Removal and Replacement

Steering Gearbox
REMOVAL
1. Set the vehicle on a lift.
2. Disconnect the ground cable from the battery.
3. Loosen the front wheel nuts.
4. Lift up the vehicle, and remove the front wheels.
5. Remove the under cover.
6. Remove the front exhaust pipe assembly. (Nonturbo model.

WARNING: Be careful not to burn yourself because the exhaust pipe is hot.

7. After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.





8. Remove the front crossmember support plate, jack-up plate and front stabilizer.
- Large type





- Small type





9. Remove the one pipe joint at the center of the gearbox, and connect the vinyl hose to the pipe and the joint. Discharge the fluid by turning the steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from other pipes.





10. Remove the universal joint.
11. Disconnect the pipe C from pressure hose first, then disconnect pipe D from the return hose.





12. Remove the clamp bolts securing the gearbox to the crossmember, and remove the clamp.





13. Remove the bolts which secure the gearbox bracket, and remove the bracket and gearbox.





INSTALLATION
1. Insert the gearbox into crossmember, being careful not to damage gearbox boot.
2. Install the gearbox and bracket. Temporarily tighten the bolts.





3. Insert bolts through the clamp to temporarily tighten the gearbox to the crossmember bracket.





4. Tighten the bolts temporarily holding the gearbox clamp and bracket together to the specified torque.
Tightening torque: 60 N-m (6.1 kgf-m, 44.1 ft-lb)
5. Connect pipe D to the return hose, then connect pipe C to the pressure hose.
Tightening torque: 15 N-m (1.5 kgf-m, 10.8 ft-lb)





6. Install the universal joint.
7. Connect the tie-rod end and knuckle arm, and tighten with castle nut.
Castle nut tightening torque: 27 N-m (2.75 kgf-m, 19.9 ft-lb)

CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.

8. After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.





9. Install the front stabilizer.
10. Install the front crossmember support plate and jack-up plate.
11. Install the front exhaust pipe assembly. (Nonturbo model.
12. Install the undercover.
13. Install the front wheels.
14. Tighten the wheel nuts to the specified torque.
Tightening torque: 120 N-m (12.2 kgf-m, 88.5 ft-lb)
15. Lower the vehicle.
16. Remove the steering wheel.
17. Align the center position of the roll connector.
18. Install the steering wheel.
19. Connect the ground cable to battery.
20. Pour fluid into the oil tank, and bleed air.
21. Check for fluid leaks.
22. Check the fluid level in oil tank.
23. After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
Tightening torque: 85 N-m (8.7 kgf-m, 62.7 ft-lb)

NOTE: When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If it becomes twisted, straighten it.