Steering Gear: Service and Repair

Steering Gear

Special Service Tools






Remover halfshaft inboard joint

205-735(LRT-54-026)





Installer halfshaft oil seal

308-626/1





Installer/Guide halfshaft oil seal

308-626/2





Impulse extractor

100-012(LRT-99-004)





Ball joint separator

205-754(LRT-54-027)

Removal
1
CAUTION: Do not turn the steering wheel with the steering column lower shaft disconnected as damage to the clockspring and steering wheel switches may occur.
Align the steering wheel to straight ahead.
- Remove the ignition key.
2 Disconnect the battery ground cable. For additional information, refer to Procedures
3 Remove the cooling fan and shroud. For additional information, refer to Cooling Fan - Vehicles Without: Supercharger Service and Repair
4
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
5 Drain the differential fluid. For additional information, refer to Differential Draining and Filling Front Drive Axle/Differential
6 Remove the front wheels and tires.
7 Remove the engine undershield. For additional information, refer to Engine Undershield Engine Undershield




8
NOTE:
RH side only.
Remove the fender splash shield lower extension panel.




9
NOTE:
RH side only.
Remove the fender splash shield upper extension panel.





10
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
RH front: Disconnect the steering gear tie rod end ball joint.
- Use the special tool.
- Loosen the tie-rod end ball joint retaining nut.
- Discard the nut.





11
CAUTION: Note the fitted position of the special washer.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
RH front: Disconnect the stabilizer bar link.
- Remove the nut.
- Remove the flat washer.





12
WARNING: Do not remove the nuts.
LH front: Release the air suspension spring.
- Loosen the 3 nuts.





13
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Disconnect the suspension height sensor link arm.
- Remove the nut.





14 LH front: Remove the suspension height sensor.
- Remove the clip.
- Disconnect the electrical connector.
- Remove the 2 bolts.





15
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
LH front: Disconnect the steering gear tie rod end ball joint.
- Use the special tool.
- Loosen the tie-rod end ball joint retaining nut.
- Discard the nut.





16
CAUTION: Note the fitted position of the special washer.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Disconnect the stabilizer bar link.
- Remove the nut.
- Remove the flat washer.





17
CAUTION: Support the lower arm.
LH front: Disconnect the lower arm.
- Remove the bolt and discard the nut.





18
CAUTION: Support the tie rod.
LH front: Disconnect the tie rod.
- Remove the bolt and discard the nut.





19
CAUTION: Support the halfshaft.
LH front: Using the special tool, disconnect the halfshaft from the differential.
- Remove and discard the retaining clip.

20 LH front: Remove and discard the halfshaft oil seal.





21
CAUTION: Do not turn the steering wheel with the steering column lower shaft disconnected as damage to the clockspring and steering wheel switches may occur.
Disconnect the lower steering column from the steering gear.
- Note the fitted position.
- Align the steering wheel to straight ahead.
- Remove and discard the Torx bolt.





22 Disconnect the steering gear electrical connector.





23
WARNING: Fluid loss is unavoidable, use absorbent cloth or a container to collect the fluid.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Disconnect the power steering feed and return fluid lines from the steering gear.
- Note the fitted position.
- Remove the 2 unions.
- Remove and discard the 4 sealing washers.





24 Release the RH engine mount.
- Support the engine.
- Remove the nut.





25 Remove the LH engine mount heat shield.
- Remove the 2 screws.





26 Release the LH engine mount.
- Remove the bolt.





27 Release the steering gear.
- Remove and discard the 2 nuts and Torx bolts.





28 Remove the steering gear.
- Raise the engine.
- With assistance, carefully rotate and release the steering gear.





29
NOTE:
Do not disassemble further if the component is removed for access only.
Remove the tie-rod end.
- Note the fitted position.
- Loosen the locknut.
- Remove and discard the locking ring.
- Remove and discard the locknut.
- Repeat the above procedure for the other side.

Installation





1
CAUTION: Make sure the locking ring taper faces the tie rod end.
Install the tie-rod end.
- Clean the components.
- Install a new locknut.
- Install a new locking ring.
- Tighten the new nut to 80 Nm (59 lb.ft).
2 Install the steering gear.
- With assistance, carefully rotate and align the steering gear.
- Tighten the new nuts and Torx bolts to 100 Nm (74 lb.ft).
3 Lower the engine onto its mounts.
- Tighten the nut and bolt to 115 Nm (85 lb.ft).
4 Install the LH engine mount heat shield.
- Tighten the screws.
5 Connect the power steering feed and return fluid lines.
- Clean the components.
- Install new sealing washers.
- Tighten the M16 union to 28 Nm (21 lb.ft).
- Tighten the M14 union to 28 Nm (21 lb.ft).
6 Connect the steering gear electrical connector.




7 Attach the lower steering column.
- Make sure that the steering gear tag is aligned correctly, as shown.
- Install a new Torx bolt and tighten to 24 Nm (18 lb.ft).




8
CAUTION: The seal protector must be left in place until the halfshaft has been installed.
LH front: Using the special tools, install a new halfshaft oil seal.
- Clean the component mating faces.
9
CAUTION: Keep the halfshaft horizontal to avoid damaging the oil seal.
CAUTION: Pull on the halfshaft inboard joint to make sure the clip has fully engaged and retains the halfshaft inboard joint within the differential case.
NOTE:
Do not fully engage the halfshaft until the oil seal protector has been removed.
LH front: Fully install the halfshaft.
- Clean the component.
- Install a new retaining clip.
- Open the halfshaft oil seal protector.
- Lubricate the seal with clean differential fluid.
- Remove and discard the halfshaft oil seal protector.

10
NOTE:
Do not fully tighten the locking nut at this stage.
LH front: Connect the tie rod.
- Install the bolt with a new nut.

11
NOTE:
Do not fully tighten the locking nut at this stage.
LH front: Connect the lower arm.
- Install the bolt with a new nut.

12
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
LH front: Connect the steering gear tie rod end ball joint.
- Clean the component mating faces.
- Tighten the new nut to 80 Nm (59 lb.ft).

13
CAUTION: Make sure the hardened steel washer is fitted against the stabilizer bar link.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Connect the stabilizer bar link.
- Install the washer.
- Tighten the nut to 100 Nm (74 lb.ft).

14 LH front: Install the suspension height sensor.
- Tighten the bolts to 3.5 Nm (2.5 lb.ft).
- Connect the electrical connector.
- Install the clip.

15
NOTE:
Use an additional wrench to prevent the ball joint rotating.
LH front: Connect the suspension height sensor link arm.
- Tighten the nut to 8 Nm (6 lb.ft).

16
CAUTION: Make sure the hardened steel washer is fitted against the stabilizer bar link.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
RH front: Connect the stabilizer bar link.
- Install the washer.
- Tighten the nut to 100 Nm (74 lb.ft).

17
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
RH front: Connect the steering gear tie rod end ball joint.
- Clean the component mating faces.
- Tighten the new nut to 80 Nm (59 lb.ft).

18 Install the front wheels and tires.
- Tighten the wheel nuts to 140 Nm (103 lb.ft).

19
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
Tighten the lower arm nuts and bolts to 165 Nm (122 lb.ft) plus a further 90 degrees.

20
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
Tighten the tie rod nuts and bolts to 165 Nm (122 lb.ft) plus a further 90 degrees.

21 Secure the air suspension spring.
- Tighten the nuts securing the air springs to 56 Nm (41 lb.ft).

22 Fill the front differential case with the correct amount of fluid. For additional information, refer to Differential Draining and Filling Front Drive Axle/Differential

23
NOTE:
RH side only.
Install the fender splash shield upper extension panel.
- Tighten the bolts to 8 Nm (6 lb.ft).

24
NOTE:
RH side only.
Install the fender splash shield lower extension panel.

25 Install the engine undershield. For additional information, refer to Engine Undershield Engine Undershield

26 Install the cooling fan and shroud. For additional information, refer to Cooling Fan - Vehicles Without: Supercharger Service and Repair

27 Connect the battery ground cable. For additional information, refer to Procedures

28 Fill and bleed the power steering system. For additional information, refer to Power Steering System Filling and Bleeding Service and Repair

29 Carry out a complete vehicle geometry check and adjustment.