Steering Gear Replacement (ZF)
Steering Gear Replacement (ZF)
Special Tools
* J 22610 /KMJ-22610 Keystone Clamp Pliers
* KM-6004-2 Tie Rod Wrench
Removal Procedure
Note: DO NOT remove subframe from the body. Subframe will just be lowered.
1. Turn the steering wheel as far as the stop.
1. Turn the steering wheel and front wheels to the straight-ahead position.
2. Remove the ignition key.
3. Allow the steering lock to engage.
Note: The bolt is accessible from the passenger compartment.
2. Remove the intermediate shaft from the steering gear.
1. Remove the clamp bolt (1) from the intermediate shaft.
2. Remove the intermediate shaft from the steering wheel.
3. Remove the rubber sleeve from the steering gear (2).
Note: Mark the position relative to the wheel hub.
4. Remove the 2 front wheels.
Remove the 10 wheel bolts.
5. Release the 2 tie rod ends. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
6. Remove the lower engine compartment cover.
Release the 8 bolts (1).
7. Remove the front exhaust pipe.
Note: The flexible part of the pipe must not be bent by more than 5 degrees.
1. Remove the 3 nuts for connecting the front pipe to the particle filter/rear catalytic converter (1).
2. Remove the 3 nuts for connecting the pipe to the front catalytic converter (2).
3. Remove the bracket from the oil pan (3).
4. Remove the exhaust pipe.
8. Remove the rear engine damping block from the transmission.
Remove the 3 bolts (1).
9. Place the vehicle jack in a position under the front frame.
10. Remove the triangular plate.
Remove the 6 bolts (1, 2).
11. Remove the center 2 bolts from the axle housing (1).
Note: Lower as little as possible, maximum 55 mm (2 in).
12. Lower the frame
13. Remove the engine damping block bracket (1) at the rear of the engine damping block.
14. Remove the rear engine damping block (2).
Remove the bolt connection.
Note: Oil will run out use a drain pan.
15. Remove the supply line (3) and return line (4) from the steering gear.
16. Remove the electro-hydraulic supply unit from the front frame.
1. Release the 2 wiring harness plugs (1, 2) and remove from the electro-hydraulic supply unit.
2. Remove the 3 nuts (3, 4) from the steering gear and the front frame.
3. Remove the electro-hydraulic supply unit with supply and return line from the steering gear and the front frame.
17. Remove the tie rods on both sides of the steering gear.
1. Remove the 2 retaining straps (1, 2).
2. Remove the 2 boots from the steering gear.
3. Remove the 2 tie rods (4) from the steering gear with KM-6004-2 .
18. Remove the steering gear from the front axle body.
1. Remove the 2 nuts (2) from the front axle body.
2. Remove the 2 bolts.
3. Remove the steering gear.
Installation Procedure
Caution: Refer to Fastener Caution (Fastener Caution).
1. Install the steering gear to the front frame.
1. Insert the 2 new bolts.
2. Tighten the 2 new nuts to 45 Nm (33 lb ft) plus 45 degrees plus 15 degrees.
Note: Clean the thread on the rack and coat with locking compound.
2. Install the 2 tie rods to the steering gear with KM-6004-2 .
1. Counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side.
2. Tighten the 2 tie rods to the steering gear to 90 Nm (67 lb ft).
Note: Ensure that the boot sits in the grooves of the tie rod and steering gear.
3. Install the 2 boots to the steering gear.
1. Place the 2 boots on the steering gear.
2. Install the 2 new retaining clamps to the steering gear with J 22610 /KMJ-22610.
3. Install the 2 boots to the tie rod using new retaining strap.
Note: Note the steering wiring harness.
4. Install the electro-hydraulic supply unit with bracket to the front frame and tighten to 22 Nm (16 lb ft).
5. Place the electro-hydraulic supply unit with the holder on the steering gear and front frame. Tighten the 3 nuts.
6. Connect the 2 wiring harness plugs to the electro-hydraulic supply unit.
7. Install the supply and return line to the steering gear and tighten to 16 Nm (12 lb ft).
Use the 2 new seal rings.
8. Install the supply and return line holder to the steering gear.
9. Install the rear engine damping block bracket to the engine damping block and tighten to 55 Nm (40 lb ft).
10. Install the bolts for the front frame.
Install the triangular plates, insert the following new bolts and leave loose.
* Tighten the 2 bolts (2) for the front axle housing to90 Nm (67 lb ft) plus 45 degrees plus 15 degrees.
* Tighten the 4 bolts (1) for the triangular plates to the vehicle underbody to 65 Nm (48 lb ft).
11. Insert the center bolts for the front frame and leave slack.
Tighten the 2 bolts for front axle housing (1) to 90 Nm (67 lb ft) plus 45 degrees plus 15 degrees .
12. Lower the vehicle.
13. Place the engine support underneath, at the back on the transmission. Tighten the bolt to 80 Nm (59 lb ft).
Note: The flexible part of the pipe must not be bent by more than 5 degrees.
14. Install the front exhaust pipe.
* Lubricate the bolts with bolt paste and install the pipe between the front and rear catalytic converters.
* Use new gaskets and new nuts and tighten to 25 Nm (18 lb ft).
* Install the bracket to the oil pan and tighten to 25 Nm (18 lb ft).
15. Install the lower engine compartment cover. Tighten the 8 bolts to 5 Nm (44 lb in).
16. Bleed the power steering system. Refer to Front Frame Replacement (Removal) (Front Frame Replacement (Removal))Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement)).
17. Inspect the straight-ahead position, adjust if necessary. Refer to Straight Ahead Inspection (Removal and Replacement).
18. Inspect the toe-in, adjust if necessary. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (Service and Repair).
19. Install the front wheels. Tighten the 10 wheel bolts to 110 Nm (81 lb ft).