Installation
Steering Gearbox Installation1. Before installing the steering gearbox, make sure that no power steering fluid is on the mating surface of the gearbox and front suspension subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove any power steering fluid from the mount cushions and bolt holes.
2. Apply a mild soap and water solution to both sides of the mount cushion mating surfaces (A).
3. Lift and pass the passenger's side of the steering gearbox (8) 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 points upward, then move the steering gearbox to the driver's side.
6. Install the 4-way brake line joint (A).
7. Install the steering gearbox mounting bolt (A) and washer (B) on the left gearbox mount, then tighten them to the specified torque.
8. Install the steering gearbox mounting bolt (A) and washer (B) on the right gearbox mount, then tighten them to the specified torque.
9. Install the gearbox stiffener (A), then tighten the mounting bolts to the specified torque.
10. Install a dynamic damper in the reverse order of removal. Portion the gearbox stiffener and front suspension subframe.
11. Install the P/S heat baffle plate (A).
12. Install the return line joint (A) in the steering gearbox, then tighten it to the specified torque.
13. Connect the feed line (A), and tighten the 14 mm flare nut to the specified torque.
14. Connect the return hose (B) securely, and tighten the adjustable hose clamp (C).
15. Connect the stepping valve motor connector (A).
16. Install the feed line holder mounting bolt (A) and return line holder mounting bolt (A) on the gearbox.
17. Install the feed line holder mounting bolt (A) and A/T wire line holder mounting bolt (B) on the gearbox stiffener.
18. Install the return hose in the clamp (C).
19. Connect the engine mount pressure hose (A) in the rear engine mount.
20. Install the rear engine mount (B), then tighten the mounting bolts and the engine mount pressure hose holder mounting bolt (C) on the gearbox stiffener to the specified torque.
21. Install the nuts (A) on the rear engine mount, then tighten them to the specified torque.
22. Wipe off any grease from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms.
23. 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).
24. 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.
25. 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.
26. Install the center guide (C).
27. Install the steering joint (A) aligning the slit (B) of the steering joint with the tab (C) of the center guide. Position the angle of the center guide as shown if necessary.
28. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolts (C). Be sure that the 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. Tighten the steering joint bolt to the specified torque.
29. Install the steering joint cover A.
30. Install the relay box (A), then connect the wire harness clips.
31. Install the front strut brace.
32. Install the front wheels, then set the wheels in the straight ahead position.
33. 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.
34. Fill the system with power steering fluid, and bleed air from the system.
35. 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 the steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, and repeat step 31. Then adjust the front toe by turning the tie-rod ends, if necessary.
36. Install the right and left front fender trim.