Steering Gear Removal and Installation

RACK AND PINION ASSEMBLY

Fig. 13 Steering Gear Replacement:

REMOVE OR DISCONNECT
1. Raise vehicle on frame contact hoist.

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the end opposite from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

2. Front tire and wheel assemblies.

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.

NOTICE: The wheels of the vehicle must be straight ahead and the steering column in the "LOCK" position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

3. Intermediate shaft lower coupling.
4. Heat shield.
5. Both tie rod ends from steering knuckles.

CAUTION: The frame must be properly supported before partially lowering. The frame should not be lowered any further than needed to gain access to the steering gear.

6. Partially lower frame to gain access.
7. Line retainer.
8. Pressure and return pipes from gear.
9. Pressure switch connector.
10. Five rack and pinion attaching bolts.
11. Rack and pinion assembly by sliding out to side.

INSTALL OR CONNECT
1. Rack and pinion assembly.
2. Five rack and pinion attaching bolts.

TIGHTEN
^ Rack and pinion attaching bolts to 68 Nm (50 lbs. ft.).

3. Return and pressure hose.

TIGHTEN
^ Hose fittings to 27 Nm (20 lbs. ft.).

4. Line retainer.
5. Raise frame and tighten body mount bolts.
6. Tie rod ends.

TIGHTEN
^ Tie rod end nut to 10 Nm (7.5 lbs. ft.) then an additional 1/3 turn (2 flats).

IMPORTANT
^ When tightening tie rod end nut, a minimum torque of 45 Nm (33 lbs. ft.) must be obtained. If 45 Nm (33 lbs. ft.) is not obtained, inspect for stripped threads. If threads are satisfactory, replace tie rod end and knuckle.
^ After tightening castellated nut to specification, align slot in nut to cotter pin hole by tightening only. Do not loosen nut for cotter pin installation.

7. Intermediate shaft coupling.

TIGHTEN
^ Intermediate shaft coupling bolt 50 Nm (30 lbs. ft.).

8. Pressure switch connector.
9. Heatshield.
10. Tire and wheel assemblies.
11. Lower vehicle.
12. Bleed power steering system.

INSPECT
^ Inspect for leaks.