Removal

REMOVAL

Fig. 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.

Intermediate Shaft Coupler Attachment To Steering Gear:

3. From interior of vehicle, remove the retaining pin from the intermediate shaft coupler pinch bolt. Then remove the pinch bolt from the intermediate shaft coupler and the separate intermediate shaft coupler, from steering gear shaft.
4. Raise vehicle on jack stands or centered on a frame contact type hoist using proper vehicle lifting procedures.
5. Remove both front wheel and tire assemblies from the vehicle.

Removing Tie Rod End Nut:

6. 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:

7. 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.

Front Suspension Crossmember Front To Back Locating Mark (Left Side Front):

Front Suspension Crossmember Front To Back Locating Mark (Left Side Rear):

8. Using an awl, scribe a line on the body 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 the left side of the vehicle is shown.

Front Suspension Crossmember Side To Side Locating Mark:

9. 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.

Stabilizer Bar Bushing Clamp Attaching Bolts:

10. 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.
11. 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.
12. If vehicle is equipped with antilock brakes, remove the 3 bolts attaching the antilock brakes hydraulic control unit to the front suspension crossmember.

Shock Clevis To Lower Control Arm Bolts:

13. Remove the bolts attaching the shock absorber clevis to the left and right lower control arms.

Engine Support Bracket To Crossmember Attaching Bolts:

14. Remove the 2 bolts attaching the under engine support bracket to the front edge of the front suspension crossmember.

Rear Support Bracket Attachment To Crossmember:

15. Remove the 2 attaching bolts from the rear support bracket at the rear of the front suspension crossmember.

Engine Support Bracket To Transaxle Bracket Bolt:

16. Remove bolt attaching engine support bracket to the transaxle mounting bracket.
17. 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.

Crossmember To Body Attaching Bolts:

18. 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.
19. 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.

Power Steering Pressure And Return Hose At Steering Gear:

20. Remove power steering fluid, pressure and return hoses from the power steering gear assembly.
21. Remove wiring harness connector, from the power steering fluid pressure switch.

Steering Gear Rear Mounting Isolator Bolt:

Steering Gear Front Mounting Bolt:

Steering Gear Saddle Bracket Mounting Bolts:

22. Remove the 2 bolts, at the isolators attaching the steering gear assembly to front suspension crossmember. Then remove the 2 bolts attaching the steering gear saddle bracket to the front suspension crossmember. Remove the steering gear assembly from the front suspension crossmember.
23. Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed.