Removal and Installation
REMOVALFig. 5:
Fig. 6:
1. Remove remote ground cable from ground stud on shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud.
2. Siphon as much power steering fluid as possible from the remote power steering fluid reservoir.
3. Place the steering wheel and front wheels in the STRAIGHT-AHEAD position. Lock the steering wheel in this position using a steering wheel holder.
Fig. 3:
4. Under the instrument panel, disconnect the intermediate shaft from the steering gear shaft. To do so, remove the pinch bolt from the intermediate shaft coupler, then slide the intermediate shaft up and off the steering gear shaft.
5. Raise vehicle on jack stands or centered on a frame contact type hoist.
6. Remove both front wheel and tire assemblies from the vehicle.
Fig. 5:
7. Remove nuts attaching both outer tie rod ends to the steering knuckles. Nuts are to be removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench.
Fig. 10:
8. Remove both tie rod end studs, from the steering knuckles, using Remover, Special Tool MB-991113.
CAUTION: This vehicles is designed and assembled using NET BUILD front suspension alignment settings. This means that front suspension alignment settings are determined as the vehicle is designed by the location of front suspension components in relation to the vehicle body. This process is carried out when building the vehicle, by accurately locating the front suspension crossmember to master gage holes located in the underbody of the vehicle. With this method of designing and building a vehicle, it is no longer necessary or possible to adjust a vehicles front suspension alignment settings. Consequently, whenever the front suspension crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. Front suspension Toe settings though are still adjustable by the outer tie rod ends.
CAUTION: Before removing the front suspension crossmember from the vehicle, locating marks for the front suspension crossmember MUST be scribed on the front suspension crossmember and body of vehicle. This must be done so front suspension crossmember can be located against body of vehicle, in the same location when it is installed back in vehicle. If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assembled, NET BUILD front suspension alignment settings will not be obtained. This may lead to handling and or tire wear problems.
NOTE: Use the following procedure to mark the side to side and front to back installed location of the front suspension crossmember to the body of the vehicle.
Fig. 11:
Fig. 12:
9. Using an awl, scribe a line on the body and marking the front to back installed location where the front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at both the front and back of where the crossmember is mounted to the vehicle and on each side of the vehicle. In and the left side of the vehicle is shown.
Fig. 9:
10. Using an awl, scribe a line on the front suspension crossmember marking the side to side installed location where front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at the side of the frame rail bracket where the crossmember is mounted to the vehicle. The locating mark is to be marked the same on each side of the vehicle. In the left side of the vehicle is shown.
Fig. 10:
11. Remove the stabilizer bar bushing clamp to body attaching bolts only. The sway bar bushing clamp to front suspension crossmember bolts do not need to be removed
12. If vehicle is equipped with antilock brakes, the hydraulic control unit can not hang from the brake tubes when lowering front suspension crossmember. Using wire, tie the antilock brakes hydraulic control unit to the body and engine so the wire will support it when the crossmember is lowered.
13. If vehicle is equipped with antilock brakes, remove the 3 bolts attaching the antilock brakes hydraulic control unit to the front suspension crossmember.
Fig. 15:
14. Remove the bolts attaching the shock absorber clevis to the left and right lower control
Fig. 12:
15. Remove the 2 bolts attaching the under engine support bracket to the front edge of the front suspension crossmember.
Fig. 17:
16. Remove the 2 attaching bolts from the rear support bracket at the rear of the front suspension crossmember.
Fig. 18:
17. Remove bolt attaching engine support bracket to the transaxle mounting bracket.
18. Position a transmission jack under the center of the front suspension crossmember. Transmission jack is used to lower, support and raise front suspension crossmember when removing steering gear assembly.
Fig. 19:
19. From each side of the vehicle, remove the 2 bolts attaching the front and rear of the front suspension crossmember to the frame rails of vehicle.
20. Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms, weight of crossmember must be supported by the transmission Jack.
Fig. 20:
21. Remove power steering fluid, pressure and return hoses from the power steering gear assembly.
22. Remove wiring harness connector, from the power steering fluid pressure switch.
Fig. 21:
Fig. 22:
Fig. 19:
23. Remove the 2 bolts, at the isolators and attaching the steering gear assembly to front suspension crossmember. Then remove the 2 bolts attaching the steering gear saddle bracketto the front suspension crossmember. Remove the steering gear assembly from the front suspension crossmember
24. Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed.
INSTALLATION
1. Install steering gear assembly on front suspension crossmember. Install the 2 long steering gear assembly to front crossmember mounting bolts and into the mounting isolators. Then install the 2 short boltsinto the saddle bracket. Tighten the 4 steering gear mounting bolts to a torque of 68 Nm (50 ft. lbs.).
2. Install the power steering fluid pressure and return lines on the ports of the power steering gear. Tighten power steering fluid pressure and return lines to steering gear tube nuts to a torque of 31 Nm (275 inch lbs.).
3. Using transmission jack, raise front suspension crossmember and steering gear against body of vehicle. Start the 2 rear bolts into tapping plates, attaching front suspension crossmember to body of vehicle. Then install the 2 front bolts, attaching front suspension crossmember to frame rails of vehicle. Tighten the 4 mounting bolts evenly, until front suspension crossmember is against body of vehicle at the 4 mounting points. Then torque the 4 mounting bolts to 2 Nm (20 inch lbs.) to hold front suspension crossmember in position.
CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribed into body of vehicle. This MUST be done to maintain NET BUILD front suspension alignment settings.
4. Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the previously scribed positioning marks on body of vehicle, and. When front suspension crossmember is correctly positioned, torque the 2 rear crossmember mounting bolts to 163 Nm (120 ft. lbs.). Then torque the 2 front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.).
5. Install the engine support bracket on the front of the front suspension crossmember. Install the 2 support bracket to suspension crossmember attaching bolts and tighten to a torque of 75 Nm (55 ft. lbs.).
6. Install bolt attaching engine support bracket to transaxle mounting bracket. Tighten bolt to a torque of 75 Nm (55 ft. lbs.).
7. Install the 2 bolts attaching the rear support bracket, for the under engine support bracket, to the rear of the front suspension crossmember. Tighten bolts to a torque of 75 Nm (55 ft. lbs.).
8. Install vehicle wiring harness connector onto power steering fluid pressure switch on steering gear assembly. Be sure locking tab on wiring harness connector is securely latched to pressure switch.
9. Install the antilock brakes hydraulic control unit mounting bracket on the front suspension crossmember. Install the 3 mounting bracket to crossmember attaching bolts and tighten to a torque of 28 Nm (250 inch lbs.).
10. Loosely install the 2 shock absorber clevis to lower control arm attaching nuts and bolts.
11. Install tie rod seal boot heat shield on tie rod end.
Fig. 23:
12. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 55 Nm (40 ft. lbs.).
13. Install and tighten the 2 stabilizer bar bushing clamp to body attaching bolts.
Fig. 25:
CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown in.
14. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm.
15. Tighten the shock absorber clevis to lower control arm bushing thru-bolt to a torque of 92 Nm (68 ft. lbs.).
16. Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts in proper sequence to a torque of 129 Nm (95 ft. lbs.).
CAUTION: Before connecting the steering column intermediate shaft coupler to the steering gear shaft, position the front wheels STRAIGHT-AHEAD. The steering wheel must also be in the centered position.
17. Under the instrument panel, reconnect the intermediate shaft to the steering gear shaft. To do so, 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 44 Nm (32 ft. lbs.).
18. Remove the steering wheel holder.
CAUTION: Do not use automatic transmission fluid in place of power steering fluid.
19. Fill power steering pump fluid reservoir to the proper level and perform Power Steering Pump Initial Operation standard procedure.
20. Check for leaks.
21. Check front alignment and adjust the front toe setting on the vehicle.
22. Tighten tie rod jam nuts to 74 Nm (55 ft. lbs.) torque.
23. Adjust steering gear to tie rod boots at tie rods.