Removal and Installation

Removal

- Special 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 of the valve body unit its lines, and the end if 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.

1. Drain the power steering fluid and disconnect the primary H02S sensor connector.
2. Raise the vehicle, and make sure it is securely supported.
3. Remove the front wheels and remove exhaust pipe A to allow clearance for the steering gearbox.
4. Remove the driver's airbag.
5. Remove the steering wheel.





6. Remove the steering joint cover.





7. Remove the steering joint bolts (A), disconnect the steering joint by moving the steering joint (B) toward the column.





8. Remove the cotter pin (A) from the 10 mm nut (B), and loosen the nut.
9. Separate the tie-rod ball joint and knuckle using the special tool.





10. Loosen the 14 mm flare nut (A), and disconnect the pump outlet hose (B).
11. Loosen the 17 mm flare nut (C), and remove the return line (D).
12. After disconnecting the hoses and lines, plug or seal them with a piece of tape or equivalent to prevent foreign materials from entering.

NOTE: Do not loosen the cylinder line A and B between the valve body unit and cylinder.





13. Grasp the right tie-rod and pull the rack all the way to the right, then remove the right and left tie-rod ends (A), and locknut (B).
14. Remove the 3 way catalytic converter.
15. Disconnect the M/T shift cable or A/T shift cable from the transmission.





16. Remove the stiffener plates (A), then remove the right mounting brackets (B).





17. Pull the steering gearbox (A) all the way down to clear the pinion shaft (B) from the bulkhead, and remove the pinion shaft grommet from the top of the valve body unit.
18. Move the steering gearbox to the right so the left rack end clears the rear beam, then place the left rack end below the rear beam.
19. Move the steering gearbox to the left, and tilt the left side down to remove it.

Installation
1. Before installing the gearbox, slide the rack all the way to right.





2. Pass the right side of the steering gearbox (A) above and through the right side of the rear beam. Be careful not to bend or damage the two power steering lines and cylinder lines when installing the gearbox.
3. Raise the left side of the steering gearbox above and through the left side of the rear beam. Then insert the pinion shaft (B) up through the bulkhead.





4. Install the pinion shaft grommet (A). Align the slot (B) in the pinion shaft grommet with the lug portion on the valve housing.





5. Install the mounting cushion (A) on the steering gearbox.
6. Install the mounting brackets (B) over the mounting cushion, then install the two gearbox mounting bolts (C). Position the split portion (D) of the mounting cushion.
7. Install the stiffener plates (E) with the two gearbox mounting bolts (F) and six stiffener plate attaching bolts (G). Install the bolts loosely first, then tighten them securely.
8. Center the steering rack within its stroke.





9. 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 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.
10. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about 2 turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.





11. Install the steering joint cover (A) with the clamps (B) and clips (C).





12. Connect the return line (A) and feed line (B) to the valve body unit (C). After connecting the fluid lines, make sure that there is no interference between the lines and other parts.





13. Thread the right and left tie-rod ends (A) and locknut (B) onto the rack an equal number of turns.





14. Wipe off any grease contamination from the ball joint tapered section and threads then reconnect tie-rod ends (A) to the steering knuckles. Install the 10 mm nut (B) and tighten it.
15. Install the new cotter pin (C) and bend it.
16. Connect the M/T shift linkage or A/T shift cable from the transmission.
17. Install the three way catalytic converter and reconnect exhaust pipe A using new gasket.
18. Install the front wheels.
19. Reconnect the primary H02S sensor connector. Fill the steering system with power steering fluid, and bleed air from the system.
20. After installation, perform the following checks.
- 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.