Steering Gearbox 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. Wrap vinyl tape on the pinion shaft.
2. Apply a mild soap and water solution to both sides 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 inlet 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 new gearbox mounting bracket (C) over the mounting cushion, and loosely install the two flange bolts.
10. Install the new gearbox mounting bolts (A) and washers (B) 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 the specified torque alternately in two or more steps.
12. Loosely connect the return line and inlet line by hand.
13. Install the inlet line holder (A) and return hose (B) on the gearbox mounting bracket (C).
14. Install the inlet line holder (D) on the front suspension subframe. Make sure that there is no interference between the inlet and return lines and any other parts.
15. Tighten the return line flare nut (A) to the specified torque.
16. Tighten the inlet line flare nut (B) to the specified torque.
17. Install the P/S heat shield (A).
18. Raise the jack supporting the front suspension subframe with the front subframe adapter until the subframe is in position.
19. Install the front suspension subframe rear bracket (A). Tighten a new 12 mm flange bolts (B) and a new 14 mm bolts (C) to the specified torque.
20. Install the front suspension subframe front bracket (A) with the 12 mm flange bolts (B) and a new 14 mm special bolts (C), and tighten them to the specified torque.
21. Install the new front suspension subframe left mid mount bolts.
22. Install the new front suspension subframe right mid mount bolts.
23. Remove the front suspension subframe supporting the front subframe adapter, and lower the jack.
24. Install the new rear engine mount bracket bolts.
25. Install the engine undercover (A).
26. Install the splash shield (A).
27. Connect the power steering pressure switch connector (A).
28. Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie-rod end (A) to the knuckle arms.
29. Install the tie-rod end ball joint nut, and tighten it to the specified torque. Install the new cotter pin (B), and bend it as shown (C) or (D).
30. Remove the engine support hanger, the hanger balance bar, and the hanger adapter set.
31. Install the front wheel, then set the wheels in the straight ahead position.
NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and inside of the wheel.
32. Lower the vehicle.
33. 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.
34. Center the steering rack within its stroke in steering joint connection.
35. Position the steering column joint (A) so the bolt (B) near to the notch (C) is within the range shown.
36. 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).
37. 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.
38. Tighten the steering joint bolt to the specified torque.
39. Install the steering joint cover A.
40. Install the steering wheel.
41. Install the driver's airbag.
42. Reconnect the negative battery cable to the battery, and do these tasks:
^ Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
^ Enter the anti-theft code for the audio or the navigation system (if equipped).
^ Set the clock (on vehicles without navigation).
^ Make sure the horn and turn signal switches work properly.
^ Make sure the steering wheel switches work properly.
43. Fill the system with power steering fluid, and bleed air from the system.
44. After installation, do these 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.
^ Check the steering wheel spoke angle. If 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.
^ Set the steering column to the center tilt position, and to the center telescopic position, then do the front toe inspection. Service and Repair
45. Install the right side engine component cover, passenger's and driver's cowl top extensions.