Steering Gearbox Installation
Steering Gearbox Installation1. Install the P/S line mounting bracket (A).
2. Pass the cylinder of the steering gearbox (A) together with the tie-rods (B) through the wheelwell opening on the driver's side.
3. Carefully move the steering gearbox toward the passenger's side until the pinion shaft (A) clears the wheelwell opening (B) on the frame. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position.
NOTE: Make sure the power steering return hose is routed between the gearbox and right tie-rod.
4. Install the pinion shaft grommet (A).
5. Insert the pinion shaft up through the bulkhead, and place the steering gearbox on the mounting brackets. Be sure that the pinion shaft grommet is in place securely.
6. Loosely install the two 10 mm flange bolts (A) and washers (B) on the left side of the gearbox.
7. Install the mounting cushion (A) on the right side of the gearbox. Position the cutout (B) on the mounting cushion as shown.
8. Install the mounting bracket (C) over the mounting cushion.
9. Install the 10 mm flange bolt and nut loosely first, then torque the flange bolt and nut alternately in two or more steps.
10. Tighten the left side flange bolts to the specified torque value.
11. Install the body stiffener (A).
12. Loosely connect the 14 mm flare nut (A) to the valve body unit, and install the feed line (B) on the P/S line mounting bracket (C). Connect the power steering pressure switch connector (D).
13. Connect the return hose (A) to the return line joint (B) securely. Install the return hose clamp (C) on the steering gearbox.
14. Install the return hose on the hose holders (D) securely.
15. Tighten the 14 mm flare nut (A) to the specified torque value, and tighten the adjustable hose clamp (B).
16. Reinstall the engine wire harness clamp and clip (A) to the mounting brackets.
17. Install the P/S heat shield (A).
18. Clean off any grease or contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the damper steering arms. Install the 12 mm nut (B), and tighten it to the specified torque value.
19. Install a new cotter pin (C), and bend it as shown (D) or (E).
20. Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:
^ Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft).
^ Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove (F) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft.
^ Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. Tighten the lower joint bolt to the specified torque value.
21. Install the driver's dashboard lower cover.
22. Install the front wheel, then set the wheels in the straight ahead position.
23. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about two and a half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.
24. Fill the system with power steering fluid, and bleed air from the system.
25. Reconnect the negative cable to the battery, and do these items:
^ Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
^ Do the power window control unit reset procedure.
^ Enter the anti-theft code for the audio system, then enter the customer's audio presets.
^ Set the clock.
^ Make sure the horn and turn signal for proper operation.
^ Make sure the steering wheel switches work properly.
^ Make sure the steering wheel is centered.
26. After installation, perform the following checks:
^ Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks.
^ Inspect the front toe.
^ Check the steering wheel spoke angle.
If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/ pinion shaft serrations, then adjust the front toe by turning the tie-rods, if necessary.