Service Procedure

1. With the ignition key in the OFF position, disconnect the negative battery cable from the battery. Then disconnect the positive battery cable from the battery.

NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.

2. Raise the vehicle on an appropriate hoist.

3. Remove and discard the two steering gear-to-crossmember attaching bolts and washers.

4. Carefully pull the steering gear assembly forward, away from the crossmember.

5. Using a grinder or wire wheel, clean the surface of the crossmember to bare metal in the area where the steering gear attaches.

6. Set the welding machine amperage and wire teed speed. Refer to the welding Procedure Specifications Chart on page 8 for welding machine set up specifications and welding process information.

CAUTION:
The welding machine ground cable should be clamped directly to the crossmember as close as possible to the welding area.

7. Inspect the weld nut area of the crossmember for cracks. If no cracks are found, proceed to Step 11. If cracks exist in the crossmember around either weld nut, both weld nuts must be replaced.

8. Chisel off and discard the existing weld nuts.

9. Using the supplied attaching bolts, position the provided weld nut on the inside of the crossmember.

10. Tack weld the new weld nut into position using a shielded metal arc (stick) or MIG welder. The weld nut only needs to be tack welded into place.

CAUTION:
To prevent fire hazard, fuel lines, power steering lines and brake lines must be protected before attempting any welding operations.

IMPORTANT:
All welding must be performed by a qualified welder.

11. Position the reinforcement plates on the outside of the crossmember.

CAUTION:
The reinforcement plates provided in the repair kit are not interchangeable. Verify that the correct plate is on the correct side by fitting the reinforcements onto the crossmember before welding.

12. Tack weld both sides of each of the reinforcement plates onto the crossmember. This will prevent the plate from warping during the final welding process.

CAUTION:
To prevent fire hazard, fuel lines, power steering lines and brake lines must be protected before attempting any welding operations.

IMPORTANT:
All welding must be performed by a qualified welder.

13. Weld the reinforcement plates to the crossmember on three sides of each plate. Each weld should be at least one inch (25 mm) long.

14. Clean all welded areas and apply a suitable primer to the bare metal surfaces. Paint the primed surfaces with chassis black paint. Then apply undercoating to provide rust protection.

15. Position the steering gear onto the crossmember and install the supplied attaching bolts and concave washers.

NOTE:
Be sure that the concave side of the washer is toward the steering gear bushing.

16. Tighten the provided steering gear attaching bolts to 150 ft-lbs. (203 Nm)

17. Lower the vehicle.

18. Connect the positive battery cable to the battery. Then connect the negative battery cable to the battery.