Steering Gear: Service and Repair

NOTE: Before proceeding with this removal and installation procedure, review Service Precautions under Steering Gear.

REMOVAL

Steering Column To Steering Gear Coupler:

1. From interior of vehicle, disconnect the steering gear coupler, from the steering column shaft coupler.
2. Raise the vehicle.
3. Remove both front wheel and tire assemblies from the vehicle.

Engine/Transaxle Bobble Dampener:

4. Remove engine/transaxle bobble dampener, on vehicles so equipped, from front suspension crossmember. Bobble strut does not need to be removed from transaxle assembly.

Removing Tie Rod End Attaching Nut:

5. 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.

Tie Rod End Removal From Steering Knuckle:

6. Remove tie rod ends from steering knuckles using Remover, Special Tool MB-991113.

Power Steering Fluid Pressure Switch Electrical Connector:

7. Remove the vehicle wiring harness connector from the power steering fluid pressure switch.

Power Steering Pressure And Return Hose Routing Bracket:

8. Remove the power steering pressure and return hose routing bracket from front suspension crossmember.

Power Steering Fluid Pressure And Return Hoses:

9. Remove the power steering fluid pressure and return hoses from the power steering gear assembly.

NOTE: This vehicle 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 possible to adjust a vehicles front suspension alignment settings to the required specifications. Due to this, 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.

Marking Front Suspension Crossmember Location:

CAUTION: Before removing front suspension crossmember from the vehicle, the location of the front suspension crossmember must be scribed on body of vehicle per. This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled. 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.

10. Using an awl, scribe a line marking the location of where front suspension crossmember is mounted against the body of the vehicle.

Supporting Front Suspension Crossmember:

11. 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.

Front Suspension Crossmember Mounting Bolts:

12. Loosen and fully remove the front 2 bolts attaching front suspension crossmember to frame rails of vehicle. Then loosen the 2 rear bolts attaching front suspension crossmember and lower control arm to body of vehicle. Lower front suspension crossmember while loosening rear bolts, but do not remove rear bolts from crossmember.

Crossmember Lowered For Removal Of Steering Gear:

13. 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 should be supported by transmission jack.

Steering Gear Assembly Mounting Bolts:

14. Loosen and remove the 4 bolts, attaching steering assembly to front suspension crossmember. Then remove the steering gear assembly from the front suspension crossmember.
15. Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed.

INSTALLATION
1. Install the steering gear on the front suspension crossmember. Install the 4 steering gear assembly to front crossmember mounting bolts. Torque the 4 steering gear mounting bolts to 68 Nm (50 ft. lbs.).
2. Using the transmission jack, raise front suspension crossmember and steering gear against body and frame rails 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, 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.

Crossmember Aligned With Positioning Marks:

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.

3. Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the 2 previously scribed positioning marks on body of vehicle. When front suspension crossmember is correctly positioned, torque the 2 rear crossmember/lower control arm 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.).
4. Install the power steering fluid pressure and return hoses into correct fluid ports on power steering gear assembly. Torque power steering fluid pressure and return lines to steering gear tube nuts to 31 Nm (275 inch lbs.).
5. Install the power steering pressure and return hose routing bracket and attaching screw on front suspension crossmember. Torque hose routing bracket to crossmember attaching bolt to 23 Nm (17 ft. lbs.).
6. Install the 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.

Torquing Tie Rod End Attaching Nut:

7. Install tie rod end into the 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.).
8. Install engine/transaxle bobble strut back on front suspension crossmember bracket. Install and securely tighten the dampener to crossmember attaching bolt.
9. Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts to 135 Nm (100 ft. lbs.) torque.
10. Lower the vehicle.
11. From interior of vehicle, reconnect the steering gear coupler with the steering column shaft coupler. Install steering gear coupler retaining pinch bolt and torque to 28 Nm (250 inch lbs.). Be sure to install the upper to lower steering coupler retaining bolt, retention pin.
12. Perform the POWER STEERING PUMP INITIAL OPERATION service procedure, which can be found under POWER STEERING PUMP, to properly fill and bleed the power steering system.
13. Adjust the front toe setting on the vehicle. Refer to WHEEL ALIGNMENT.