Steering Gear Replacement (TRW without NR1, NS1, NS2)

Steering Gear Replacement (TRW without NR1, NS1, NS2)


Special Tools
* KM-6004-2 Tie Rod Wrench
* J 22610 Keystone Clamp Pliers



Removal Procedure






Important: To remove the steering gear, the front frame must be removed.


1. Remove the front frame. Refer to Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement))Front Frame Replacement (Removal) (Front Frame Replacement (Removal)) .
2. Remove the engine damping block bracket (1) at the rear of the engine damping block.
3. Remove the holder (2).

Important: Oil runs out, use drain pan.


4. Place a drain pan under the power steering line connections and remove the supply line (3) and return line (4) from the steering gear.

Important: Note the wiring route.


5. Disconnect the wiring harness for the steering from the front frame.




6. Remove the electro-hydraulic supply unit from the front frame.

* Remove the 3 nuts (1, 2) from the steering gear and the front frame.
* Remove the electro-hydraulic supply unit with supply and return line from the steering gear and the front frame.





7. Remove the tie rods on both sides of the steering gear.

* Remove the 2 retaining straps (1, 2).
* Remove the 2 boots from the steering gear.
* Remove the 2 tie rods (4) from the steering gear with KM-6004-2 .
Counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side.

8. Remove the steering gear from the front frame.

* Remove the 2 nuts (2) from the front frame.
* Remove the 2 bolts.
* Remove the steering gear from the front frame.




Installation Procedure


Notice: Refer to Fastener Notice (Fastener Notice) .

1. Install the steering gear to the front frame.
Insert 2 new bolts.

Tighten the 2 new nuts 45 N.m (33 lb ft) plus 45 degrees plus 15 degrees.


Important:
* Clean the thread on the rack and coat with locking compound.

* Counterholding is no longer necessary in vehicles from model year 2006.



2. Install the 2 tie rod to the steering gear with KM-6004-2 .
Counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side.

Tighten to 90 N.m (66 lb ft).


Important:
* Ensure that the boot sits in the grooves of the tie rod and the steering gear.

* Ensure that the boot sits in the grooves of the tie rod.



3. Install the 2 boots to the steering gear.

* Place the 2 boots on the steering gear.
* Install the 2 new retaining clamps to the steering gear with J 22610 .
* Install the 2 boots to the tie rod using the new retaining strap.


Important: Note the steering wiring harness.


4. Install the electro-hydraulic supply unit with bracket to the front frame .

Tighten to 22 N.m (16 lb ft).
Place the electro-hydraulic supply unit with the holder on the steering gear and front frame.

Tighten 3 nuts to 22 N.m (16 lb ft).


Important: Ensure that the wiring is routed properly.


5. Install the wiring harness for the steering to the front frame.
6. Install the supply and return line to steering gear .
Use the 2 new seal rings.

Tighten to 30 N.m (22 lb ft).

7. Install the supply and return line holder to the steering gear.
8. Install the rear engine damping block bracket to the engine damping block.

Tighten to 55 N.m (41 lb ft).

9. Install the front frame. Refer to Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement))Front Frame Replacement (Removal) (Front Frame Replacement (Removal)) .
10. Charge and bleed the hydraulic system. Refer to Hydraulic Brake System Bleeding (Service and Repair) .
11. Inspect the straight-ahead position, adjust if necessary. Refer to Straight Ahead Inspection (Removal and Replacement) .
12. Check the toe-in, adjust if necessary. Refer to Front Toe Adjustment (Service and Repair) .