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Steering Gear Replacement




Steering Gear Replacement (HP2)

Special Tools

J-42640 - Steering Column Anti-Rotation Pin

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

Removal Procedure





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.

1. With the front wheels of the vehicle in the straight ahead position, use the J-42640 - Pin in order to lock the steering column.

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Failure to follow the procedures exactly as written may result in serious injury or death.


Note: The steering gear harness is not repairable. Replace the steering gear harness.

Note: The wiring harness protective cover is intended to keep the wiring harness connectors contaminant free. Do not remove the protective cover from the power steering assist motor wiring harness connectors until the harness is in the correct position in the vehicle.

2. Perform the high voltage disabling procedure. Refer to High Voltage Disabling (High Voltage Disabling).
3. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
4. Use mechanics wire in order to support the power steering assist motor.
5. Disconnect the power steering assist motor from the steering gear. Refer to Power Steering Assist Motor Replacement (Service and Repair).
6. Disconnect the steering shaft coupling from the steering gear. Refer to Steering Shaft Coupling Replacement (Steering Shaft Coupling Replacement).
7. Disconnect the steering linkage outer tie rods from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
8. Support the steering gear with jack stands.




9. Remove the steering gear bolts (1) from the left side of the steering gear.




10. Remove the steering gear bolts (1) from the right side of the steering gear.
11. Remove the steering gear from the vehicle.
12. Transfer any parts as necessary.

Installation Procedure

1. Position the steering gear in the vehicle.
2. Support the steering gear with jack stands.





Note: Start all steering gear bolts by hand before finalizing the torques.

3. Install the steering gear bolts (1) at the right side of the steering gear.

Caution: Refer to Fastener Caution (Fastener Caution)

4. Tighten the right side steering gear bolts to 100 Nm (74 lb ft).




5. Install the steering gear bolts (1) to the left side of the steering gear.
6. Tighten the left side steering gear bolts to 200 Nm (148 lb ft).
7. Remove the jack stands.
8. Connect the steering linkage outer tie rods to the steering knuckles. Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
9. Connect the steering shaft coupling to the steering gear. Refer to Steering Shaft Coupling Replacement (Steering Shaft Coupling Replacement).
10. Connect the power steering assist motor to the steering gear. Refer to Power Steering Assist Motor Replacement (Service and Repair).
11. Remove the mechanics wire from the power steering assist motor.
12. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).




13. Remove the J-42640 - Pin from the steering column.
14. Perform the high voltage enabling procedure. Refer to High Voltage Enabling (High Voltage Enabling).
15. Perform the power steering control module setup procedure. Refer to Power Steering Control Module Programming and Setup (Testing and Inspection).
16. Measure and adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment).

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