Replacement

REMOVAL
1. Disconnect battery minus terminal.
2. Loosen front wheel nut.
3. Lift vehicle and remove front wheels.
4. Remove front exhaust pipe assembly.

WARNING: Be careful, exhaust pipe is hot.





5. Using a puller, remove tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut.





6. Remove jack-up plate and front stabilizer.





7. Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe.





8. Remove lower side bolt of universal joint, then remove upper side bolt and lift the joint upward.

NOTE: Place a mark on the joint and mating serration so that they can be re-installed at the original position.





9. Disconnect pipes C and D from pipe of gearbox.

CAUTION: Be careful not to damage these pipes.

NOTE: Disconnect upper pipe D first, and lower pipe second.





10. Remove clamp bolts securing gearbox to crossmember, and remove gearbox.

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 (6.0 ± 1.2 kg-m, 43 ± 9 ft. lbs.)

3. How to install the joint.
(1) 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.
(2) Then pull the short yoke all way out of the serrated portion of the gear box, setting the bolt hole in the cutout.
(3) Insert the bolt through the short yoke, pull the joint and confirm that the bolt is on cutout of the gearbox.





(4) Fasten the short yoke side with a spring washer and bolt, then fasten the long yoke side.

Tightening torque: 24 ± 3 Nm (2.4 ± O.3 kg-m, 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 (2.75 ± 0.25 kg-m, 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: 8 ± 10 Nm (9.0 ± 1.0 kg-m, 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 (8.5 ± O.5 kg-m, 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.