Removal and Installation

Steering Gearbox Removal

Special 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 of the valve body unit its lines, and the end of the gearbox. Blow dry with compressed air.
- Be 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 vehicle, and make sure it is securely supported.
3. Remove the front wheels.
4. Remove the driver's airbag assembly.
5. Remove the steering wheel.





6. Remove the steering joint cover.





7. Remove the steering joint bolts (A), disconnect the steering joint by moving the steering joint (B) toward the column.





8. Remove the cotter pin (A) from the 10 mm nut (B), and loosen the nut.
9. Separate the tie-rod ball joint and knuckle using the special tool.





10. Grasp the right tie-rod and pull the rack all the way to the right, then remove the right and left tie-rod ends (A), and lockouts (B).





11. Remove the exhaust pipe A and mounting bracket B.
12. Disconnect the A/T shift cable (C) from the transmission.





13. Loosen the 14 mm flare nut (A), and disconnect the pump outlet hose (B).
14. Loosen the 17 mm flare nut (C), and remove the return line (D).
15. After disconnecting the hoses and 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 cylinder.





16. Remove the stiffener plates (A), then remove the right mounting brackets (B) and the cushion (C).





17. Pull the steering gearbox (A) down until the pinion shaft (B) clears the bulkhead, and remove the pinion shaft grommet from the top of the valve body unit.
18. Move the steering gearbox to the passenger's side until the driver's side rack end rests on the end of the rear beam.
19. To get the driver's side rack end around the rear beam, push up and back on the passenger's side rack end, then pull down on the driver's side of the steering gearbox.

Steering Gearbox Installation
1. Before installing the gearbox, slide the rack all the way to right.





2. Pass the passenger's side of the steering gearbox (A) above and through the passenger's side of the rear beam. Be careful not to bend or damage the power steering lines and cylinder lines when installing the gearbox.
3. Raise the driver's side of the steering gearbox above and through the driver's side of the rear beam. Then insert the pinion shaft (B) up through the bulkhead.





4. Install the pinion shaft grommet (A). Align the slot (B) in the pinion shaft grommet with the lug portion on the valve housing.





5. Install the mounting cushion (A) on the steering gearbox.
6. Install the mounting brackets (B) over the mounting cushion, then install the two gearbox mounting bolts (C). Position the split portion (D) of the mounting cushion as shown.
7. Install the stiffener plates (E) with the two gearbox mounting bolts (F) and six stiffener plate attaching bolts (G). Install the bolts loosely first, then tighten them securely.
8. Center the steering rack within its stroke.





9. Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:
^ Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft).
^ Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole (F) 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.
^ Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it.
10. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about two and half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.





11. Install the steering joint cover (A) with the clamps (B) and clips (C).





12. Connect the return line (A) and feed line (B) to the valve body unit (C). After connecting the fluid lines, make sure that there is no interference between the lines and other parts.





13. Thread the right and left tie-rod ends (A) and locknut (B) onto the rack an equal number of turns.





14. Wipe off any grease contamination from the ball joint tapered section and threads then reconnect tie-rod ends (A) to the steering knuckles. Install the 10 mm nut (B) and tighten it.
15. Install the new cotter pin (C) and bend it as shown.





16. Connect the A/T shift cable to the transmission.
17. Install the exhaust pipe A (B) and mounting bracket B (C).
18. Install the front wheels.
19. Fill the system with power steering fluid, and bleed air from the system.
20. 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 equally, if necessary.