the steering gearbox toward the passenger's side until the pinion shaft clears the wheelwell opening on the body.
5. Rotate the steering gearbox so the pinion shaft (A) points upward.
6. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. Make sure the power steering return line and feed line are routed above the gearbox.
7. Remove the vinyl tape from the pinion shaft, and install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the valve housing.
8. Position the cutout (A) on the mounting cushion (B) as shown, and install it on the cylinder of the gearbox securely.
9. Install the gearbox mounting bracket (C) over the mounting cushion, and loosely install the two flange bolts.
10. Install the steering stiffener plate (A) and gearbox mounting bolts on the left side of the gearbox, then tighten them to the specified torque.
11. Tighten the flange bolts on the right side of the gearbox to specified torque alternately in two or more steps.
12. Loosely connect the return line and feed line by hand securely.
13. Install the feed line holder (A) and return hose (B) on the gearbox mounting bracket (C)
14. Install the feed line holder (D) on the front suspension subframe. Make sure that there is no interference between the feed and return lines and any other parts.
15. Retighten the return line flare nut (A) to the specified torque.
16. Retighten the feed line flare nut (B) to the specified torque.
17. Install the front suspension subframe left mid mount (A).
18. Install the P/S heat baffle plate (A).
19. Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms.
20. Install the tie-rod end ball joint nut, and tighten it to the specified torque. Then install the new cotter pin (B), and bend it as shown (C) or (D).
21. Install the new cover seal (A) all the way around in the steering joint cover B. Make sure there are no wrinkles in the seal, then install the steering joint cover B.
22. Center the steering rack within its stroke.
23. Position the steering column joint (A) so the bolt (B) opposite to the notch (C) is within the range shown.
24. With the rack in the straight ahead driving position, cut the wire (D)and slip the lower end of the steering joint on to pinion shaft (E).
25. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Make sure the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure the steering joint is fully seated.
26. Tighten the steering joint bolt to the specified torque.
27. Install the steering joint cover A.
28. Install the front wheel, then set the wheels in the straight ahead position.
29. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about three full turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.
30. Fill the system with power steering fluid, and bleed air from the system.
31. After installation, do the following checks.
^ Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up to the fluid. Check the gearbox for leaks.
^ Do the front toe inspection.
^ Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steeling wheel and rack are not centered), correct the engagement of the joint/ pinion shaft serrations, then adjust the front toe by turning the tie-rod ends, if necessary.