Removal and Installation
Steering GearboxREMOVAL
1. Disconnect battery ground cable.
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 universal joint.
9. Disconnect pipes C (Pressure pipe assembly) and D (Return pipe assembly) from pipe of gearbox.
CAUTION: Be careful not to damage these pipes.
NOTE: Disconnect upper pipe D (Return hose assembly) first, and lower pipe C (Pressure hose assembly) 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 Nm (6.0 kgf-m, 43 ft. lbs.)
3. Connect pipes C and D to pipe of gearbox.
NOTE: Connect lower pipe C first, and upper pipe D second.
CAUTION: Be careful not to damage these pipes.
4. Install universal joint.
5. 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 Nm (2.75 kgf-m, 19.9 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.
6. Install front stabilizer to vehicle.
7. Install front exhaust pipe assembly.
8. Install tires.
9. Tighten wheel nuts to the specified torque.
Tightening torque: 88 Nm (9.0 kgf-m, 65 ft. lbs.)
10. Connect battery ground cable.
11. Pour fluid into oil tank, and bleed air.
12. Check for fluid leaks.
13. Install jack-up plate.
WARNING: Be careful, exhaust manifold is hot.
14. Lower vehicle.
15. Check fluid level in oil tank.
16. After adjusting toe-in and steering angle, tighten lock nut on tie-rod end.
Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft. lbs.)
CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.