Steering Gear: Service and Repair

Steering Gear - Four Wheel Drive (4WD)

















Removal

NOTICE: When repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result.

1. Remove the front wheels and tires. For additional information, refer to Wheels and Tires Removal and Replacement.

2. Place the steering wheel in the straight-ahead position and remove the ignition key.
- Rotate the steering wheel until the steering column locks into position.

3. Remove the power steering fluid cooler. For additional information, refer to Power Steering Fluid Cooler Service and Repair.

4. Loosen the tie-rod jam nuts.

5. Remove and discard the outer tie-rod end cotter pins and nuts.

6. NOTICE: Do not damage the tie-rod boot when installing the Tie-Rod End Remover.

NOTE: Remove the adapter from the ball end of the Tie-Rod End Remover. Apply a small amount of grease to the tie-rod end stud and the ball of the Tie-Rod End Remover.

Using the Tie-Rod End Remover, separate the outer tie-rod ends from the wheel knuckles.





7. Remove the outer tie-rod ends.
- Count and record the number of turns required to remove the outer tie-rod end.

8. Remove the stabilizer bar and link. For additional information, refer to Front Suspension - Four Wheel Drive (4WD) Service and Repair.

9. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may result. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. For additional information, refer to Supplemental Restraint System Service and Repair.

Remove the lower steering column shaft-to-steering gear bolt and disconnect the shaft from the steering gear.

- Discard the bolt.

10. Remove the steering line clamp plate nut and disconnect the pressure and return lines.
- Discard the O-ring seals.

11. NOTICE: Hold the tops of the steering gear studs to avoid damaging the steering gear fluid transfer tubes.

Remove the 2 steering gear nuts and steering gear studs.

12. Rotate the steering gear control valve housing toward the front of the vehicle.





13. Turn the steering gear input shaft to the right until the stop is reached.

14. Move the steering gear as far to the RH side of the vehicle as possible.





15. Move the LH inner tie rod forward to clear the frame crossmember.





16. Remove the steering gear.





Installation

1. NOTICE: Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in the steering gear bellows boot.

NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached.

Turn the steering gear input shaft to the right until the stop is reached. Count and record the number of turns required.

2. NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle.

Install the steering gear into the RH opening of the crossmember.





3. NOTICE: Take care not to scuff or tear the steering gear bellows boots.

Move the steering gear as far to the RH side of the vehicle as possible.





4. Move the LH inner tie rod into the opening in the crossmember and move the steering gear into position.





5. To place the steering gear in the straight-ahead position, turn the steering gear input shaft to the left by one-half the number of turns previously recorded.

6. Rotate the steering gear control valve housing toward the rear of the vehicle.





7. Install the 2 steering gear studs.

8. NOTICE: Hold the tops of the steering gear studs to avoid damaging the steering gear fluid transfer tubes.

Install the 2 steering gear nuts.

- Tighten to 150 Nm (111 lb-ft).

9. NOTICE: New O-rings must be installed any time the lines are disconnected from the steering gear or a fluid leak may occur.

Position the pressure and return lines and install the steering line clamp plate nut.

- Tighten to 35 Nm (26 lb-ft).

10. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may result. If there is evidence that the steering column has rotated, the clockspring must be removed and re-centered. For additional information, refer to Supplemental Restraint System Service and Repair.

Connect the steering column shaft to the steering gear and install a new bolt.

- Tighten to 55 Nm (41 lb-ft).

11. Install the stabilizer bar and link. For additional information, refer to Front Suspension - Four Wheel Drive (4WD) Service and Repair.

12. Install the outer tie-rod ends.
- Rotate the outer tie-rod ends the number of turns recorded during removal.

13. Position the outer tie-rod ends and install the new nuts and new cotter pins.
- Check that the brake disc shields are not bent and are not in contact with the outer tie-rod end boots.

- Tighten to 80 Nm (59 lb-ft).

14. Install the power steering fluid cooler. For additional information, refer to Power Steering Fluid Cooler Service and Repair.

15. Tighten the tie-rod jam nuts.
- Tighten to 80 Nm (59 lb-ft).

16. Fill the power steering system. For additional information, refer to Steering System Power Steering System Filling.

17. Check and, if necessary, adjust the front toe. For additional information, refer to Suspension System - General Information Toe Adjustment.