Steering Gearbox Installation

1.Pass the cylinder of the steering gearbox (A) together with the tie-rods (B) through the wheelwell opening on the driver's side.

 

2.Carefully move the steering gearbox toward the passenger's side until the pinion shaft clears the wheelwell opening on the frame. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position.

NOTE: Make sure the power steering return hose is routed between the gearbox and right tie-rod.

 

3.Install the pinion shaft grommet (A).

 

4.Install the mounting cushion on the cylinder side of the gearbox.

5.Insert the pinion shaft up through the bulkhead, and place the steering gearbox on the mounting brackets. Be sure that the pinion shaft grommet is in place securely.

6.Loosely install the two 10 mm flange bolts and washers on the left side (RHD: right side) of the gearbox.

 

7.Position the cutout (A) on the mounting cushion (B) as shown, and install it on the housing of the gearbox securely fitted. Install the mounting bracket (C) over the mounting cushion.

 

8.Install the 10 mm flange bolt and nut loosely first, then torque the flange bolt and nut alternately in two or more steps.

9.Tighten the left side (RHD: right side) of the flange bolts to the specified torque value.

 

10.On the driver's side, connect feed line (A) securely, and tighten the 14 mm flare nut to specified torque.

LHD: 

RHD: 

11.Install the feed line clamps (B) and P/S return line bracket (LHD model) (C) on the gearbox.

12.Connect the return hose (A) securely, and tighten the adjustable hose clamp (B).
Install the return line clamp (C) (RHD model) on the gearbox.

LHD: 

RHD: 

13.Install the P/S return line bracket (LHD model) (A) and return line clamp (B) on the gearbox. Make sure that there is no interference between the feed and return lines any other parts.

 

14.Reinstall the air cleaner.

 

15.Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the damper steering arms.Install the 10 mm nut (B) and tighten it to the specified torque.

 

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

17.Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:

  • Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft).
  • Slip the lower end of the steering joint onto the pinion shaft (C) (line up the bolt hole with the groove (F) around the shaft), and loosely install the lower joint bolt. Be sure that the lower 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. Then install the upper joint bolt and tighten it. Tighten the steering joint bolts to specified torque.

 

18.Install the driver's dashboard lower covers.

19.Install the front wheels, then set the wheels in the straight ahead position.

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

21.Fill the system with power steering fluid, and bleed air from the system.

22.After installation, perform the following checks.

  • Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks.
  • Perform the front toe inspection.
  • 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 serrations, then adjust the front toe by turning the tie-rods, if necessary.