Cooler Lines

REMOVAL
1. Secure the steering wheel in the STRAIGHT AHEAD position using a steering wheel holding tool.
2. Under the instrument panel, disconnect the intermediate shaft from the steering gear shaft. To do so, perform one of the following that applies:

Fig. 25:

a. On early production vehicles, remove the "E" clip from the steering column intermediate shaft coupler pinch bolt. Next, remove the pinch bolt from the intermediate shaft coupler by backing off the nut, then separate the intermediate shaft from steering gear shaft.






b. On later production vehicles, remove the pinch bolt from the intermediate shaft coupler, then slide the intermediate shaft up and off the steering gear shaft.

3. Siphon as much power steering fluid as possible from the power steering fluid reservoir.
4. Raise the vehicle using a frame contact type hoist or supported as required using jack stands. Refer to Maintaince for the required hoisting or jacking procedure to be used for this vehicle.
5. Remove the left front wheel/tire.
6. Remove the front fascia and the grill as an assembly from the vehicle.






7. Remove the hose clamps from the power steering fluid hoses. Drain power steering fluid from the hoses and the power steering fluid cooler.






8. Remove the bracket attaching the power steering fluid cooler lines to the left front frame rail.
9. Lower the front suspension crossmember. Refer to the Steering Gear, Service and Repair for the required procedure for the removal of the front suspension crossmember.






10. Remove the clip holding the power steering fluid cooler lines together.
11. Remove the hose clamp attaching the power steering fluid return hose from the engine, to the power steering fluid cooler lines.






12. Remove the power steering fluid return hose from the power steering gear.
13. Remove the power steering fluid cooler lines from the routing clip on the left front frame rail.
14. Separate the power steering cooler line assembly into 2 separate pieces.
15. Remove each cooler line separately from the vehicle. The cooler lines are removed out through the front of the vehicle in the area between the radiator and the closure panel.

INSTALLATION
1. Install the cooler lines individually using the reverse procedure of their removal.
2. Install the cooler lines in the routing clip on the left frame rail

CAUTION: Only the original equipment crimp style clamp can be used when installing the power steering fluid hoses. Use of a different style clamp may not provide proper retention of the hose to the power steering oil cooler.

3. Install the hose clamps on the power steering fluid hoses.
4. Install the power steering fluid return hose coming from the engine on the power steering cooler line. Be sure hose clamp is installed on hose past the upset bead on the power steering cooler line.
5. Using Crimper, Hose Clamp, Special Tool C-4124 properly crimp the clamps on the power steering fluid hoses at the power steering oil cooler line.






6. Install the power steering fluid return hose on the steering gear. Then using a crow foot and torque wrench tighten the tube nut to a torque of 21 Nm (275 inch lbs.).
7. Install the clip holding the 2 power steering fluid cooler lines together.
8. Install the front suspension crossmember. Refer to the Steering Gear Service and Repair for the required procedure for the installation of the front suspension crossmember.
9. Install the left front wheel/tire.
10. Install the bracket attaching the power steering cooler lines to the left frame rail. Install bracket attaching bolt and tighten to a torque of 7 Nm (60 inch lbs.).

CAUTION: Only the original equipment crimp style clamp can be used when installing the power steering fluid hoses on the power steering fluid cooler. Use of a different style clamp may not provide proper retention of the hose to the power steering fluid cooler.

11. Install the hose clamps on the power steering fluid hoses.
12. Install power steering fluid hoses on the power steering fluid cooler. Be sure hose clamps are installed on hose past the upset bead on the power steering fluid cooler.
13. Using Crimper, Hose Clamp, Special Tool C-4124 properly crimp the clamps on the power steering fluid hoses at the power steering fluid cooler.
14. Install the front fascia and grill on the vehicle.
15. Lower the vehicle to a point where front tires are just off the ground.
16. Under the instrument panel, reconnect the intermediate shaft to the steering gear shaft. To do so, perform one of the following that applies:
a. On early production vehicles, reconnect the steering column intermediate shaft to the steering gear shaft. Install a new intermediate shaft coupler pinch bolt through the coupler and into its nut, then tighten the nut and pinch bolt to a torque of 27 Nm (240 inch lbs.).
b. On later production vehicles, align the flats and slide the intermediate shaft onto the steering gear shaft aligning the pinch bolt hole with the notch formed into the steering gear shaft. Install a new pinch bolt in the intermediate shaft coupler, then tighten the pinch bolt to a torque of 34 Nm (300 inch lbs.).

17. On early production vehicles, install a new "E" clip on the end of the pinch bolt.
18. Start the engine and let run for a few seconds, then turn the engine off.
19. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine.
20. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
21. Add power steering fluid if necessary.
22. Stop the engine. Check the fluid level and refill as required.
23. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure.