Steering Gear Replacement

Steering Gear Replacement

Special Tools

EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Removal Procedure

1. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).

Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:

* The steering column
* The intermediate shaft(s)
* The steering gear

After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

2. Turn the front wheels to the straight forward position and secure the steering wheel from moving.
3. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
6. Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (Front Compartment Insulator Replacement).
7. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (Service and Repair).
8. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (Service and Repair).
9. Disconnect the steering linkage outer tie rod from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).




10. Use an allen wrench in order to hold the stabilizer shaft link ball stud. Remove the lower stabilizer link shaft nut (2) on both sides.
DISCARD the nuts.
11. Disconnect the stabilizer shaft link (1) from the stabilizer shaft.




12. Remove the 4 fasteners (1) from the engine side cover on both sides.




13. Remove the 4 fasteners (1) from the front engine compartment cover.




14. Remove the front transmission mount bracket bolt (1).
15. Remove the rear transmission mount bracket bolt (2).




16. Remove the 2 rear suspension frame bolts (2).
DISCARD the bolts.
17. Remove the rear frame reinforcements (1).
18. Lower the drivetrain and front suspension frame 55 mm (2 in) in order to access the steering gear. Refer to Drivetrain and Front Suspension Frame Replacement (Service and Repair).





Note: Connector latches are difficult to access

19. Disconnect the electrical connector (3).

1. Use a flat blade tool in order to release the lock (2) in the direction of the arrow.
2. Use a flat blade tool in order to push down the latch (1) and pull off the electrical connector.




20. Disconnect electrical connector (2).

1. Use an angled flat blade tool in order to gently lift the latch (3).
2. Pull off the electrical connector (2).

21. Disconnect electrical connector (1).

1. Use an angled flat blade tool in order to gently lift the latch (4).
2. Pull off the electrical connector (1).




22. Use a suitable tool in order to carefully disconnect the 2 wiring harness plugs (3) from the steering gear.
23. Remove the 2 wiring harness bracket bolts (4).
24. Remove the bracket (2).
25. Disconnect the wiring harness retainer (1) from the steering gear.




26. Remove the 2 right stabilizer shaft insulator clamp bolts (2).
DISCARD the bolts.
27. Use mechanics wire in order to hold the stabilizer shaft (1) to the body.




28. Remove the 2 steering gear bolts (4) and the nuts (1, 3) from front suspension frame.
DISCARD the nuts and the bolts.
29. Carefully remove the steering gear (2) through the right front wheel house.
30. If necessary, refer to the following procedures:

* Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement)
* Steering Linkage Inner Tie Rod Replacement (Steering Linkage Inner Tie Rod Replacement)
* Steering Gear Boot Replacement (Steering Gear Boot Replacement)

Installation Procedure





Caution: Ensure that the steering column dash seal is installed properly onto steering gear rack pinion housing. The sealing lip MUST rest on lower steering column cover surface evenly. To ease installation of the seal, apply liquid soap to the sealing lip. After installation, verify that the seal lip does not protrude into the vehicle's interior. Improper installation could result in poor sealing performance and water intrusion into the vehicle.

Note: Check correct wiring routing in order to assure correct installation.

1. Carefully install the steering gear (2) through the right front wheel house and position the steering gear on the frame.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the NEW steering gear bolts (4) and the NEW nuts (1, 3) and tighten to 110 Nm (81 lb ft).
3. Use the EN-45059 - sensor in order to tighten the steering gear bolts and nuts an additional 150 degrees to 160 degrees.




4. Install the wiring harness bracket (2).
5. Install the 2 wiring harness bracket bolts (4) and tighten to 9 Nm (80 lb in).
6. Connect the wiring harness retainer (1) to steering gear.
7. Connect the 2 wiring harness plugs (3) to the steering gear.





Note: Connector latches are difficult to access

8. Connect the electrical connector (1). Push on the connector body until you hear a click.
9. Connect the electrical connector (2). Push on the connector body until you hear a click.




10. Connect electrical connector (3). Push on the connector body until you hear a click.
11. Push the lock (2) in the opposite direction of the arrow until you hear a click.




12. Remove the mechanics wire from the stabilizer shaft (1).
13. Position the stabilizer shaft and the bracket onto the suspension frame.
14. Install the NEW right stabilizer shaft insulator clamp bolts (2) and tighten to 22 Nm (16 lb ft).
15. Use the EN-45059 - sensor in order to tighten the NEW right stabilizer shaft insulator clamp bolts an additional 30 degrees.
16. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (Service and Repair).




17. Install the frame reinforcements (1).
18. Install the NEW frame rear bolts (2) and tighten to 160 Nm (118 lb ft).




19. Install the front transmission mount bolt (1) and tighten to 58 Nm (43 lb ft).
20. Install the rear transmission mount bracket bolt (2) and tighten to 100 Nm (74 lb ft).




21. Install the 4 fasteners (1) to the engine side cover on both sides.




22. Install the 4 fasteners (1) to the front engine compartment cover.
23. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (Front Compartment Insulator Replacement).
24. Install the engine shield, if equipped. Refer to Engine Shield Replacement (Service and Repair).
25. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (Service and Repair).
26. Connect the steering linkage outer tie rod to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).




27. Connect the stabilizer shaft link (1) to the stabilizer shaft on both sides.
28. Install the NEW lower stabilizer link shaft nut (2) on both sides. Use an allen wrench in order to hold the stabilizer shaft link ball stud. Tighten the lower stabilizer link shaft nut to 35 Nm (26 lb ft).
29. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
30. Lower the vehicle.
31. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).
32. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).
33. Measure and adjust the wheel alignment. Refer to Wheel Alignment Measurement (Wheel Alignment Measurement).
34. Center the steering angle sensor and learn the software end stops. Refer to Power Steering Control Module Calibration (Power Steering Control Module Calibration).
35. Program the power steering control module. Refer to Power Steering Control Module Programming and Setup (Power Steering Control Module Programming and Setup).
36. Program the Volatile Memory. Refer to Volatile Memory Programming (Testing and Inspection).