Astro, Safari 1997-2005

Removal & Installation

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2wd Models




NOTE
The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove lower fan shroud.
  4.  
  5. Remove intermediate shaft pinch bolt from the intermediate shaft coupling.
  6.  
  7. Disconnect intermediate shaft from the power steering gear.
  8.  
  9. Place a drain pan under the steering gear.
    NOTE
    Cap or tape the ends of the hoses and the gear fittings to prevent spillage and contamination.

  10.  
  11. Disconnect power brake booster outlet hose from the steering gear.
  12.  
  13. Disconnect power steering cooler pipe from the steering gear.
  14.  
  15. Raise the vehicle.
  16.  
  17. Remove pitman arm from the steering gear.
  18.  
  19. Remove steering gear mounting bolts and washers.
  20.  
  21. Remove steering gear from the vehicle.
  22.  

To install:

  1. Install steering gear to the vehicle.
  2.  
  3. Install steering gear washers and bolts. Tighten to 55 ft. lbs. (75 Nm).
  4.  
  5. Install pitman arm to the steering gear.
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect power steering cooler pipe to the steering gear and tighten to 20 ft. lbs. (27 Nm).
  10.  
  11. Connect power brake booster outlet hose to the steering gear and tighten the fitting to 20 ft. lbs. (27 Nm).
  12.  
  13. Remove the drain pan from under the vehicle.
  14.  
  15. Connect intermediate shaft to the power steering gear.
  16.  
  17. Install intermediate shaft pinch bolt to the intermediate shaft coupling and tighten to 30 ft. lbs. (41 Nm).
  18.  
  19. Install the lower fan shroud.
  20.  
  21. Bleed the power steering system

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear mounting-2002 vehicle shown, others similar

  22.  

4wd Models



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove tire and the wheel.
  6.  
  7. Remove pitman arm-to-connecting rod retaining nut.
  8.  
  9. Remove pitman arm from the connecting rod.
  10.  
  11. Remove stabilizer links.
  12.  
  13. Rotate the stabilizer shaft downward.
  14.  
  15. Lower the vehicle.
  16.  
  17. Install steering column lock pin no. J 42640 into the lower steering column trim cover in order to lock the steering column.
  18.  
  19. Remove lower fan shroud.
  20.  
  21. Remove intermediate shaft-to-power steering gear pinch bolt.
  22.  
  23. Remove intermediate shaft from the power steering gear.
  24.  
  25. Place a drain pan under the vehicle.
  26.  
  27. Disconnect power steering cooler hose from the power steering gear.
  28.  
  29. Remove hydraulic brake booster from the power steering gear.
  30.  
  31. Raise the vehicle.
  32.  
  33. Remove power steering gear mounting bolts, then lower the vehicle.
  34.  
  35. Remove power steering gear.
  36.  
  37. Remove pitman arm from the power steering gear.
  38.  

To install:

  1. Install pitman arm to the power steering gear.
  2.  
  3. Install power steering gear to the vehicle.
  4.  
  5. Install pitman arm to the connecting rod.
  6.  
  7. Using the aid of an assistant, position the power steering gear to the frame and install the power steering mounting bolts. Tighten the power steering mounting bolts to 106 ft. lbs. (143 Nm).
  8.  
  9. Connect power brake booster outlet hose to the power steering gear and tighten to 20 ft. lbs. (27 Nm).
  10.  
  11. Connect power steering cooler hose to the power steering gear and tighten to 20 ft lbs. (27 Nm).
  12.  
  13. Install intermediate shaft to the power steering gear.
  14.  
  15. Install intermediate shaft to power steering gear pinch bolt and tighten to 30 ft. lbs. (41 Nm).
  16.  
  17. Install lower fan shroud.
  18.  
  19. Remove the lock pin from the steering column.
  20.  
  21. Install pitman arm-to-connecting rod retaining nut and tighten to 48 ft. lbs. (62 Nm).
  22.  
  23. Rotate the stabilizer shaft to the correct position.
  24.  
  25. Install stabilizer links.
  26.  
  27. Install tire and the wheel.
  28.  
  29. Lower the vehicle.
  30.  
  31. Bleed the power steering system.
  32.  

 
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