Disassembly

TOOL REQUIRED
^ ST 926200000 Stand
^ ST 925700000 Wrench
^ ST 926230000 Spanner

DISASSEMBLE
1. Disconnect four pipes from gearbox.





2. Secure gearbox removed from vehicle in vice using ST.

CAUTION: Secure the gearbox in a vice using the ST as shown. Do not attempt to secure it without this ST.

3. Remove tie-rod end and lock nut from gearbox.





4. Remove small clip from boot using pliers, and move boot to tie-rod end side.





5. Remove boot together with large clips.





6. Straighten lock washer under ball joint

CAUTION:
^ Be extremely careful not to hit surface of right hand rack; otherwise, oil leakage may result.
^ Tie-rod lock washer must be replaced with a new one whenever it is removed.





7. Loosen ball joint using ST and spanner and remove tie-rod from rack

NOTE: When loosening ball joint, securely fix the rack using ST





8. Loosen lock nut using ST, and remove adjusting screw
9. Remove spring and sleeve
10. Remove dust seal

CAUTION: Be careful not to damage housing and input shaft, or to allow foreign matters to get inside when removing dust seal.

INSTALLATION
1. Insert gearbox into crossmember, being careful not to damage gearbox boot.





2. Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque. Tightening torque: 59 ± 12 Nm (43 ± 9 ft. lbs.).
3. How to install the joint.
a. Push the long yoke of the joint, all the way into the serrated portion of the steering shaft, setting the bolt hole in the cutout.
b. Then pull the short yoke all way out of the serrated portion of the gear box, setting the bolt hole in the cutout.
c. Insert the bolt through the short yoke, pull the joint and confirm that the bolt is on cutout of the gearbox.





d. Fasten the short yoke side with a spring washer and bolt, then fasten the long yoke side. Tightening torque: 24 ± 3 Nm (17.4 ± 2.2 ft. lbs.).





4. Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock. Castle nut tightening torque: Tighten to 27.0 ± 2.5 Nm (19.9 ± 1.8 ft. lbs.), and tighten further within 60° until cotter pin hole is aligned with a slot in the nut.

CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.

5. Install front stabilizer to vehicle.
6. Install front exhaust pipe assembly.
7. Install tires.
8. Tighten wheel nuts to the specified torque. Tightening torque: 88 ± 10 Nm (65 ± 7 ft. lbs.)
9. Connect ground cable to battery.
10. Pour fluid into oil tank, and bleed air.
11. Check for fluid leaks.
12. Install jack-up plate.

WARNING: Be careful, exhaust manifold is hot.

13. Lower vehicle.
14. Check fluid level in oil tank.





15. After adjusting toe-in and steering angle, tighten lock nut on tie-rod end. Tightening torque: 83 ± 5 Nm (61.5 ± 3.6 ft. lbs.)

CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.