Manual Steering Gear Replacement

Tools Required
• J 44015 Steering Linkage Installer
• SA91100C Tie Rod Separator
• SA9140E Torque Angle Gage

Removal Procedure

1. Disconnect negative battery cable.

Caution

Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

2. Raise vehicle on hoist.
3. Remove front wheels.
4. Remove and discard torque prevailing nut. A new nut will be required during assembly.

Notice

Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

5. Using SA91100C , remove tie rod ends from steering knuckle.

Important

Remove front section of shield first, then rear.

6. Remove left side splash shield.
1. Remove two push pins.

Important

If molded-in fasteners are damaged or broken, drill out with a 5/16 in. bit and replace with a push pin.

2. Remove lower shield to cradle molded-in fasteners at cradle by gently prying at three fastener locations.




7. Loosen intermediate shaft cover from steering gear and move up enough to access pinch bolt.
8. Remove pinch bolt.
9. Remove steering gear to cradle fasteners and remove steering gear from vehicle through left fenderwell.

Installation Procedure

1. Place steering gear in vehicle.

Notice

Refer to Fastener Notice in Cautions and Notices.

2. Install steering gear-to-frame bolts and new nuts.
Tighten

Tighten Steering Gear-to-Frame Fasteners 50 N·m (37 lb ft).






Important

Use Loctite 242® Threadlocker (or equivalent) on thread of pinch bolt.

3. Install intermediate shaft onto steering gear and torque the pinch bolt.
Tighten

Tighten Intermediate Steering Shaft-to-Steering Gear Pinch Bolt 47 N·m (35 lb ft).






Important

Install rear section of splash shield first, then front.

4. Install left side splash shield.
5. Install tabs in body cut-out.

Important

Make sure splash shield flaps are tucked in at body locations.

6. Align molded-in shield fasteners with holes in cradle. Push straight in to install.
7. Install push pins.

Important

Tie rod end threads must be thoroughly cleaned before tightening nut. Do not lubricate any portion of stud.

Important

Use new nut, torque retention of old nut may not be sufficient.

8. Seat tie rod end into steering knuckle by using J 44015 or equivalent.
Tighten

Tighten Tie Rod Linkage Installer 45 N·m (33 lb ft).

Important

This procedure requires a SA9140E (or equivalent).

9. Remove linkage installer and install new tie rod end nut.
Tighten

Tighten Tie Rod-to-Steering Knuckle Nut 25 N·m (19 lb ft) +134°.






Important

Lower control arm ball stud threads should be thoroughly cleaned and lubricated before installing and tightening nut.

10. Tighten ball joint stud castle nut.
Tighten

Tighten Ball Joint Stud Castle Nut to 75 N·m (55 lb ft).

Important

If necessary to rotate castle nut to align with hole in the stud, always tighten the nut to align it; never loosen it. Install new cotter pin.

11. Connect negative battery cable.
Tighten

Tighten Battery Cable Bolts to 17 N·m (13 lb ft).

Notice

Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

12. Position wheel onto hub.
13. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to make sure torque is correct.
Tighten

Tighten Wheel Nuts to 140 N·m (103 lb ft).

14. Lower vehicle from hoist.
15. Set toe. Refer to Wheel Alignment Specifications in Wheel Alignment.