Manual Steering Gear Assembly Service Removal/Installation
1. Disconnect negative battery cable.CAUTION:
MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
2. Raise vehicle on hoist.
3. Remove front road wheels.
4. Remove and discard steering linkage outer tie rod end (cotter) pin on one side of vehicle.
5. Remove tie rod end-to-steering knuckle castle nut.
NOTICE:
Do not attempt to separate the tie rod ends from steering knuckle using a wedge-type tool because the seal and/or steering knuckle may be damaged.
6. Using Tie Rod Separator SA91100C (or equivalent), remove tie rod end from steering knuckle.
7. Repeat steps 4 through 6 to remove tie rod end from steering knuckle on other side of vehicle.
IMPORTANT:
Remove front section of splash shield first, then rear section of splash shield.
8. Remove left side splash shield.
a. Remove two push pins.
IMPORTANT:
If molded-in fasteners are damaged or broken, drill out with a 5/16 bit and replace with a push pin.
b. Remove lower shield to cradle molded-in fasteners at cradle by gently prying at three fastener locations and remove splash shield.
9. Loosen intermediate steering shaft cover from steering gear assembly and move up enough to access pinch bolt.
10. Remove pinch bolt.
NOTICE:
After pinch bolt is removed, do not allow steering wheel or intermediate shaft to rotate, or SIR coil assembly could be damaged.
11. Remove steering gear assembly-to-cradle bolts and nuts and remove steering gear assembly from vehicle through left fenderwell.
IMPORTANT:
New outer tie rod ends are included with the new steering gear assembly and must be installed on inner tie rods prior to installing steering gear assembly into vehicle.
12. Thread inner tie rod jam nuts onto inner tie rods approximately 15 full turns.
13. Thread outer tie rods onto inner tie rods approximately 15 full turns.
14. Place new steering gear assembly in vehicle.
15. Install steering gear assembly-to-cradle bolts and new nuts.
Torque: 50 N.m (37 ft-lbs)
IMPORTANT:
Use Loctite(R) 242 Threadlocker (or equivalent) on thread of pinch bolt.
16. Install intermediate shaft onto the steering gear assembly and torque pinch bolt.
Torque: 47 N.m (35 ft-lbs)
17. Position intermediate steering shaft cover over steering gear assembly.
IMPORTANT:
Install rear section of splash shield first, then front section of splash shield.
18. Install left side splash shield.
19. Install tabs in body cut-out.
IMPORTANT:
Make sure shield flaps are tucked in at body locations.
20. Align molded-in shield fasteners with holes in cradle. Push straight in to install.
21. Install push pins.
IMPORTANT:
Tie rod end stud threads must be thoroughly cleaned and lubricated before tightening tie rod end-to-steering knuckle castle nut. Lubricate only the thread part of the stud. Do not lubricate the smooth tapered portion of stud.
22. Install tie rod end into steering knuckle on one side of vehicle.
23. Install tie rod end-to-steering knuckle castle nut.
Torque: 45 N.m (33 ft-lbs)
IMPORTANT:
If it is necessary to rotate the tie rod end-to-steering knuckle castle nut after tightening to orient it to the hole in the stud, always tighten the tie rod end-to-steering knuckle castle nut to align it; never loosen it.
24. Install new steering linkage outer tie rod end (cotter) pin into tie rod end-to-steering knuckle castle nut and bend ends to secure tie rod end pin.
25. Repeat steps 22 through 24 to install tie rod end into steering knuckle on other side of vehicle.
Torque: 17 N.m (151 in-lbs)
NOTICE:
Before installing wheels remove rust or corrosion from wheel mounting surfaces and brake rotor mounting surfaces. Failure to do so can cause wheel nuts to loosen in service.
26. Position front road wheels onto hubs.
27. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to make sure torque is correct.
Torque: 140 N.m (103 ft-lbs)
28. Lower vehicle from hoist.
29. Connect negative battery cable.