Removal and Installation
RemovalNOTE: Using solvent and a brush, wash any oil and dirt off the valve body unit its lines, and the end if the gearbox. Blow dry with compressed air.
1. Drain the power steering fluid.
2. Raise the front of vehicle, and support it on safety stands in the proper locations.
3. Remove the front wheels.
4. Remove the driver's airbag assembly and steering wheel.
5. Remove the cotter pin from the tie-rod ball joint nut, and remove the nut.
6. Install the 12 mm hex nut on the ball joint.
Be sure that the 12 mm hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damaged by the special tool.
NOTE: Remove the ball joint using the special tool.
7. Separate the tie-rod ball joint and knuckle using the special tool.
CAUTION: Avoid damaging the ball joint boot.
8. Remove the steering joint bolts, then disconnect the steering joint by moving the joint toward the column.
9. Remove the splash guard.
10. Disconnect the feed line from the valve body unit upper side.
CAUTION: After disconnecting the feed line, plug or seal the line fitting with a piece of tape or equivalent to prevent foreign materials from entering the valve body unit.
11. Remove the clamps from the line mounting cushions, then remove the feed line from the cushions.
12. Disconnect the three lines (sensor inlet line, 10 mm return line and 6 mm return line) from the hoses.
CAUTION: After disconnecting the line, plug or seal the line with a piece of tape or equivalent.
13. Remove the mounting brackets and steering gearbox.
NOTE: Before removing the steering gearbox, place a jack stand under the gearbox to support it.
CAUTION: Be careful not to bend or damage fluid lines when removing the steering gearbox.
Installation
CAUTION: Be careful not to bend or damage cylinder lines A and B or the four fluid lines when installing the gearbox.
1. Assemble the mounting bracket over the mount cushion, then loosely install the gearbox on the rear beam with two gearbox mounting bolts.
NOTE: Move the feed line over the gearbox so that it does not interfere with the gearbox during installation.
2. Position the line mounting cushions by aligning the marks on the 10 mm return line (large diameter line).
3. Install the feed line on the slot of the cushions.
4. Install the two line clamps on the line mounting cushions.
5. Reconnect the feed line to upper side of the valve.
6. Reconnect the three lines (sensor inlet line, 10 mm return line and 6 mm return line) to the hoses.
NOTE:
- Make sure that there is no interference between the feed line, the rear beam or any other parts.
- For hose clamps installation.
7. Tighten the two gearbox mounting bolts on the mounting bracket that were loosely installed in step 1.
8. Install the splashguard with the two gearbox mounting bolts and splashguard attaching bolts.
NOTE: Install the bolts loosely first, then tighten them securely.
9. Install the steering joint, and reconnect the steering shaft and pinion shaft.
NOTE: Make sure the steering joint is connected as follows:
a. Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole with the flat on the shaft), and loosely install the upper joint bolt.
b. Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove 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.
c. Pull on the steering joint to make sure that the steering joint is fully seated. Then tighten the joint bolts.
10. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise about two turns. The arrow mark on the label should point straight up. Reinstall the steering wheel.
11. Reconnect the tie-rod ends to the steering knuckles, tighten the castle nut ('96 - 98 models) or hex nut ('99 - 01 models) to the specified torque, and install new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off any grease contamination from the ball joint tapered section and threads.
CAUTION: Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.
12. Install the front wheels.
13. Fill the system with the recommended power steering fluid, and bleed air from the system.
14. 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.
- Adjust the front toe.
- Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equally.