Steering Gear Replacement

Steering Gear Replacement (Two Mode Hybrid)

Removal Procedure

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Failure to follow the procedures exactly as written may result in serious injury or death.


Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:

* The steering column
* The intermediate shaft(s)
* The steering gear

After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

Note:
* The steering gear harness is not repairable. Only replace the harness and never attempt to repair it.
* The wiring harness protective cover is intended to keep the wiring harness connectors contaminant free. Do not remove the protective cover from the power steering assist motor wiring harness connectors until the harness has been routed to the correct position.

1. Perform the high voltage disabling procedure. Refer to High Voltage Disabling (High Voltage Disabling).
2. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).




3. Remove the steering shaft coupling bolt (1) at the steering gear.
4. Separate the steering shaft coupling from the steering gear.




5. Remove the steering linkage outer tie rod nuts from the steering linkage outer tie rods (1) and discard them.
6. Separate the steering linkage outer tie rods from the steering knuckles.
7. Support the steering gear with jackstands.




8. Remove the steering gear bolts (1) from the left side of the steering gear.




9. Remove the steering gear bolts (1) from the right side of the steering gear.
10. Remove the steering gear from the vehicle.
11. Transfer any parts as needed.

Installation Procedure

1. Position the steering gear in the vehicle and support it with jackstands.





Caution: Refer to Fastener Caution (Fastener Caution).

Note: Start all steering gear bolts by hand before finalizing the torques.

2. Install the steering gear bolts (1) at the right side of the steering gear and tighten to 100 Nm(74 lb ft).




3. Install the steering gear bolts (1) to the left side of the steering gear and tighten to 200 Nm(148 lb ft).




4. Connect the steering linkage outer tie rods (1) to the steering knuckles.
5. Install the new steering linkage outer tie rod nuts and tighten to 60 Nm(44 lb ft).




6. Connect the steering shaft coupling to the steering gear.
7. Install the steering shaft coupling bolt (1) at the steering gear and tighten to 47 Nm(35 lb ft).
8. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
9. Perform the high voltage enabling procedure. Refer to High Voltage Enabling (High Voltage Enabling).
10. Perform the power steering control module setup procedure. Refer to Power Steering Control Module Programming and Setup (Programming and Relearning).