Manual Steering Gear

MANUAL

REMOVAL





1. Disconnect negative battery cable.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.

2. Raise vehicle on hoist.
3. Remove front road wheels.
4. Remove and discard torque prevailing nut. A new nut will be required during assembly.

NOTICE: Do not attempt to separate the joint using a wedge-type tool because the seal may be damaged.





5. Using Tie Rod Separator SA91100C (or equivalent), remove tie rod ends from steering knuckle.

IMPORTANT: Remove front section of shield first, then rear.





6. Remove left side splash shield.
a. Remove two push pins.

IMPORTANT: If molded-in fasteners are damaged or broken, drill out with a 5/16 inch bit and replace with a push pin.

b. Remove lower shield to cradle molded-in fasteners at cradle by gently prying at three fastener locations.





7. Loosen intermediate shaft cover from steering gear and move up enough to access pinch bolt.
8. Remove pinch bolt.
9. Remove steering gear to cradle fasteners and remove steering gear from vehicle through left fenderwell.

INSTALLATION





1. Place steering gear in vehicle.
2. Install steering gear-to-cradle bolts and new nuts.
Torque: 50 Nm (37 ft. lbs.)

IMPORTANT: Use Loctite 242 Threadlocker (or equivalent) on thread of pinch bolt.





3. Install intermediate shaft onto steering gear and torque the pinch bolt.
Torque: 47 Nm (35 ft. lbs.)

IMPORTANT: Install rear section of splash shield first, then front





4. Install left side splash shield.
5. Install tabs in body cut-out.

IMPORTANT: Make sure splash shield flaps are tucked in at body locations.

6. Align molded-in shield fasteners with holes in cradle. Push straight in to install.
7. Install push pins.

IMPORTANT: Tie rod end threads must be thoroughly cleaned before tightening nut. Do not lubricate any portion of stud.

IMPORTANT: Use new nut, torque retention of old nut may not be sufficient.





8. Install tie rod end into steering knuckle.
Torque: 55 Nm (41 ft. lbs.)
9. Using linkage installer J44015 (or equivalent) to seat tie rod end into knuckle.
Torque: 45 Nm (33 ft. lbs.)
10. Remove linkage installer and install new tie rod end nut.

IMPORTANT: Lower control arm ball stud threads should be thoroughly cleaned and lubricated before installing and tightening nut.





11. Tighten ball joint stud castle nut.
Torque: 75 Nm (55 ft. lbs.)

IMPORTANT: If necessary to rotate castle nut to align with hole in the stud, always tighten the nut to align it; never loosen it. Install new cotter pin.

12. Connect negative battery cable.
Torque: 17 Nm (13 ft. lbs.)

NOTICE: Before installing wheels remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

13. Position wheel onto hub.
14. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to make sure torque is correct.
Torque: 140 Nm (103 ft. lbs.)
15. Lower vehicle from hoist.
16. Set toe. (Refer to "Wheel Alignment".)