Steering Gear Boot Replacement

- TOOLS REQUIRED
- SA9164C Clamp Pliers
- SA91 100C Tie Rod Separator
- J44015 Steering Linkage Installer

REMOVAL

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.





1. Raise vehicle on hoist.
2. Remove wheel and tire assembly.





3. Loosen outer tie rod-to-inner tie rod jam nut.
4. Remove tie rod end-to-knuckle nut and discard.

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

5. Using Tie Rod Separator SA91100C (or equivalent), separate tie rod end from steering knuckle.
6. Unthread outer tie rod from inner tie rod and remove from vehicle.
7. Remove inner tie rod to outer tie rod jam nut.





8. Remove boot clamp (tie rod end).
9. Remove boot clamp (steering gear housing end) with cutters and discard.
10. Remove steering gear boot from steering gear.

INSTALLATION





1. Install new boot clamp onto steering gear boot (steering gear housing end).
2. Apply grease in service kit to locations shown in illustration prior to boot installation. This grease provides a water barrier and must be used to protect internal gear components from corrosion.





3. Install boot onto inner tie rod assembly. Slide boot along rod assembly until large end of boot is seated in steering gear housing groove.
4. Using clamp pliers SA9164C, crimp clamp on housing end of boot.
5. Install clamp on inner tie rod end of boot.





6. Install inner tie rod to outer tie rod jam nut.





7. Thread outer tie rod onto inner tie rod.

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 the tie rod end into the knuckle and tighten.
Torque: 45 Nm (35 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 and tighten.
Torque: 60 Nm (45 ft. lbs.)





11. Hand tighten inner tie rod-to-outer tie rod jam nut.

IMPORTANT: 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.

12. Install wheel and tire assemblies.
13. Install wheel bolts and tighten in a crisscross pattern. Repeat tightening to make sure torque is correct.
Torque: 125 Nm (92 ft. lbs.)
14. Set toe. (Refer to "Wheel Alignment" in "Alignment, Wheels & Tires" procedure in this manual.)