Steering Shaft Coupler: Service and Repair
COUPLING-STEERING - LOWERREMOVAL
NOTE: Before proceeding, Refer to Steering Column/Service precautions.
1. Place the steering wheel in the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
2. At the base of the steering column, remove the coupling retainer clip (4), back off the pinch bolt nut, and remove the steering column coupling pinch bolt (1) (the pinch bolt nut is caged to the coupling and is not removable). Separate the upper (2) from the lower (3) steering column coupling.
3. Raise and support the vehicle.
4. Release the locking tab on the wiring harness connector (1) at the power steering fluid pressure switch (3), then disconnect the wiring harness connector.
5. Remove the wheel mounting nuts (3), then the right front tire and wheel assembly (1).
6. Remove the one fastener (2) securing the wheel house splash shield (1) to the drive belt splash shield (3).
NOTE: Depending on application, it may be necessary to remove some fasteners securing the front fascia (1) to the body lower reinforcement in order to access drive belt splash shield forward fastener.
7. Remove the fastener (5) securing the drive belt splash shield (3) to the front suspension crossmember (6).
8. Remove the fasteners (4) securing the splash shield (3) to the body (2).
9. Remove the drive belt splash shield (3).
10. Remove the mounting nuts (1, 3), then the pencil strut (2) from the right front corner of the crossmember and body of the vehicle. Remove the washer (4) behind the strut from the torque strut (5) bolt.
11. Remove the bolt (5) mounting the engine torque strut (2) to the crossmember (1).
NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be scribed on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost.
12. Using an appropriate marker (2), draw a line (1) as necessary marking the location of the front suspension crossmember (3) where mounted against the body of the vehicle.
13. Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember.
14. Loosen all six bolts attaching the front suspension crossmember to the frame rails of the vehicle. Do not completely remove the two mounting bolts going through the lower control arm rear isolator bushings. They are designed to disengage from the body threads yet stay within the lower control arm rear isolator bushing. Back the two bolts out just enough to disengage the threaded tapping plates in the body of the vehicle. Completely remove the other four bolts.
CAUTION: Lower the steering gear slowly, paying special attention to the power steering fluid hoses. Do not strain or overextend the hoses because damage to the hoses or connecting hardware may occur.
15. Lower the front suspension crossmember (3) using the transmission jack (4) just enough to allow access to the steering column lower coupling (1). When lowering front suspension crossmember, do not let crossmember hang from lower control arms. The weight should be supported by the transmission jack.
16. Remove the roll pin (3) securing the steering column coupling (1) to the power steering gear pinion shaft (2) using a roll pin punch (4). Push the steering column lower coupling up and off of the power steering gear pinion shaft.
17. Remove the coupling (1) from the vehicle.
INSTALLATION
1. Push the column end of the steering column lower coupling (1) partway up through the hole in the dash panel, then match the flat on the inside of the coupling to the flat on the power steering gear pinion shaft and slide the coupling onto the shaft.
2. Align the roll pin hole in the coupling to the notch in the gear pinion shaft and install the roll pin (3) through the coupling until it is centered.
3. Center the power steering gear rack in its travel.
4. Using the transmission jack (4), raise the front suspension crossmember and power steering gear until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the steering column lower coupling (1) up through its hole in the dash panel.
5. Start the two crossmember mounting bolts through the lower control arm rear isolator bushings into the tapping plates mounted in the body. Next, install the two front and the two rear mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all six mounting bolts to approximately 2 Nm (20 inch lbs.) to hold the front suspension crossmember in position at this time.
NOTE: When installing the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost.
6. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously made positioning marks (3) on the body of the vehicle. Once the front suspension crossmember is correctly positioned, tighten the two crossmember mounting bolts through the lower control arm rear isolator bushings to a torque of 250 Nm (185 ft. lbs.), then tighten the four remaining crossmember mounting bolts to a torque of 153 Nm (113 ft. lbs.).
7. Install the engine torque strut (2) to the crossmember (1). Properly align and tighten the torque strut.
8. Install the washer (4) on the end of the stud extending from the torque strut bolt at the crossmember.
9. Position the pencil strut (2) on the right front corner of the crossmember and body of the vehicle and install the mounting nuts (1, 3). Tighten the nuts to 52 Nm (38 ft. lbs.).
10. Position the drive-belt splash shield (3) and install the fasteners (4) securing it to the body (2).
11. Install the fastener (5) securing the drive belt splash shield (3) to the front suspension crossmember (6).
12. If previously removed, install the fasteners securing the front fascia (1) to the body lower reinforcement.
13. Install the one fastener (2) securing the wheel house splash shield (1) to the drive belt splash shield (3).
14. Install the tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.).
15. Connect the wiring harness connector (1) to the power steering fluid pressure switch (3). Be sure the locking tab on the wiring harness connector is securely latched following installation.
16. Lower the vehicle.
17. Position the dash-to-lower coupling seal in place over the lower coupling's plastic collar.
NOTE: Verify that grease is present on the lip of the dash-to-coupling seal where it contacts the coupling's plastic collar.
18. Verify the front wheels of vehicle are in the STRAIGHT-AHEAD position.
NOTE: Do not tighten the coupling pinch bolt anytime the vehicle is not at curb riding height. It may cause unwanted conditions within the steering column if the vehicle is suspended in any manner when the pinch bolt is tightened.
19. If necessary, rotate the steering column shaft until the upper coupling (2) lines up with the rounded side of the lower coupling (3).
20. Slide the upper coupling (2) over the end of the lower coupling (3) and install the pinch bolt (1). Tighten the pinch bolt nut to 28 Nm (250 inch lbs.).
21. Install the pinch bolt retainer clip (4).
22. Remove the steering wheel holder.
23. While looking under the instrument panel at the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does not squeak against the dash-to-coupling seal.