Hydraulic Power Steering Gearbox Installation

Hydraulic Power Steering Gearbox Installation

1. Place the steering gearbox in position on the front subframe.

2. Loosely install the stiffener plates (A) and the gearbox mounting bolts on the left side of the steering gearbox.






3. Position the cutout (A) on the mounting cushion (B) as shown, and install it on the right side of the steering gearbox securely.

4. Install the gearbox mounting bracket (C) over the mounting cushion, and loosely install the two 10 mm bolts.

5. Tighten the 10 mm bolts on both sides of the steering gearbox to the specified torque alternately in two or more steps.






6. Install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the valve housing. The grommet must not have a gap at the mating surface of the grommet and valve housing.

7. Carefully raise the front subframe with the front subframe adaptor and the transmission jack or the powertrain lift until the subframe is in position, then loosely install new subframe mounting bolts.
NOTE: Be sure that the pinion shaft grommet is in place securely. Make sure the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water, mud, and noise.






8. Align the front subframe reference marks (A) to the body (B), as noted during removal.






9. Tighten the new front subframe rear mounting bolts (A) to the specified torque.






10. Tighten the new front subframe front mounting bolts (A) to the specified torque.






11. Install the new lower torque rod bracket bolts (A), and tighten to the specified torque.






12. Install the new front subframe middle mount bolt (A) on the left side, and tighten it to the specified torque.






13. Install the new front subframe middle mount bolt (A) on the right side, and tighten it to the specified torque.

14. Lower the transmission jack supporting the front subframe.






15. Connect the lower arm (A) to the lower ball joint (B).






16. Install a new flange bolt and the new self-locking nuts. After lightly tightening all three fasteners, tighten them to the specified torque in the following order; the flange nut on the front (C), the flange nut on the rear (D), then the flange bolt (E).

17. Connect the inlet line (A), and loosely install the 18 mm flare nut (B). Do not tighten the flare nut to the specified torque yet.

18. Connect the return hose (C) securely, and tighten the adjustable hose clamp (D). Service and Repair






19. Install the inlet line clamp bolt (A). Install the return line holder (B), and the return line clamp bolt (C) on the front subframe.
NOTE: Make sure that there is no interference between the inlet line, the return line, and any other parts.

20. Tighten the inlet line 18 mm flare nut to the specified torque value.

21. Install the front splash shield, 2-door, Front Splash Shield Replacement (2-Door) 4-door. Front Splash Shield Replacement (4-Door)






22. Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B), and tighten it.

23. Install the new cotter pin (C), and bend it as shown (D) or (E).






24. Install the pump outlet hose clamp (A).

25. Remove the engine hanger, support bolt, and support hanger from the vehicle.

26. Install the front wheel, then set the wheels in the straight ahead position.
NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and inside of the wheel.

27. Lower the vehicle.

28. Center the steering rack within its stroke in the steering joint connection.






29. With the rack in the straight ahead driving position, cut the wire (A) and slip the lower end of the steering joint onto the pinion shaft (B) in the range shown.






30. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Tighten the steering joint bolt to the specified torque.






31. Install the steering joint cover (A).

32. Install the driver's dashboard undercover. Drivers Dashboard Undercover Removal/Installation

33. Install the steering wheel. Steering Wheel Installation






34. Install the air cleaner housing mounting bracket (A) on the cylinder head.

35. Install the air cleaner housing. Service and Repair

36. Install the under-cowl panel and cowl cover. Service and Repair

37. Do the battery terminal reconnection procedure, Procedures and do these tasks:
- Turn the ignition switch to ON (II) and check; the SRS indicator comes on for about 6 seconds and then goes off.

- Make sure the horn and turn signal switches work properly.

- Make sure the steering wheel switches work properly.

38. Fill the system with power steering fluid, and bleed air from the system. Service and Repair

39. After installation, do these checks:
- Start the engine, and let it idle Turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the steering gearbox for leaks.. Power Steering Fluid Leakage Inspection (Without EPS)

- Check the steering wheel spoke angle.
If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft splines.

- Set the steering column to the center tilt position, and to the center telescopic position, then do the front toe inspection. Service and Repair