Removal:

1. Prepare the car for servicing.

a. Unlock the steering column by turning the ignition key.

b. Engage the parking brake.

c. Raise and support the car.

d. Clean any loose dirt or oil from the power steering gear and boot bellows.

Figure 2:

e. Remove the wheel and tire assembly.

2. Disconnect the outer tie rod end from the steering knuckle.

a. Loosen the jam nut and keep flush with outer tie rod.

b. Disconnect the outer tie rod from the steering knuckle. Remove the cotter pin and castle nut by using a Tie Rod End Remover (TOOL-3290-D), Figure 2.

3. Mark the threads at the jam nut location.

a. Count and record the number of turns to remove the outer tie rod end from the inner tie rod. This information is useful in estimating the alignment setting.

b. Remove the jam nut from the inner tie rod spindle.

4. Remove the left and right steering gear boot bellows along with the breather tube.

CAUTION: USE CARE NOT TO DAMAGE THE BELLOWS.

5. Remove the rivet or rollpin securing the inner tie rod to the steering gear rack.

a. Use a sharp chisel to gently pry up the rivet or rollpin. DO NOT CUT OFF.

Figure 3:

Figure 4:

b. Use side cutters to remove the rivet, Figures 3 & 4.

Figure 5:

CAUTION:
THE RIVET HAS A STEEL CORE WHICH WILL DEFORM THE STEERING GEAR RACK THREADS IF IT IS NOT COMPLETELY REMOVED.

c. Use Rotunda Tool, Locknut Pin Remover D81P-3504-N to remove the rollpin, Figure 5.

Figure 6:

6. If the rivet is not accessible, unscrew the inner tie rod until it is accessible (less than 1 full turn). Use Rotunda Tool, Yoke Locknut wrench (T81P-3504-G) on the inner tie rod and an adjustable wrench on the rack teeth.

CAUTION:
HAVE STEERING GEAR AT OR NEAR THE FULL TURN (LOCK) POSITION. USE A WRENCH ON THE RACK TEETH (FLAT) TO RESIST RACK ROTATION AND PREVENT DAMAGE TO THE PINION DURING REMOVAL AND INSTALLATION, FIGURE 6.

Figure 7:

Allowing the rack and pinion to internally resist tightening or loosening may cause damage to the steering gear.

7. Remove the inner tie rod from the steering gear rack using a wrench on the rack teeth in combination with Rotunda Tool, Inner Tie Rod Socket D90P-3290-A as shown in Figure 7 and the stated cautionary notes.



8. Clean the following components.

^ The steering gear housing/boot bellows interface to both housing OD and boot ID

^ All parts to be reused (inspect and replace as required.)

^ Rack and housing bore.

CAUTION:
THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THIS IS EXTREMELY HARMFUL TO HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE.