Steering Gear: Service and Repair

Steering Gear Replacement (All Wheel Drive)

Special Tools
* CH-49200 - Steering Gear Support
* J-6627-A - Tie Rod Puller

Removal Procedure

Caution: Refer to Steering Column in Lock Position Caution (Steering Column in Lock Position Caution).

1. LOCK the steering column with the front wheels in the straight ahead position.




2. Turn back the floor carpet and remove the 2 clips (2, 3).
3. Remove the column hole cover silencer sheet (1).




4. Place match marks (1) on the intermediate shaft assembly and on the steering gear pinion shaft.
5. Remove the bolt from the intermediate shaft.
6. Separate the intermediate shaft assembly from the steering gear pinion shaft.




7. Remove 3 clips (1, 2, 3).
8. Remove the steering column hole cover and disengage clip (4) from the body.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
10. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
11. Remove the left side engine splash shield. Refer to Engine Splash Shield Replacement - Left Side (Engine Splash Shield Replacement - Left Side).
12. Remove the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side (Engine Splash Shield Replacement - Right Side).




13. Remove the cotter pin and the nut (1) from the left side tie rod end.
14. Use the J-6627-A - puller , or equivalent, in order to separate the left side tie rod end from the knuckle.
15. Install, but do not tighten, the nut in order to loosely hold the left tie rod end to the knuckle.
16. Remove the cotter pin and the nut from the right side tie rod end.
17. Use the J-6627-A - puller , or equivalent, in order to separate the right side tie rod end from the knuckle.
18. Install, but do not tighten, the nut in order to loosely hold the right tie rod end to the knuckle.




19. Remove the bolt (3) and the 2 nuts (1, 2) from the left front control arm.
20. Remove the bolt and the 2 nuts from the right front control arm.
21. Use wire in order to secure the steering gear to the transfer case.
22. Lower the front suspension crossmember as much as necessary in order to access the steering gear. Refer to Front Suspension Crossmember Replacement (All Wheel Drive) (Front Suspension Crossmember Replacement)Front Suspension Crossmember Replacement (Two Wheel Drive) (Front Suspension Crossmember Replacement).




23. On the left side, hold the nut (2) and remove the bolt (1) from the steering gear.




24. On the right side, hold the nut (1) and remove the bolt (2) from the steering gear.
25. Remove the 4 bolts from the stabilizer shaft insulator clamps.
26. Remove the 2 nuts from the 2 outer tie rod ends.
27. Remove the wire and the steering gear from the crossmember.




28. Remove the steering column hole cover (1) from the steering gear.




29. Wrap tape (1) around the CH-49200 - support (2).
30. Use the CH-49200 - support and a vise in order to hold the steering gear.




31. Use paint in order to place match marks (2, 4) on the tie rod ends (5) and on the inner tie rods (1).
32. Remove the tie rod ends and the lock nuts (3).

Inspection Procedure




1. Using a torque wrench (1) and a socket, inspect the total preload around the steering rack center position. If the total preload is not within the specified range, replace the steering gear.

The standard preload is 0.7 to 1.1 Nm (7 to 9 lb in).

2. Inspect the ball joint seal on each of the tie rod ends. If the seal is damaged or not holding the lubricant, replace the damaged tie rod end.




3. Clamp each of the tie rod ends in a soft-jawed vise.
4. Install a nut to the stud.
5. Move the ball joint back and forth 5 times.
6. Use a beam type torque wrench and a socket on the nut in order to turn the ball joint continuously at a rate of 2 to 4 seconds per turn.
7. Measure the turning torque on the 5th turn. If the turning torque is not within the specified range, replace the tie rod end.

The standard turning torque is 0.3 to 1.9 Nm (3 to 17 lb in).




8. Inspect the steering column hole cover (1) for damage. If the cover is damaged, replace the cover.

Installation Procedure




1. Install, but do not tighten, the lock nuts (3) and the tie rod ends (5) to the inner tie rods (1). Align the match marks (2, 4).




2. Align the round hole in the steering column hole cover (1) with the protrusion on the steering gear. Install the cover.
3. Position the steering gear near the transfer case. Use wire in order to secure the steering gear to the transfer case.
4. Position the tie rod ends on the knuckles. Install, but do not tighten, the nuts in order to loosely hold the tie rod ends to the knuckles.
5. Raise and support the front suspension crossmember close to the steering gear.
6. Install the stabilizer shaft insulator brackets.

Caution: Refer to Fastener Caution (Fastener Caution).

7. Install the 4 bolts to the brackets and tighten to 24 Nm (18 lb ft).




8. On the left side, install the bolt (1) and the nut (2) in order to retain the steering gear to the crossmember. Hold the nut and tighten the bolt to 82 Nm (60 lb ft).




9. On the right side, install the bolt (2) and the nut (1) in order to retain the steering gear to the crossmember. Hold the nut and tighten the bolt to 82 Nm (60 lb ft).
10. Install the front suspension crossmember. Refer to Front Suspension Crossmember Replacement (All Wheel Drive) (Front Suspension Crossmember Replacement)Front Suspension Crossmember Replacement (Two Wheel Drive) (Front Suspension Crossmember Replacement).
11. Remove the wire supporting the steering gear.




12. Install the 2 nuts (1, 2) and the bolt (3) to the left front control arm and tighten to 89 Nm (66 lb ft).
13. Install the 2 nuts and the bolt to the right front control arm and tighten to 89 Nm (66 lb ft).




14. Tighten the 2 tie rod end nuts (1) to 49 Nm (36 lb ft).
If the nut does not align with the hole for the cotter pin, tighten the nut up to an additional 60 degrees.
15. Install 2 NEW cotter pins.




16. Engage the clip (4) onto the body and install the steering column hole cover onto the body.
17. Install the 3 clips (1, 2, 3).




18. Align the match marks (1) and install the intermediate shaft to the steering gear pinion shaft.
19. Install the bolt and tighten to 35 Nm (26 lb ft).
20. Ensure the front wheels are in the straight ahead position.




21. Install the column hole cover silencer sheet (1) with the 2 clips (2, 3).
22. Install the floor carpet.
23. Install the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side (Engine Splash Shield Replacement - Right Side).
24. Install the left side engine splash shield. Refer to Engine Splash Shield Replacement - Left Side (Engine Splash Shield Replacement - Left Side).
25. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
26. Measure the wheel alignment. Refer to Wheel Alignment Measurement (Wheel Alignment Measurement).
27. Adjust the front toe and tighten the tie rod end lock nuts. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment).
28. Lower the vehicle.