Installation
CAUTION: Be careful not to bend or damage the two power steering lines and cylinder lines when installing the gearbox.1. Before installing the gearbox, slide the rack all the way to right.
2. Install the pinion shaft grommet.
NOTE: Align the slot in the pinion shaft grommet with the lug portion on the valve housing.
3. Pass the right side of the steering gearbox above and through the right side of the rear beam.
4. Raise the left side of the steering gearbox above and through the left side of the rear beam.
5. Install the pinion shaft grommet, then insert the pinion shaft up through the bulkhead.
6. Install the mounting cushion.
NOTE: Position the split portion of the mounting cushion as shown.
7. Install the right mounting bracket over the mounting cushion, then loosely install two gearbox mounting baits.
8. Tighten the four mounting bolts on the stiffener plate first, then tighten the two mounting bolts on the right mounting brackets.
NOTE: After installing the steering gearbox, make sure that there is no interference between the cylinder lines and rear beam.
9. Center the steering rack in the middle of its stroke, then install the steering joint, and reconnect the steering shaft and pinion shaft.
NOTE: Make sure the steering joint is connected as follows:
a. Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole with the flat on the shaft), and loosely install the upper joint bolt.
b. Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove 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.
c. Pull on the steering joint to make sure that the steering joint is fully seated. Then tighten the upper and lower joint bolts.
10. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise approximately two turns. The arrow mark on the label should points straight up. Reinstall the steering wheel.
11. Install the steering joint cover with the clamps and clips.
12. Center the steering rack within its stroke.
13. Connect the fluid lines to the valve body unit.
NOTE: After connecting the fluid lines, make sure that there is no interference between the lines and other parts.
14. Install exhaust pipe A with the new gaskets and new self-locking nuts, and connect the heated oxygen sensor (H02S) connector.
15. Install the center beam.
16. Thread the right and left tie-rod ends onto the rack an equal number of turns.
17. Reconnect the tie-rod ends to the steering knuckles, tighten the castle nut ('97 model) or nut ('98 - 99 model) to the specified torque, and install new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off any grease contamination from the ball joint tapered section and threads.
CAUTION: Torque the castle nut 1'97 model) to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.
18. Install the front wheels.
19. Fill the system with the recommended power steering fluid, and bleed air from the system.
20. 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.
- Adjust the front toe.
- Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equally.