Removal/Installation

Fig. 6 Power Steering Gear Removal:

Removal
1. Raise and support vehicle, then remove wheels.
2. Disconnect both hoses from pinion housing. Plug connections and hoses.
3. Remove right side steering gear heat shield, then disconnect lower universal joint from pinion shaft.
4. Working from inside of vehicle, at driver's footwell, remove pinch bolts securing universal joint to lower and upper column.
5. Slide universal joint free from upper column.
6. Remove universal joint from lower shaft (1) Fig. 6.
7. Loosen clip securing water seal to lower column.
8. From below vehicle, push lower column through bulkhead until lower universal joint disengages from pinion shaft.
9. Move universal joint clear of pinion and withdraw lower column assembly from housing.
10. Remove self locking nuts securing outer tie rods to steering arms. Use separator tool No. JD24 or equivalent, to disconnect both tie rods.
11. Remove bolt, washer and self locking nut securing steering rack top mount to crossmember.
12. Note number and position of packing washers, then remove steering rack from crossmember.

Fig. 5 Power Steering Gear Installation:

Installation
1. Ensure wheels are in straight ahead position. Place rack into correct mounting position.
2. Ensure single rack mounting lug is shimmed so it is central between crossbeams.
3. Measure gap between face of rubber thrust washers and single lug. Correct gap is 0.10-0.12 inch.
4. Insert mounting bolts, but do not tighten.
5. Loosen clips securing bellows to rack housing. Pull bellows (1) Fig. 5, clear of inner ball joint assemblies.
6. Connect two attachment brackets of rack checking fixture tool No. JD36A or equivalent, on heads of lower control arm fulcrum shaft bolts (2) Fig. 5.
7. Release locking screw (3), on forward arm of tool and position slide so slot engages with front welded flange of cross beam. Tighten lock screw.
8. Rotate alignment legs (4) Fig. 5, of tool until one or both rest on rack shaft.
9. Adjust position of rack if necessary, until both legs are in contact with rack shaft.
10. Tighten mounting bolts to secure rack.
11. Remove tool, then install bellows and clips.
12. Connect outer tie rod to steering knuckle, then install lower steering universal joint into position through housing.
13. Engage lower joint onto pinion shaft.
14. Engage upper joint onto steering column.
15. Install pinch bolts, then secure water seal to lower column.
16. Install rack and exhaust heat shields.
17. Tighten to specifications and check front wheel alignment.