Removal and Installation
Steering Gearbox RemovalSpecial Tools Required
Ball joint remover, 28 mm 07MAC-SL00200
Note these items during removal:
- Using solvent and a brush, wash any oil and dirt off the valve body unit, its lines, and the end of the gearbox. Blow dry with compressed air.
- Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.
- Lower the front subframe from the body and remove/install the steering gearbox through the gap produced by lowering the front subframe.
1. Drain the power steering fluid.
2. Record the customer's radio station presets, then disconnect the battery cable.
3. Remove the driver's airbag assembly.
4. Remove the steering wheel.
5. Remove the steering joint cover (A).
6. Remove the steering joint bolts, disconnect the steering joint by moving the steering joint (A) toward the column.
7. Disconnect the pump outlet hose (A) from the power steering pump, and remove the feed hose clamp (B).
8. Remove the 10 mm flange bolts on the engine side mount bracket (A).
9. Raise the vehicle, and make sure it is securely supported.
10. Remove the front wheels.
11. Remove the cotter pin (A) from the 12 mm nut (B), and loosen the nut.
12. Separate the tie-rod ball joint and knuckle using the special tool.
13. Remove the subframe stiffener plate.
14. Disconnect the secondary heated oxygen sensor (secondary H02S) connector (A) from the engine compartment.
15. Remove the three self-locking nuts, and disconnect the three way catalytic converter (TWC) (A) and mufflers (B).
16. Remove the 10 mm flange bolts of the exhaust rubber mount (A).
17. Disconnect the power steering pressure (PSP) switch connector (A).
18. Remove the propeller shaft protector.
19. Remove the splash shield.
20. Place a jack (A) under the front tube of the front subframe (B), and support it by raising the jack. Place a transmission jack (C) under the center of the transfer case (D).
21. Loosen the two 14 mm flange bolts (A) on the front subframe so they are about 30 mm (1 3/16 inch) from the mounting surface. Do not loosen the 14 mm flange bolts more than necessary.
22. Remove the four 12 mm flange bolts from the front stiffener plates (A).
23. Support the transfer case securely by raising the transmission jack, then remove the two 12 mm flange bolts (A).
24. Remove the two 14 mm special bolts (B) and rear stiffener plates (C) from the front subframe.
25. Lower the transmission jack slowly until the front subframe has dropped about 50 mm (1 15/16 inch)
26. Remove the P/S line mounting brackets (A) from the front subframe and gearbox mounting bracket.
27. Loosen the 14 mm flare nut (A), and disconnect the feed line (B).
28. Loosen the adjustable hose clamp (C) and disconnect the return hose (D).
29. Remove the two 10 mm flange bolts from the right side of the gearbox, then remove the mounting bracket (A) and cushion (B).
30. Remove the two 10 mm flange bolts from the left side of the gearbox.
31. Lower the transmission jack slowly until the front subframe has dropped 100 mm (3 15/16 inch) total.
32. Remove the gearbox stiffener bracket (A) from the left side of the front subframe.
33. Slide the steering gearbox (A) between the body and front subframe toward the left, and remove the steering gearbox.
Steering Gearbox Installation
1. Install the pinion shaft grommet (A) on the valve housing.
2. Slide the steering gearbox (B) between the front subframe and body from the driver's side. Place the gearbox in position on the front subframe.
3. Install the gearbox stiffener bracket (A) on the front subframe, and tighten the bolt and nut to the specified torque.
4. Loosely install the two 10 mm flange bolts on the left side of the gearbox.
5. Install the mounting cushion (A) on the right side of the gearbox.
6. Install the mounting bracket (B) over the mounting cushion, then install the two 10 mm flange bolts (C). Tighten the four 10 mm flange bolts for the gearbox to the specified torque.
7. Connect the return hose (A) securely, and tighten the adjustable hose clamp (B).
8. Connect the feed line (C), and tighten the 14 mm flare nut (D) to the specified torque.
9. Install the P/S line mounting brackets (A) on the front subframe and gearbox mounting bracket.
10. Carefully raise the front subframe with the transmission jack (transfer case supporting jack).
11. Install the rear stiffener plates (A). Tighten the 12 mm flange bolts (B) and 14 mm special bolts (C) to specified torque.
12. Install the front stiffener plates (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to specified torque.
13. Lower the front subframe supporting jack and the transmission jack.
14. Install the splash shield (A).
15. Install the propeller shaft protector.
16. Connect the power steering pressure (PSP) switch connector (A).
17. Connect the three way catalytic converter (TWC) (A) and mufflers (B). Install the new 10 mm self-locking nuts and tighten them to specified torque.
18. Install the exhaust rubber mount on the frame.
19. Connect the secondary heated oxygen sensor (secondary HO2S) connector (A), and install the wire harness on the clamp and clip. Make sure the wire harness is routed and fastened properly.
20. Install the subframe stiffener plate.
21. Install the 10 mm flange bolts on the engine side mount bracket (A).
22. Connect the pump outlet hose (A) from the power steering pump, and install the feed hose clamp (B).
23. Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it.
24. Install the new cotter pin (C) and bend it as shown.
25. Center the steering rack within its stroke, then install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:
- Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft).
- Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole (F) with the groove (G) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft.
- Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it.
26. Center the cable reel first by rotating it clockwise until it stops. Then rotate it counterclockwise (about two and half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.
27. Install the steering joint cover (A) with the clamps (B) and clips (C).
28. Install the front wheels.
29. Connect the battery cable.
- Do the PCM idle learn procedure.
- Do the power window control unit reset procedure.
- Enter the anti-theft codes for the radio and the navigation system, then the customer's radio station preset's.
- Set the clock.
30. Fill the system with power steering fluid, and bleed air from the system.
31. After installation, perform the following:
- Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks.
- Adjust the front toe.
- Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally, if necessary.