Power Steering Gear Replacement

- TOOLS REQUIRED
- SA9llOOC Tie Rod Separator
- J42089 Steering Linkage Installer
- SA9140E Torque Angle Gauge
- J43628 Frame Alignment Fixture

REMOVAL

NOTICE: Rotating steering wheel while it is disconnected from the steering gear may cause damage to SIR coil.





1. From inside vehicle, remove intermediate shaft to steering gear pinch bolt. Disconnect shaft from steering gear.





2. On vehicles equipped with L81 engines, remove rear exhaust manifold pipe heat shield.





3. Remove rear transaxle mount through bolt, and transaxle mount-to-frame bolt.





4. Place an approved drain container under pressure and return hoses at steering gear.
5. Remove power steering pump pressure and return hoses from steering gear and allow system to drain.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.





6. Raise vehicle on hoist.
7. Remove front wheel and tire assemblies.
8. Remove right front lower splash shield.





9. Remove exhaust manifold pipe on L81 engines and on L61 engines with manual transmissions. (L81 shown)





10. Remove remaining rear transaxle mount-to-frame bolts.





11. Remove tie rod end torque prevailing nuts and discard nuts.

NOTICE: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

12. Using Tie Rod Separator SA9llOOC (or equivalent), separate tie rod end from steering knuckle.





13. Remove steering gear-to-frame assembly bolts.
14. Vehicles equipped with L61 engines and automatic transaxle, remove steering gear heat shield.





15. Remove stabilizer bar links from strut assembly.





16. Remove the front suspension support assemblies.





17. Loosen remaining frame-to-body attachment fasteners until there is enough clearance to remove steering gear through drivers side wheel opening.
18. Remove steering gear from vehicle.





INSTALLATION

1. One at a time, remove frame bolts and replace cage nuts which are located in the body and use new bolts. Torque retention of old nuts and bolts may not be sufficient.
2. Install steering gear into vehicle through left wheel opening.





3. Using powertrain support dolly and frame alignment tool J43628, raise frame assembly to vehicle and tighten fasteners.
Torque: 90 Nm (66 ft. lbs.) + 45 - 60.
4. Install new cage nuts for suspension supports. Torque retention of old nuts may not be sufficient.





5. Install suspension supports using new bolts and tighten.
Torque: 90 Nm (66 ft. lbs.) + 45 - 60°

NOTICE: New bolts must be used as torque retention of old bolts may not be sufficient.





6. Using new bolts, install steering gear to frame.
Torque: 45 Nm (35 ft. lbs.) + 45 - 60°
7. Vehicles equipped with L61 engines and automatic transaxle, install steering gear heat shield.
Torque: 4 Nm (35 inch lbs.)

IMPORTANT: The tie rod ends must be thoroughly cleaned before installing and tightening.





8. Install tie rod end into steering knuckle.
9. Using linkage installer J44015 (or equivalent) seat tie rod end into knuckle.
Torque: 45 Nm (33 ft. lbs.)

NOTICE: Use new nut; torque retention of old nut may not be sufficient.

10. Remove linkage installer and install new tie rod end nut.
Torque: 60 Nm (44 ft. lbs.)





11. Install stabilizer bar link-to-strut assembly.
Torque: 65 Nm (48 ft. lbs.)





12. Install rear transaxle mount to frame bolts.
Torque: 60 Nm (44 ft. lbs.)





13. Install power steering high pressure and return lines.
Torque: 27 Nm (20 ft. lbs.)





14. Install exhaust manifold pipe on vehicles equipped with L81 engines, and L61 engines with manual transaxles.
15. Tighten exhaust manifold pipe to exhaust manifold nuts.
Torque: 30 Nm (22 ft. lbs.)
16. Tighten exhaust manifold pipe to exhaust pipe bolts.
Torque: 20 Nm (15 ft. lbs.)

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.

17. Install wheel and tire assemblies onto hub.
18. Install wheel bolts and tighten in a crisscross pattern. Repeat tightening to make sure torque is correct.
Torque: 125 Nm (92 ft. lbs.)





19. Install the remaining rear transaxle mount to frame bolt.
Torque: 60 Nm (45 ft. lbs.)
20. Install rear transaxle mount through bolt.
Torque: 90 Nm (66 ft. lbs.)





21. Install exhaust manifold pipe heat shield on vehicles equipped with L81 engines.
Torque: 8 Nm (71 inch lbs.)

IMPORTANT: Use Loctite 242 Threadlocker (or equivalent) on thread of pinch bolt.





22. Install the intermediate shaft onto steering gear and torque pinch bolt.
Torque: 28 Nm (21 ft. lbs.)
23. Bleed power steering system. (Refer to "Power Steering Bleed" procedure.)
24. Set toe. (Refer to "Wheel Alignment" procedure.)