Removal and Replacement

Rack and Pinion Assembly Removal and Installation

NOTE: The unit repair of the rack and position assembly in this vehicle is not serviceable. A faulty rack and pinion assembly must be replaced with a new one.

Removal

Tools Required:
KM-507-B Ball Joint Remover

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the wheels.
4. Disconnect the power steering gear fluid outlet pipe. Place a drain pan under the steering gear to catch the power steering fluid.
5. Disconnect the power steering gear fluid inlet pipe.





6. Position the steering gear straight ahead by turning the steering wheel until the steering wheel spokes are vertical and pointed to the left.
7. Scribe a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower coupling.





8. Remove the intermediate shaft pinch bolt.





9. Remove the outer tie rod nuts and disconnect the tie rod ends from the strut assembly using the ball joint remover KM507-B
10. Remove the crossmember assembly.
11. On vehicles equipped with an automatic transaxle, remove the transaxle center bracket.
12. On vehicles equipped with a manual transaxle, remove the bolts securing the transaxle center bracket to the transaxle and the engine. Move the transaxle center bracket out of the way.





13. Remove the nuts and bolts from the steering gear mounting bracket.





14. Remove the return line from the clip on the crossmember. 15) Disconnect the rack and pinion assembly from the crossmember assembly.





Installation
1. Install the rack and pinion assembly on the crossmember. The steering gear must be in a straight-ahead position, and the steering wheel spokes must be vertical and pointing to the left. Align the marks on the shafts to ensure proper positioning. Seat the stub shaft into the intermediate shaft.





2. Install the bolts and nuts on the steering gear mounting bracket.
Tighten:
Tighten the steering gear mounting bracket bolts and nuts to 60 Nm (44 ft. lbs.).





3. Install the return line into the clip on the crossmember.
Tighten:
Tighten the return line clip bolt to 8 Nm (71 in. lbs.).
4. On vehicles equipped with a manual transaxle, position the transaxle center bracket in place and install the bolts securing the bracket to the engine and the transaxle.
Tighten:
Tighten the transaxle center bracket-to-transaxle bolts and the transaxle center bracket-to-engine bolt to 80 Nm (59 ft. lbs.).
5. On vehicles equipped with an automatic transaxle, install the transaxle center bracket.
6. Install the crossmember.





7. Connect the tie rod ends to the strut assembly.
8. Install the outer tie rod nuts.
Tighten:
Tighten the outer tie rod nuts to 50 Nm (37 ft. lbs.).





9. Install the lower intermediate shaft pinch bolt.
Tighten:
Tighten the lower intermediate shaft pinch bolt to 25 Nm (18 ft. lbs.).





10. Connect the power steering gear fluid inlet and outlet pipe.
Tighten:
Tighten the steering gear inlet and outlet pipe fitting to 28 Nm (21 ft. lbs.).
11. Perform a front toe adjustment.
12. Install the wheels.
13. Lower the vehicle.
14. Do a straight-ahead check.
15. Refill the power steering system and check for leaks. If leaks are found, correct the cause of the leak and bleed the system.
16. Connect the negative battery cable.