Steering Gearbox Removal/Installation

Steering Gearbox Removal and Installation

Special Tools Required

- Ball Joint Thread Protector, 10 mm 07AAF-SECA120
- Ball Joint Remover, 28 mm 07MAC-SL0A202
- Ball Joint Thread Protector, 14 mm 071AF-S3VA000

Note these items during removal:

- Using solvent and a brush, wash any oil and dirt off the end of the steering gearbox, but avoid any electrical parts. Blow dry with compressed air.
- Be sure to remove the steering wheel before disconnecting the steering joint or damage to the cable reel can occur.

Removal

1. Do the 12 volt battery terminal disconnection procedure Procedures.

2. Raise and support the vehicle Service and Repair.

3. Remove the front wheels.

4. Tilt the steering column to the center position.

5. Remove the steering joint cover (A).






6. Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and joint yoke (D) of the upper shaft to prevent the lower slide from pulling out.






7. Remove the steering joint bolt (A) from the steering joint (B).






8. Center the steering wheel spokes, and install a commercially available steering wheel holder tool (A).






9. Disconnect the steering joint by moving the steering joint toward the column.

10. Remove the center guide (A) (if equipped) from the top of the pinion shaft (B), and discard it. The center guide is for factory assembly use only.






11. Remove the cotter pin (A) from the tie-rod end ball joint, then remove the nut (B) on both sides.






12. Disconnect the tie-rod end ball joint from the knuckle using the ball joint remover and the ball joint thread protector on both sides Ball Joint Removal.

13. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B) from both sides.





14. Disconnect the lower arm ball joint and the knuckle using the ball joint remover and the ball joint thread protector Ball Joint Removal on both sides.

15. Remove the stabilizer link from the stabilizer bar Service and Repair on both sides.

16. Raise and support the vehicle Service and Repair.

17. Remove the splash shield Splash Shield Replacement.

18. Disconnect the EPS motor 2P connector (A), and torque sensor 4P connector (B) from the torque sensor.

NOTE: Wrap the connectors with the vinyl tape to avoid contamination from grease or water.






19. Remove the secondary HO2S harness bracket (A) from the steering gearbox.

NOTE: Do not disconnect the secondary HO2S 4P connector and the secondary HO2S.






20. Place a jack (A) under the engine oil pan.






21. Remove the torque rod (A).

NOTE: Make sure the tab (B) on the bolt head aligned with the guide (C) on the front subframe.






22. Attach a transmission jack (A) to the middle of the front subframe (B), and support the front subframe securely by raising the transmission jack.





23. Remove the front subframe mounting bolts (C).

24. Lower the front subframe and the steering gearbox as an assembly by lowering the transmission jack slowly.

25. Remove the steering gearbox (A) from the front subframe (B).






26. Remove the pinion shaft grommet (A) from the top of the torque sensor.






Installation

1. Install the pinion shaft grommet (A). Align the ledge portion (B) in the pinion shaft grommet with the lug portion (C) on the torque sensor 3P connector. The grommet must not have a gap at the mating surface of the grommet and torque sensor.






2. Place the steering gearbox (A) on the front subframe (B).





3. Loosely install the stiffener plates (C), and new gearbox mounting bolts, then tighten the bolts to the specified torque in the sequence shown.

4. Turn the lip (D) of the pinion shaft grommet to ease installation.

5. Set the front subframe (A) with the steering gearbox on the transmission jack, and support it.





6. Carefully raise the front subframe with the transmission jack, and pass the pinion shaft into the passenger's compartment.

NOTE:

- Be sure that the pinion shaft grommet (B) is securely in place. Make sure the lip of the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water and mud, or noise.
- Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.

7. Loosely install new front subframe mounting bolts, then tighten the bolts to the specified torque in the sequence shown.

8. Install the torque rod (A).

NOTE: Be sure to install the torque rod with the "UP" mark facing up.





9. Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then tighten the new torque rod mounting bolt and nut in the numbered sequence shown.

10. Remove the jack (A).






11. Install the secondary HO2S harness bracket (A) on the steering gearbox.






12. Remove the vinyl tape from the connectors.

13. Connect the EPS motor 2P connector (A) and the torque sensor 4P connector (B) to the torque sensor.






14. Install the splash shield Splash Shield Replacement.

15. Install the stabilizer links to the stabilizer bar Service and Repair.

16. Lower the vehicle.

17. Wipe off any grease contamination from the tapered section and threads of the tie-rod end ball joint . Connect the tie-rod end (A) to the knuckles. Install the nut (B), and tighten to the specified torque on both sides.






18. Install the new cotter pin (C), and bend it as shown on both sides.

19. Wipe off any grease contamination from the tapered section and threads of the ball joint. Connect the lower arm (A) to the knuckle. Install a new castle nut (B) and tighten it to the specified torque on both sides.

NOTE:

- Be careful not to damage the lower ball joint boot (C). Check the ball joint boot for deformation before connecting the knuckle.
- Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the joint pin clip hole. Do not align the castle nut by loosening it.





20. Install the lock pin (D).

21. Install the front wheels, then set the wheels in the straight ahead position.

NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.

22. Cut the wire (A).





23. Slip the lower end of the steering joint (B) onto the pinion shaft (C) taking care to align the gap (D) within the angle shown.

24. Remove the steering wheel holder tool.

25. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower steering joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft.





26. Pull on the steering joint to make sure that the steering joint is fully seated, then tighten the lower joint bolt to the specified torque.

27. Install the steering joint cover (A).

NOTE: Check the steering joint cover for damage and cracks. If the steering joint cover is cracked, replace the steering joint cover.





28. With the tires raised off the ground, check for the following symptoms by turning the steering wheel fully to the right and left several times.





29. Do the 12 volt battery terminal reconnection procedure Procedures.

30. Do the memorizing of the torque sensor neutral position Testing and Inspection.

31. After installation, check these items:

- Start the engine, allow it to idle, and turn the steering wheel from lock to lock several times.Check that the EPS indicator does not come on.
- Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then adjust the front toe by turning the tie-rod ends, if necessary.

32. Check the wheel alignment, and adjust it if necessary Service and Repair.