Service Procedure

1. With the ignition key in the OFF position, disconnect 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 the steering gear-to4ront crossmember attaching bolts (Figure 1).

4. Pull the steering gear assembly forward, away from the crossmember.

5. Grind the surface of the crossmember in the area where the steering gear attaches.

6. 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.

7. Chisel off the existing weldnuts.

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

IMPORTANT:
All welding requirements should be completed by a certified welder experienced in frame repair.





8. Use the supplied attaching bolts to position the provided weld nuts on the inside of the crossmember (Figure 2).

9. Tack weld the new nuts into position using a standard arc or MIG weld.

10. Remove the attaching bolts and then arc or MIG weld the nuts along the sides (Figure 2).

11. Prime the crossmember surface in the area where the steering gear attaches with a weldable primer.





12. Position the reinforcement plates on the outside of the crossmember as shown in Figures 2 and 3.

13. Arc or MIG 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 the 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 washers (Figure 1).

16. Tighten the provided attaching bolts to 150 ft-lbs (203 N.m).

17. Lower the vehicle.

18. Connect the negative battery terminal.