Power Steering Gear Replacement

REMOVAL PROCEDURE





1. Raise and support the vehicle.
2. Place a drain pan under the vehicle.
3. Remove the tire and wheel assembly.

CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of steering control which could result in personal injury.

4. Remove the intermediate steering shaft lower pinch bolt at the steering gear stub shaft.

NOTICE: Set steering shaft so the block tooth on the upper steering shaft is at the 12 o'clock position, the wheels on the vehicle are straight ahead and set the ignition switch to the LOCK position. Failure to follow these procedures could result in damage to the coil.

5. Remove the intermediate steering shaft from the steering gear stub shaft.
6. Remove both of the tie rod ends from the steering knuckles.





7. Support the rear of the frame (3) using jackstands.
8. Remove the frame bolts from the rear of the frame.

NOTICE: Do not lower the rear of the frame too far as damage to the engine components nearest to the cowl may result.

9. Lower the rear of the frame (3).
10. Remove the power steering pressure line from the power steering gear.
11. Remove the power steering return line from the power steering gear.
12. Remove the power steering gear mounting bolts and nuts (1), (4).





13. Remove the power steering gear through the left wheel opening.

INSTALLATION PROCEDURE





1. Install the power steering gear through the left wheel opening.





NOTICE: Refer to Fastener Notice in Service Precautions.

2. Install the power steering gear mounting bolts and nuts (1), (4).
- Tighten the power steering gear mounting bolts to 80 Nm (59 ft. lbs.).

3. Inspect the threads on the power steering pressure line and the power steering return hose.
4. Inspect the O-ring seals on the power steering lines.
5. Replace the seals if damaged, lubricate the seals before installation.
6. Install the clamp that holds the power steering lines to the power steering gear
7. Install the power steering pressure line to the power steering gear.
8. Install the power steering return line to the power steering gear.
9. Raise the frame into position (3).
10. Install NEW rear frame bolts.
11. Remove the jackstands.
12. Install the tie rod ends to the steering knuckles.





NOTICE: Set steering shaft so the block tooth on the upper steering shaft is at the 12 o'clock position, the wheels on the vehicle are straight ahead and set the ignition switch to the LOCK position. Failure to follow these procedures could result in damage to the coil.

IMPORTANT: During the installation of the intermediate steering shaft, ensure the steering shaft is seated before you install the pinch bolt. The two mating shafts may disengage if the pinch bolt is inserted into the coupling before the steering shaft installation.

13. Install the intermediate steering shaft to the stub shaft (5).





14. Install the intermediate steering shaft lower pinch bolt.
- Tighten the intermediate steering shaft lower pinch bolt to 47 Nm (35 ft. lbs.).

15. Install the tire and wheel assembly.
16. Remove the drain pan from under the vehicle.
17. Lower the vehicle.
18. Fill the power steering system with power steering fluid.
19. Bleed the power steering system.
20. Inspect the power steering system for leaks.
21. Preform a front end alignment.