Power Steering Gear

POWER STEERING GEAR

^ TOOLS REQUIRED
- J 43628 Frame Alignment Fixture
- J44015 Steering Linkage Installer
- SA91100C Tie Rod Separator

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 THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

6. Raise vehicle on hoist.
7. Remove front wheel and tire assemblies.
8. Remove right front lower splash shield.
9. Disconnect 02 sensor electrical connection.





10. Remove 02 sensor clamp to underbody attachment nut on vehicle equipped with L61.





11. Remove 02 sensor from exhaust manifold pipe on L81 engines.





12. Remove exhaust manifold pipe on L81 engines and on L61 engines with manual transmissions. (L.81 shown).





13. Remove remaining rear transaxle mount-to-frame bolts.
14. Remove rear transaxle mount.





NOTICE: Hold ball stud from turning when removing nut. The boot can become torn and damaged if the ball stud turns.

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

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

16. Using Tie Rod Separator SA91100C (or equivalent), separate tie rod end from steering knuckle.





17. Remove cradle to shifter link pivot pin clip on vehicles equipped with L61 engine and manual transaxle.





18. Remove steering gear-to-frame assembly bolts.
19. Vehicles equipped with 161 engines and automatic transaxle, remove steering gear heat shield.





NOTICE: Hold ball stud from turning when removing nut. The boot can become torn and damaged if the ball stud turns.

20. Remove stabilizer bar links from strut assembly.





21. Remove the front suspension support assemblies.





22. Loosen remaining frame-to-body attachment fasteners until there is enough clearance to remove steering gear through drivers side wheel opening.
23. 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 Fixture J43628, raise frame assembly to vehicle and tighten fasteners.
^ Frame Assembly-to-Body Bolts: 90 Nm (66 ft. lbs.) + 45° to 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.
^ Suspension Support-to-Body Bolts: 90 Nm (66 ft. lbs.) + 45° to 60°





6. On vehicles equipped with L.61 and manual transaxle, install cradle-to-shifter link pivot pin clip.





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

7. Using new bolts and nuts, install steering gear to frame.
^ Steering Gear-to-Frame: 45 Nm (35 ft. lbs.) + 90° to 105°
8. Vehicles equipped with L61 engines and automatic transaxle, install steering gear heat shield.
^ Steering Gear Heat Shield-to-Frame: 4 Nm (35 inch lbs.)





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

9. Install tie rod end into steering knuckle.
10. Using Steering Linkage Installer J44015 (or equivalent) seat tie rod end into knuckle.
^ Tie Rod End Linkage Installer: 45 Nm (33 ft. lbs.)

NOTICE: Use a new nut. Torque retention of old nut may not be sufficient.

NOTICE: Hold ball stud from turning when installing nut. The boot can become torn and damaged if the ball stud turns.

11. Remove linkage installer and install new tie rod end nut.
^ Tie Rod End-to-Steering Knuckle Nut: 60 Nm (44 ft. lbs.)
12. Inspect boot for damage and replace if damaged.





NOTICE: Hold ball stud from turning when installing nut. The boot can become torn and damaged if the ball stud turns.

13. Install stabilizer bar link-to-strut assembly
^ Stabilizer Bar Link-to-Strut: 65 Nm (48 ft. lbs.)
14. Inspect boot for damage and replace if damaged.
15. Install rear transaxle mount.





16. Install rear transaxle mount to frame bolts.
^ Rear Transaxle Mount-to-Frame Bolts: 60 Nm (44 ft. lbs.)





17. Install power steering high pressure and return lines.
^ Power Steering Lines-to-Steering Gear: 27 Nm (20 ft. lbs.)





18. Install exhaust manifold pipe on vehicles equipped with L81 engines, and L61 engines with manual transaxles.
19. Tighten exhaust manifold pipe to exhaust manifold nuts.
^ Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (22 ft. lbs.)
20. Tighten exhaust manifold pipe to exhaust pipe bolts.
^ Exhaust Manifold Pipe-to-Exhaust Pipe Bolts: 20 Nm (15 ft. lbs.)





21. Install 02 sensor clamp to underbody attachment nut on vehicles equipped with L61.
^ 02 Sensor Clip-to-Underbody Attachment Nut: 4 Nm (35 inch lbs.)
22. Connect 02 sensor electrical connector.

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.

23. Install wheel and tire assemblies onto hub.
24. Install wheel bolts and tighten in a crisscross pattern.
24.1. Hand tighten all five wheel bolts.
24.2. Use a torque wrench to tighten wheel bolts using a crisscross pattern.
^ Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
24.3. Use a torque wrench to final tighten wheel bolts using a crisscross pattern.
^ Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)





25. Lower vehicle.
26. Install the remaining rear transaxle mount to frame bolt.
^ Rear Transaxle Mount-to-Frame Bolts: 60 Nm (44 ft. lbs.)
27. Install rear transaxle mount through bolt and heat shield (on vehicle with L61 and auto transaxle).
^ Rear Transaxle Mount Through Bolt: 90 Nm (66 ft. lbs.)





28. Install 02 sensor on exhaust manifold pipe on vehicles equipped with L81 engines.
^ 02 Sensor on Exhaust Manifold Pipe (L81): 45 Nm (33 ft. lbs.)





29. Install exhaust manifold pipe heat shield on vehicles equipped with L81 engines.
^ Exhaust Manifold Pipe Heat Shield Bolts (L81): 8 Nm (71 inch lbs.)





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

30. Install the intermediate shaft onto steering gear and torque pinch bolt.
^ Intermediate Shaft Pinch Bolt: 30 Nm (22 ft. lbs.)
31. Bleed power steering system.
32. Set toe.