Removal and Installation

TOOL REQUIRED
- 07MAC-SL00200 Ball Joint Remover, 28 mm

NOTE: Using solvent and a brush, to wash any oil and dirt off the gearbox. Blow dry with compressed air.

REMOVAL
1. Raise the front of vehicle, and support it on safety stands in the proper locations.
2. Remove the front wheels.
3. Remove the steering wheel.





4. Remove the steering joint cover.





5. Remove the steering joint lower bolt, and disconnect the steering joint by moving the joint toward the column.





6. Remove the cotter pin from the castle nut and remove the newt
7. Install the 10 mm hex nut on the ball joint. Be sure that the 10 mm hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damaged by the ball joint remover.

NOTE: Remove the ball joint using the special tool. Refer to section 18 for how to use the ball joint remover.

8. Separate the tie-rod ball joint and knuckle using the special tool.

CAUTION: Avoid damaging the ball joint boot.

9. Remove the left tie-rod end, then slide the rack all the way to the right.
10. Separate the exhaust pipe A or TWC.
11. Disconnect the shift linkage.





12. Remove the stiffener plate.





13. Remove the mounting bracket.
14. Pull the steering gearbox all the way down to clear the pinion shaft from the bulkhead, then remove the pinion shaft grommet.





15. Move the steering gearbox to right so the left rack end clears the rear beam, then tilt the left side down to remove it from the car.

INSTALLATION
1. Slide the rack all the way to the right.





2. Install the pinion shaft grommet, and insert the pinion shaft up through the bulkhead.

NOTE: Align the notch in the pinion shaft grommet with the tab on the gear housing.





3. Install the mounting brackets with the two gearbox mounting bolts on the cushion.





4. Install the stiffener plate with the two gearbox mounting bolts and stiffener plate attaching bolts.

NOTE: Install the bolts loosely first, then tighten them securely.

5. Center the steering rack within its stroke.





6. Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove around the shaft), and tighten the lower bolt.

NOTE:
- Connect the steering shaft and pinion with the steering wheel and steering rack centered.
- Be sure that the lower steering joint bolt is securely in the groove in the steering gearbox pinion.
- If the steering wheel and rack are not centered, reposition the serrations at lower end of the steering joint.

7. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (approximately two turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.





8. Install the steering joint cover with the clamps and clips.





9. Reconnect the tie-rod ends to the steering knuckles, then tighten the castle nut to the specified torque, and install new cotter pins.

NOTE: Before connecting the tie-rod ends, wipe off any grease contamination from the ball joint tapered section and threads.

CAUTION: Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.

10. Install the exhaust pipe A or TWC.
11. Connect the shift linkage.
12. Install the front wheels.
13. After installation, perform the following checks.
a. Adjust the front toe.
b. Check the steering wheel spoke angle. Adjust by turning the right and led tie-rods, if necessary.

NOTE: Turn the right and left tie-rods equally.