Steering Gear - Installation

INSTALLATION

1. If necessary, install outer tie rods onto inner tie rod threads. As outer tie rods are installed, count out same number rotations as were counted on tie rod removal. This will get toe setting somewhat close to specification before vehicle is aligned at end of this procedure.
2. Carefully install power steering gear through left wheel opening using the reverse of how it was removed. Use care not to cut tie rod boots on shields as gear is installed.

NOTE: When installing steering gear mounting bolts, note driver's side mounting bolt is longer than passenger's side bolt.

3. Center gear mounting bosses over mounting holes in cradle and install two power steering gear mounting bolts. Tighten mounting bolts to 163 Nm (120 ft. lbs.).




4. On vehicles equipped with 4.0L engine, install right stabilizer bar cushion retainer (1) (With heat shield). Install cushion retainer mounting bolts (2) and tighten to 54 Nm (40 ft. lbs.).




5. On vehicles equipped with 4.0L engine, install mounting screws (2) securing heat shield (1) in front of steering gear. Tighten mounting screws to 4 Nm (35 in. lbs.).

NOTE: Before installing power steering hoses on power steering gear, wipe clean connections with a lint-free cloth and replace O-rings. Lubricate O-rings using clean power steering fluid.





NOTE: On vehicles equipped with 3.8L engine, when installing hoses to steering gear, it is important to position hose tubes within 18 mm of one another to avoid incorrect routing issues due to engine movement during driving maneuvers.

6. Install pressure hose (3) into power steering gear (1) port. Thread pressure hose tube nut into gear and tighten to 31 Nm (23 ft. lbs.).
7. Install return hose (2) into power steering gear (1) port. Thread return hose tube nut into gear and tighten to 31 Nm (23 ft. lbs.).




8. Find power steering gear's center of travel, then match splines inside intermediate shaft extension (3) with that on steering gear (5) shaft. Slide extension onto steering gear shaft.




9. Install roll pin fastening intermediate shaft extension to power steering gear shaft as follows:
a. Insert Installer (1), Special Tool 6831A, through extension (5) and steering gear shaft (4).
b. Slide roll pin (3) onto Installer shaft.
c. Thread knurled nut (2) all way onto end of Installer.
d. While holding Installer head stationary, turn hex nut pulling roll pin into shafts. Stop installing roll pin once it is centered intermediate shaft extension.
e. Remove tool.
10. Slide shaft cover down over top of steering gear.




11. On each side of vehicle, attach outer tie rod (4) to knuckle (1). Start NEW nut (5) onto outer tie rod stud. While holding stud stationary, tighten nut using a wrench. Using a crowfoot wrench on a torque wrench, tighten nut to 47 Nm (35 ft. lbs.). Then, tighten nut an additional 1/2 (180°) turn after that torque is met.
12. Snug tie rod jam nuts on both sides of vehicle. Do not tighten at this time. Tighten tie rod jam nuts to specification while performing wheel alignment at end of this procedure.




13. On each side of vehicle, install tire and wheel assembly (1) Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.).
14. Lower vehicle.
15. Connect negative (-) battery cable on negative battery post.




16. Remove steering wheel holder.
17. Fill and bleed power steering system. Service and Repair
18. Inspect for leaks.
19. Perform wheel alignment setting toe to specifications. Service and Repair