Gear

NOTE: The numbers found below in parenthesis ( ), refer to that number (and that part/component) found in the illustration.

REMOVAL
1. Remove the hose connected to the return pipe on the steering system. Plug the hose.
2. Install a length of hose onto the pipe and place the other end in a bottle or similar receptacle that holds at least 0.5 liters. Turn the steering wheel to full left lock and full right lock until all the fluid has run out of the steering system.
3. Remove the length of hose from the return pipe and refit the return hose.
4. Disconnect the ground (negative) cable from the battery.
5. Remove the main fuse box.
6. Remove the lower section of the dashboard on the driver's side.
7. Remove the bolt from the joint on the steering column shaft (1).
8. Turn the steering wheel to the straight ahead position.





a. Separate the joint on the steering column shaft from the steering gear.
b. Remove the track rod from the steering gear (2).
c. Raise the car and remove the lefthand front wheel.
d. Remove the track rod from the MacPherson strut, using special tool 89 96 696 to press out the ball joint (3).
e. Lift out the track rod and lower the car to the floor.
f. Remove the fixing clamps on the lefthand and righthand sides (4).

WARNING: TO AVOID TWISTING THE COIL SPRING BY SUCH AN AMOUNT THAT IT BREAKS, FIX THE STEERING WHEEL SO THAT IT WILL NOT MOVE OUT OF THE STRAIGHT AHEAD POSITION.

NOTE: One method of fixing the steering wheel is to tape it to the dashboard by means of heavy duty adhesive tape of fabric type.

IMPORTANT: Note the cable holder on the righthand side.

9 Disconnect the delivery and return pipes from the steering gear (5). Use special tool 87 91 287. Plug the pipes and the connections on the valve body.
10. Disconnect both internal pipe connections from the valve body and bend them upwards. Plug the pipes and the connections.
11. Remove the steering gear through the lefthand wheel housing.





INSTALLATION
1. Move the bulkhead seal and rubber bushes on the righthand and lefthand sides away from the valve body (replacement of steering gear only).
2 Disconnect the internal pipes from the steering gear and plug them (replacement only).
3 Lift the steering gear into place through the lefthand wheel housing.
4. Remove the plugs and connect the pipes to the valve body.
5. Remove the plugs and connect the delivery and return pipes (1). Use special tool 87 91 287.
6. Mount the fixing clamps on lefthand and righthand sides (2).

IMPORTANT: Note the cable holder on the righthand side.

7. Install the track rod to the steering swivel member and tighten the connection, using a torque wrench.
Tightening torque: 60 Nm (44.3 ft. lbs.).
8. Install both track rods to the steering gear and tighten the connections, using a torque wrench (3).
Tightening torque: 85 - 100 Nm (62.7 - 73.8 ft. lbs.).





9. Install the steering column shaft joint to the steering gear (4).
10. Remove the tape holding the steering wheel in position.

IMPORTANT: If the steering wheel has moved, the coil spring must be readjusted.

11. Refit the lower section of the dashboard.
12. Install the main fuse box.
13. Connect the ground (negative) cable to the battery.
14. Fill the hydraulic fluid reservoir with hydraulic fluid, start the engine and turn the steering wheel two or three times from full lock to full lock. Switch off the engine and top up the fluid reservoir.
15. Install the road wheel and tighten the wheel bolts.
Tightening torque: 105 - 130 Nm (77.5 - 95.9 ft. lbs.).
16. Lower the car to the floor.
17. Check the toe-in and adjust if necessary.