Removal

REMOVAL





1. Remove the battery ground cable from the ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the ground stud.
2. Position the front tires of the vehicle so that they are facing Straight-Ahead.





3. Using a steering wheel holding clamp, lock the steering wheel from rotating.

CAUTION: Before removing the steering column coupler from the intermediated steering shaft be sure the steering wheel is locked from rotating. If the steering wheel is allowed to rotate freely after it is disconnected from the intermediated shaft, the clockspring will be damaged and will need to be replaced.





4. Remove the retaining pin and the coupler bolt from the steering column coupler. Separate the intermediate steering shaft from the steering column coupler.
6. Raise the vehicle on a frame contact hoist until the front tires of the vehicle are just off the floor.





6. Remove caps from both wiper arms at the attachment to the pivots to expose the wiper arm attaching nut. Remove the nut attaching each wiper arm to its pivot.
7. Remove the wiper arms from the pivots. Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots.





8. Remove the wiper module cover and cowl cover from the vehicle.





9. Remove the eight bolts attaching the cowl reinforcement to the strut towers and the one bolt attaching the wiper module to the reinforcement. Remove the reinforcement from the vehicle.





10. Remove the in-line resonator and inlet hose from the throttle body and air let hose coming from the lid of the air cleaner housing.





11. If the steering gear being removed from the vehicle is a speed proportional steering gear, disconnect the wiring harness connector from the solenoid control valve electrical connector. The connector is located on the steering gear end cap below the brake master cylinder..





12. Remove the two nuts mounting the master cylinder to the vacuum booster.
13. Disconnect the brake fluid level switch connector on the side of the master cylinder fluid reservoir.
14. Remove the master cylinder with the brake tubes connected from the power brake vacuum booster. Carefully position the master cylinder in an upright position on the left side valve cover of the engine.

CAUTION: Do not allow brake fluid to leak onto painted surfaces. Paint damage may occur.

15. Remove the vacuum supply hose to the power brake vacuum booster at the check valve in the vacuum booster. Position the vacuum hose out of the way.





16. Bend back the retaining tabs on the mounting plate for the tie rod to steering gear mounting bolts.





17. Remove the bolts, mounting plate and washers attaching the tie rods to the steering gear. Lay the tie rods on top of the transaxle bell housing.

NOTE: The following step should be done to prevent excessive spilling of power steering fluid when the power steering fluid lines are removed from the steering gear.

18. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.





19. Remove the power steering fluid pressure hose and return hose from the steering gear.





20. Remove the two bolts attaching the left side of the steering gear to the crossmember.





21. Remove the two bolts attaching the steering gear's right side mounting bracket to the crossmember.





NOTE: It may be necessary to loosen the two mounting bolts attaching the right mounting bracket to the steering gear in order to clear the air conditioning lines.

22. Slide steering gear and intermediate shaft forward into the engine compartment to allow access to the roll pin retaining the intermediate shaft flex coupler to the steering gear shaft.





23. Using roll pin Remover, Special Tool 6831A, remove roll pin from flex joint of intermediate shaft. Roll pin is removed from coupler using following procedure:
a. Remove knurled nut from small end of tool.
b. Insert small end of Remover through center of roll pin, then install and hand tighten knurled nut.
c. Position sleeve of removal tool on flex joint as shown.
d. While holding threaded shaft of tool from turning, tighten nut, pulling roll pin out of flex joint.

24. Separate the intermediate steering shaft from the steering gear.
25. Raise vehicle.
26. Remove the right front tire/wheel.





27. Remove the nutattaching the tie rod end to the steering arm on the right strut.





28. Remove the tie rod end from the steering arm of the strut using Puller, Special Tool C-3894-A.
29. Remove the tie rod from the vehicle.





NOTE: If the vehicle is equipped with a 2.7 liter engine, rotate the front of the left front tire/wheel as far outward as possible. This is necessary to have the required clearance to allow the removal of the steering gear from a vehicle with this engine application.

30. Remove the steering gear from the vehicle using the following steps.





a. Slide the end of the steering gear through the tie rod hole in the right side inner fender. Steering gear needs to be slid through tie rod hole until about half of the steering gear is through the hole.





b. Lift the left end of the steering gear upward, with the steering gear positioned as shown, between the back of the engine and the front of the cowl.
c. To remove the steering gear from the vehicle, pull the steering gear toward the passenger side of the vehicle out from between the cowl and the engine.