AutoZone 1994 Ford Truck Aerostar 4WD 4.0L MFI 6cyl | Repair Guides | Steering | Power Rack & Pinion Steering Gear | Removal & Installation | AutoZone.com

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    Mitsubishi Car 1999-05

    Removal & Installation

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    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear removal procedure-Galant


    WARNING
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and properly support the vehicle.
    4.  
    5. Remove both front wheel assemblies.
    6.  
    7. Remove the bolt holding lower steering column joint to the rack and pinion input shaft.
    8.  
    9. Remove the stabilizer bar.
    10.  
    11. Remove the cotter pins, and using joint separator MB991113 or equivalent, disconnect the tie rod ends from the steering knuckle.
    12.  
    13. On vehicles equipped with Electronic Control Power steering (EPS), detach the wiring harness from the solenoid connector.
    14.  
    15. Locate the two triangular braces near the crossmember and remove both.
    16.  
    17. Support the center crossmember. Remove the through-bolt from the front round roll stopper and remove the bolts securing the center crossmember.
    18.  
    19. Remove the center crossmember.
    20.  
    21. Properly support the engine and remove the rear roll stopper through-bolt.
    22.  
    23. Disconnect the power steering fluid pressure pipe and return hose from the rack fittings. Plug the fittings to prevent excessive fluid leakage.
    24.  
    25. Remove the clamp bolts and the two bolts securing the rack assembly to the chassis.
    26.  
    27. Remove the rack and pinion steering assembly and its rubber mounts.
    28.  


    NOTE
    When removing the rack and pinion assembly, tilt the assembly to the vehicle side of the compression lower arm and remove from the left side of the vehicle.

    To install:

    1. Center the rack assembly and insert the pinion into the steering column shaft.
    2.  
    3. Install the rack and mounting bolts. Tighten the mounting bolts to 51 ft. lbs. (69 Nm).
    4.  
    5. Install the pinch bolt and tighten the bolt to 13 ft. lbs. (18 Nm).
    6.  
    7. Connect the power steering fluid lines to the rack and tighten the pressure hose fitting to 11 ft. lbs. (15 Nm). Secure the return hose with the clamp.
    8.  
    9. Raise the engine into position.
    10.  
    11. Install the rear roll stopper through-bolt and tighten to 32 ft. lbs. (43 Nm).
    12.  
    13. Raise the crossmember into position. Install the center member mounting bolts; tighten the front bolts to 58-65 ft. lbs. (78-88 Nm) and the rear bolt to 51-58 ft. lbs. (69-78 Nm).
    14.  
    15. Install the front roll stopper bolt and tighten the nut to 32 ft. lbs. (43 Nm).
    16.  
    17. Install the two triangular braces and tighten the mounting bolts to 50-56 ft. lbs. (69-78 Nm).
    18.  
    19. Install the stabilizer bar.
    20.  
    21. Connect the tie rod ends and tighten the nuts to 20 ft. lbs. (27 Nm).
    22.  
    23. On vehicles equipped with EPS, connect the wiring harness to the solenoid connector.
    24.  
    25. Install the wheel assemblies and lower the vehicle.
    26.  
    27. Refill the reservoir with power steering fluid and bleed the system.
    28.  
    29. Have a front end alignment performed.
    30.  


    NOTE
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clockspring and render SRS system inoperative.

    1. Drain the power steering system.
    2.  
    3. Disconnect the battery negative cable. Raise the vehicle and support safely.
    4.  
    5. Disconnect the Heated Oxygen (HO 2 S) sensor and remove the front exhaust pipe.
    6.  
    7. Properly support the engine.
    8.  
    9. Remove both roll stopper mounting bolts and the four center member installation bolts. Remove the center member.
    10.  
    11. Remove the center member.
    12.  


    NOTE
    Matchmark the pinion input shaft of the rack to the lower steering column joint for installation purposes.

    1. Remove the pinch bolt holding the lower steering column joint to the rack and pinion input shaft.
    2.  
    3. Remove the cotter pins and disconnect the tie rod ends from the steering knuckle.
    4.  
    5. Disconnect the power steering fluid pressure pipe and return hose from the rack fittings.
    6.  
    7. Remove the rack and pinion steering assembly and its rubber mounts from the right side of the vehicle.
    8.  

    To install:

    1. Align the matchmarks of the input shaft and install the rack to the vehicle.
    2.  
    3. Secure the rack using the retainer clamps and bolts. Tighten the bolts to 51 ft. lbs. (70 Nm).
    4.  
    5. Tighten the steering column pinch bolt to 13 ft. lbs. (18 Nm).
    6.  
    7. Using new O-rings, connect the power steering fluid lines to the rack fittings.
    8.  
    9. Install the center member.
    10.  
    11. Install the front exhaust pipe.
    12.  
    13. Connect the HO 2 S sensor.
    14.  
    15. Connect the tie rod ends to the steering knuckles and tighten the castle nuts to 25 ft. lbs. (34 Nm). Install new cotter pins.
    16.  
    17. Install the wheels and connect the negative battery cable.
    18.  
    19. Refill the reservoir and bleed the system.
    20.  
    21. Have a front end alignment performed.
    22.  



    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-Mirage


    NOTE
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Disconnect the front exhaust pipe.
    6.  
    7. If equipped with AWD, remove the transfer case assembly.
    8.  
    9. Remove the bolt holding the lower steering column joint to the rack and pinion input shaft.
    10.  
    11. Remove the cotter pins and disconnect the tie rod ends.
    12.  
    13. Remove the left and right frame members.
    14.  
    15. Remove the stabilizer bar bracket.
    16.  
    17. If equipped with four-wheel steering, disconnect the lines going to the rear pump.
    18.  
    19. Remove the rack and pinion steering assembly and its rubber mounts. Move the rack to the right to remove it from the crossmember.
    20.  

    To install:

    1. Install the rack and install the mounting bolts, tightening bolts to 51 ft. lbs. (70 Nm). When installing the rubber rack mounts, align the projection of the mounting rubber with the indentation in the crossmember. Install the pinch bolt.
    2.  
    3. Connect the pressure and return lines to the rack and to the rear pump, if equipped.
    4.  
    5. Install the frame members and tighten the bolts to 43-51 ft. lbs. (60-70 Nm).
    6.  
    7. Connect the tie rods and install new cotter pins.
    8.  
    9. Install the transfer case and front exhaust pipe.
    10.  
    11. Refill the reservoir and bleed the system.
    12.  
    13. Perform a front end alignment.

      Click image to see an enlarged view

      Fig. Exploded view of the power steering gear removal-3000GT



      Click image to see an enlarged view

      Fig. Proper tie-rod end removal method

    14.  


    NOTE
    Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clock spring and render SRS system inoperative.

    1. Remove or disconnect the following:

      Negative battery cable.
       
      Front exhaust pipe
       
      Transfer case assembly, if equipped with All Wheel Drive (AWD)
       
      Bolt holding the lower steering column joint to the rack and pinion input shaft
       
      Tie rod ends
       
      Left and right frame members
       
      Stabilizer bar bracket
       
      Lines going to the rear pump, if equipped with Four Wheel Steering (4WS)
       
      Rack and pinion steering assembly and its rubber mounts. Move the rack to the right to remove it from the crossmember.
       

    2.  

    To install:

    1. Install or connect the following:

      Rack and install the mounting bolts, tightening bolts to 51 ft. lbs. (70 Nm). When installing the rubber rack mounts, align the projection of the mounting rubber with the indentation in the crossmember. Install the pinch bolt.
       
      Pressure and return lines to the rack and to the rear pump, if equipped
       
      Frame members and tighten the bolts to 43-51 ft. lbs. (60-70 Nm)
       
      Tie rods and install new cotter pins
       
      Transfer case and front exhaust pipe
       

    2.  
    3. Refill the reservoir and bleed the system.
    4.  
    5. Perform a front end alignment.

      Click image to see an enlarged view

      Fig. Power steering rack and related components-Diamante



      Click image to see an enlarged view

      Fig. Tie rod tool installation

    6.  

    1. Disconnect the negative battery cable.
    2.  
    3. Drain the power steering fluid into a suitable container.
    4.  
    5. Raise and safely support the vehicle.
    6.  
    7. Remove the stabilizer bar.
    8.  
    9. For 2.0L non-turbo engines, remove the windshield washer fluid reservoir.
    10.  
    11. For 2.0L turbo and 2.4L engines, perform the following:
      1. Remove the brake fluid reservoir.
      2.  
      3. Unbolt the A/C compressor and position aside. Do NOT disconnect the refrigerant lines.
      4.  

    12.  
    13. Remove the joint assembly and gear body connecting bolt.
    14.  
    15. Disconnect the power steering pipe connection.
    16.  
    17. Use a suitable puller to separate the tie rod end and knuckle connection.

      Click image to see an enlarged view

      Fig. Exploded view of the power steering gear assembly-1999 2.0L non-turbo engine, shown other engines similar

    18.  
    19. Unfasten the retaining bolts, then remove the left and right side stays.
    20.  
    21. Remove the retainers, then remove the center member assembly.
    22.  
    23. Unfasten the retaining clamp, then remove the power steering gear assembly.
    24.  
    25. Installation is the reverse of the removal procedure.
    26.  
    27. Refill the reservoir with power steering fluid and bleed the system.
    28.  
    29. Have a repair shop check the front end alignment, and adjust if necessary.
    30.  


    NOTE
    Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Install or connect the following:

      Negative battery cable
       

    2.  
    3. Drain the power steering fluid.

      Stabilizer bar
       
      Windshield washer reservoir
       
      Pinch bolt from the joint assembly
       
      Fluid lines from the steering rack
       
      Tie rod ends from the steering knuckles
       
      Left and right stays (supports)
       

    4.  
    5. Support the engine and remove the center member.

      Clamp and the mounting bolts
       
      Left lower compression arm from the body side of the vehicle and support it with wire or string
       
      Steering rack from the joint assembly and remove the rack from the left side of the vehicle
       

    6.  

    To install:

    1. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly.
    2.  
    3. Install or connect the following:

      Left lower compression arm to the body
       
      Center member
       
      Left and right stays and remove the engine support fixture or jack
       
      Tie rods to the steering knuckles
       
      Fluid lines to the steering rack
       
      Pinch bolt in the joint assembly
       
      Stabilizer bar and the windshield washer reservoir
       

    4.  
    5. Safely lower the vehicle.
    6.  
    7. Connect the negative battery cable.
    8.  
    9. Refill and bleed the power steering system.
    10.  
    11. Perform a front end alignment.

      Click image to see an enlarged view

      Fig. Power steering rack and related components-2002-2003 Eclipse



      Click image to see an enlarged view

      Fig. Disconnect the lower compression arm from the body-2002-2003 Eclipse

    12.  


    NOTE
    Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable. Remove the driver-s side air bag module.
    2.  
    3. Remove the steering wheel. Remove the column lower cover. Remove the clock spring.
    4.  
    5. Drain the power steering fluid.
    6.  
    7. Remove the front exhaust pipe. Remove the stabilizer bar. Remove the roll stopper bracket.
    8.  
    9. Remove the steering rack cover assembly. Remove the steering shaft assembly and rack retaining bolt.
    10.  
    11. On the 2.4L engine, remove the stay.
    12.  
    13. Disconnect the tie rod end and knuckle connection. Disconnect and plug the pressure tube connection.
    14.  
    15. Remove the power steering rack retaining clamp. Remove the assembly from the vehicle.
    16.  

    To install:

    1. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly.
      NOTE
      When installing the clock spring be sure that the springs mating marks are properly aligned. If not the steering wheel may not rotate completely during a turn, or the flat cable in the clock spring could be damaged. This would prevent normal SRS operation and possibly cause serious injury to the driver.

    2.  
    3. After aligning the mating surfaces of the clock spring, turn the front wheels to the straight ahead position. Install the clock spring to the column switch.
      NOTE
      Turn the clock spring clockwise fully. Then turn it back approximately 3 turns counterclockwise to align the mating marks.

    4.  
    5. Continue the installation in the reverse order of the removal procedure.
    6.  
    7. Check and adjust the front end alignment, as required.

      Click image to see an enlarged view

      Fig. Clock spring mating marks-2004-2005Eclipse



      Click image to see an enlarged view

      Fig. Power steering rack and related components-2004-2005 Eclipse

    8.  


    WARNING
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and properly support the vehicle.
    4.  
    5. Remove both front wheel assemblies.
    6.  
    7. Remove the bolt holding lower steering column joint to the rack and pinion input shaft.
    8.  
    9. Remove the stabilizer bar.
    10.  
    11. Remove the cotter pins, and using joint separator MB991113 or equivalent, disconnect the tie rod ends from the steering knuckle.
    12.  
    13. On vehicles equipped with Electronic Control Power steering (EPS), detach the wiring harness from the solenoid connector.
    14.  
    15. Locate the two triangular braces near the crossmember and remove both.
    16.  
    17. Support the center crossmember. Remove the through-bolt from the front round roll stopper and remove the bolts securing the center crossmember.
    18.  
    19. Remove the center crossmember.
    20.  
    21. Properly support the engine and remove the rear roll stopper through-bolt.
    22.  
    23. Disconnect the power steering fluid pressure pipe and return hose from the rack fittings. Plug the fittings to prevent excessive fluid leakage.
    24.  
    25. Remove the clamp bolts and the two bolts securing the rack assembly to the chassis.
    26.  
    27. Remove the rack and pinion steering assembly and its rubber mounts.
      NOTE
      When removing the rack and pinion assembly, tilt the assembly to the vehicle side of the compression lower arm and remove from the left side of the vehicle.

    28.  

    To install:

    1. Center the rack assembly and insert the pinion into the steering column shaft.
    2.  
    3. Install the rack and mounting bolts. Tighten the mounting bolts to 51 ft. lbs. (69 Nm).
    4.  
    5. Install the pinch bolt and tighten the bolt to 13 ft. lbs. (18 Nm).
    6.  
    7. Connect the power steering fluid lines to the rack and tighten the pressure hose fitting to 11 ft. lbs. (15 Nm). Secure the return hose with the clamp.
    8.  
    9. Raise the engine into position.
    10.  
    11. Install the rear roll stopper through-bolt and tighten to 32 ft. lbs. (43 Nm).
    12.  
    13. Raise the crossmember into position. Install the center member mounting bolts; tighten the front bolts to 58-65 ft. lbs. (78-88 Nm) and the rear bolt to 51-58 ft. lbs. (69-78 Nm).
    14.  
    15. Install the front roll stopper bolt and tighten the nut to 32 ft. lbs. (43 Nm).
    16.  
    17. Install the two triangular braces and tighten the mounting bolts to 50-56 ft. lbs. (69-78 Nm).
    18.  
    19. Install the stabilizer bar.
    20.  
    21. Connect the tie rod ends and tighten the nuts to 20 ft. lbs. (27 Nm).
    22.  
    23. On vehicles equipped with EPS, connect the wiring harness to the solenoid connector.
    24.  
    25. Install the wheel assemblies and lower the vehicle.
    26.  
    27. Refill the reservoir with power steering fluid and bleed the system.
    28.  
    29. Have a front end alignment performed.

      Click image to see an enlarged view

      Fig. Power steering rack and related components-1999-2003 Galant

    30.  


    NOTE
    Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable. Drain the power steering fluid. Remove the front under cover.
    2.  
    3. Remove the center crossmember. Remove the lower arm assembly.
    4.  
    5. Remove the driver-s side air bag module. Remove the steering wheel. Remove the column lower cover. Remove the clock spring.
    6.  
    7. Remove the floor console assembly. Remove the front scuff plate and cowl side trim. Remove the trunk lid opener cover.
    8.  
    9. Remove the accelerator pedal stopper. Remove the front floor carpet.
    10.  
    11. Disconnect the stabilizer link and stabilizer bar. Remove the steering shaft pad.
    12.  
    13. Disconnect the steering column assembly and steering rack connection. Remove the rear roll stopper connecting bolt.
    14.  
    15. Remove the front axle crossmember bracket. Remove the return tube clamp bolt and nut. Remove the pressure tube clamp bolt and nut.
    16.  
    17. Disconnect and plug the return tube connection. Disconnect and plug the pressure hose connection. Discard the O-ring.
    18.  
    19. Disconnect the pinch clamp. Pinch the steering column shaft clip with a pliers, and pull upward on the shaft to disengage the steering column assembly.
      NOTE
      If the steering column shaft is removed accidentally, remove the steering column assembly and be sure to insert the steering column shaft into the steering column.

    20.  
    21. From inside the vehicle loosen the three clips from the body panel, near the steering column to floor hole.
    22.  
    23. Use a transmission jack to hold the crossmember, and then remove the crossmember mounting nuts and bolts. Lower the crossmember with the rear roll stopper, then the stabilizer bar and steering rack.
    24.  
    25. Remove the steering column dash panel cover. Remove the steering rack linkage protector, on the 3.8L engine.
    26.  
    27. Remove the power steering rack bracket. Remove the rack retaining bolts. Remove the assembly from the vehicle.
    28.  

    To install:

    Click image to see an enlarged view

    Fig. Steering gear pinch cover installation- 2004-2005 Galant

    1. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly.
    2.  
    3. When installing the steering column dash panel cover pinch clamp, align the steering column dash panel cover notch -A- with the steering gear lug (arrow -B- and then install the steering column dash panel cover to the steering gear.
      NOTE
      When installing the clock spring be sure that the springs mating marks are properly aligned. If not the steering wheel may not rotate completely during a turn, or the flat cable in the clock spring could be damaged. This would prevent normal SRS operation and possibly cause serious injury to the driver.

    4.  
    5. After aligning the mating surfaces of the clock spring, turn the front wheels to the straight ahead position. Install the clock spring to the column switch.
      NOTE
      Turn the clock spring clockwise fully. Then turn it back approximately 3 ¾ turns counterclockwise to align the mating marks.

    6.  
    7. Continue the installation in the reverse order of the removal procedure.
    8.  
    9. Check and adjust the front end alignment, as required.

      Click image to see an enlarged view

      Fig. Power steering rack and related components-2004-2005 Galant

    10.  


    NOTE
    Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable. Drain the power steering fluid.
    2.  
    3. Remove the driver-s side air bag module. Remove the steering wheel. Remove the column lower cover. Remove the clock spring.
    4.  
    5. Disconnect the front exhaust pipe.
    6.  
    7. Separate the steering rack ends from their mounting.
    8.  
    9. Remove the crossmember. Remove the rear roll stopper.
    10.  
    11. Remove the joint cover grommet. Disconnect and plug the fluid return hose.
    12.  
    13. Disconnect the return tube and remove it. Discard the O-ring.
    14.  
    15. Remove the eye bolt. Remove the pressure hose assembly clamp.
    16.  
    17. Remove the steering rack retaining bolts. Remove the rack from the vehicle.
    18.  

    To install:

    1. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly.
    2.  
    3. To install the joint cover grommet, align the joint cover grommet notch (arrow -A-) with the steering gear lug (arrow -B-). Install the steering joint cover to the steering gear.

      Click image to see an enlarged view

      Fig. Joint cover installation-Lancer and Evolution

    4.  
    5. Continue the installation in the reverse order of the removal procedure.
    6.  
    7. Check and adjust the front end alignment, as required.

      Click image to see an enlarged view

      Fig. Power steering rack and related components-Lancer

    8.  


    NOTE
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clockspring and render SRS system inoperative.

    1. Drain the power steering system.
    2.  
    3. Disconnect the battery negative cable. Raise the vehicle and support safely.
    4.  
    5. Disconnect the Heated Oxygen (HO 2 S) sensor and remove the front exhaust pipe.
    6.  
    7. Properly support the engine.
    8.  
    9. Remove both roll stopper mounting bolts and the four center member installation bolts. Remove the center member.
    10.  
    11. Remove the center member.
      NOTE
      Matchmark the pinion input shaft of the rack to the lower steering column joint for installation purposes.

    12.  
    13. Remove the pinch bolt holding the lower steering column joint to the rack and pinion input shaft.
    14.  
    15. Remove the cotter pins and disconnect the tie rod ends from the steering knuckle.
    16.  
    17. Disconnect the power steering fluid pressure pipe and return hose from the rack fittings.
    18.  
    19. Remove the rack and pinion steering assembly and its rubber mounts from the right side of the vehicle.
    20.  

    To install:

    1. Align the matchmarks of the input shaft and install the rack to the vehicle.
    2.  
    3. Secure the rack using the retainer clamps and bolts. Tighten the bolts to 51 ft. lbs. (70 Nm).
    4.  
    5. Tighten the steering column pinch bolt to 13 ft. lbs. (18 Nm).
    6.  
    7. Using new O-rings, connect the power steering fluid lines to the rack fittings.
    8.  
    9. Install the center member.
    10.  
    11. Install the front exhaust pipe.
    12.  
    13. Connect the HO 2 S sensor.
    14.  
    15. Connect the tie rod ends to the steering knuckles and tighten the castle nuts to 25 ft. lbs. (34 Nm). Install new cotter pins.
    16.  
    17. Install the wheels and connect the negative battery cable.
    18.  
    19. Refill the reservoir and bleed the system.
    20.  
    21. Have a front end alignment performed.

      Click image to see an enlarged view

      Fig. Power steering rack and related components -Mirage

    22.  

    Evolution




    NOTE
    Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable. Drain the power steering fluid.
    2.  
    3. Remove the driver-s side air bag module. Remove the steering wheel. Remove the column lower cover. Remove the clock spring.
    4.  
    5. Remove the front floor carpet. Remove the center bar.
    6.  
    7. Disconnect the lower arm ball joint connection. Disconnect the stabilizer link. Disconnect the lower arm assembly. Remove the shaft cover.
    8.  
    9. Remove the steering shaft assembly and steering gear connecting bolt.
    10.  
    11. Remove the tie rod end and knuckle connection self locking nut.
    12.  
    13. Disconnect the return hose and the return line. Discard the O-ring.
    14.  
    15. Disconnect the high pressure hose connection. Discard the gasket.
    16.  
    17. Remove the rear roll stopper rod connecting bolt.
    18.  
    19. Position a floor jack under the crossmember. Remove the crossmember retaining bolts and remove the crossmember.
    20.  
    21. Remove the engine rear roll stopper rod and engine rear roll stopper rod bracket.
    22.  
    23. Remove the joint cover grommet. Remove the cover assembly.
    24.  
    25. Remove the steering rack mounting bolts. Remove the steering rack from the vehicle.
    26.  
    27. Remove the steering rack retaining bolts. Remove the rack from the vehicle.
    28.  

    To install:

    1. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly.
    2.  
    3. To install the joint cover grommet, align the joint cover grommet notch (arrow -A-) with the steering gear lug (arrow -B-). Install the steering joint cover to the steering gear.
    4.  
    5. Continue the installation in the reverse order of the removal procedure.
    6.  
    7. Check and adjust the front end alignment, as required.

      Click image to see an enlarged view

      Fig. Power steering rack and related components-Evolution

    8.  

    Front Steering Rack




    NOTE
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative.

    1. Disconnect the negative battery cable.
    2.  
    3. Disconnect the front exhaust pipe.
    4.  
    5. If equipped with AWD, remove the transfer case assembly.
    6.  
    7. Remove the bolt holding the lower steering column joint to the rack and pinion input shaft.
    8.  
    9. Remove the cotter pins and disconnect the tie rod ends.
    10.  
    11. Remove the left and right frame members.
    12.  
    13. Remove the stabilizer bar bracket.
    14.  
    15. If equipped with four-wheel steering, disconnect the lines going to the rear pump.
    16.  
    17. Remove the rack and pinion steering assembly and its rubber mounts. Move the rack to the right to remove it from the crossmember.
    18.  

    To install:

    1. Install the rack and mounting bolts. Tighten the bolts to 51 ft. lbs. (70 Nm). When installing the rubber rack mounts, align the projection of the mounting rubber with the indentation in the crossmember. Install the pinch bolt.
    2.  
    3. Connect the pressure and return lines to the rack and to the rear pump, if equipped.
    4.  
    5. Install the frame members and tighten the bolts to 43-51 ft. lbs. (60-70 Nm).
    6.  
    7. Connect the tie rods and install new cotter pins.
    8.  
    9. Install the transfer case and front exhaust pipe.
    10.  
    11. Refill the reservoir and bleed the system.
    12.  
    13. Have a front end alignment performed.
    14.  

    Rear



    1. Disconnect the negative battery cable.
    2.  
    3. Raise the vehicle and support safely.
    4.  
    5. Drain the power steering fluid.
    6.  
    7. Remove the main muffler assembly.
    8.  
    9. Remove the rear shock absorber lower mounting bolts.
    10.  
    11. Using the proper equipment, support the weight of the rear differential. Remove the 2 small crossmember brackets.
    12.  
    13. Remove the large self-locking crossmember mounting nuts on the differential side.
    14.  
    15. Remove the oil line clamp bolts.
    16.  
    17. Remove the pressure tubes.
    18.  
    19. Hold the tie rod ends stationary and remove the tie rod end nuts. Remove the tie rod ends from the trailing arms.
    20.  
    21. Remove the mounting bolts and remove the rear steering gear.
    22.  

    To install:

    1. Secure the unit to the crossmember. Move the power cylinder piston rod over its full stroke to determine its neutral position.
    2.  
    3. Align the tie rod ends with the holes in the trailing arms and install the nuts. Adjust the length of the tie rods with the nuts if necessary. The difference in length between the 2 tie rod ends should not exceed 0.04 in. (1mm). The nuts' torque specification is 42 ft. lbs. (58 Nm).
    4.  
    5. Replace the O-rings and install the pressure tubes. Clamp in place.
    6.  
    7. Install the large self-locking crossmember mounting nuts on the differential side. Tighten to 80-94 ft. lbs. (110-130 Nm).
    8.  
    9. Remove the support equipment.
    10.  
    11. Install the 2 small crossmember brackets.
    12.  
    13. Install the shock mounting bolts.
    14.  
    15. Install the muffler assembly.
    16.  
    17. Refill the reservoir and bleed the system.
    18.  
    19. Have a front end alignment performed.
    20.  

     
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