See Figure 1
If your vehicle is equipped with manual steering, it is of the rack and pinion type. The gear input shaft is connected to the steering shaft by a double U-joint. A pinion gear, machined on the input shaft, engages the rack. The rotation of the input shaft pinion causes the rack to move laterally. The rack has tow tie rods whose ends are connected to the front wheels. When the rack moves so do the front wheel knuckles. Toe adjustment is made by turning the outer tie rod ends in or out equally as required.
REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5 and 61984-85 Models
- Disconnect the negative battery cable from the battery. Jack up the front of the car and support it safely on jackstands.
- Turn the ignition switch to the On/Run position. Remove the lower access (kick) panel from below the steering wheel.
- Remove the intermediate shaft bolts at the gear input shaft and at the steering column shaft.
- Spread the slots of the clamp to loosen the intermediate shaft at both ends.
- Remove the cotter pin from each tie rod end.
- Remove the nuts from each tie rod end and discard.
- Separate the outer tie rod ends from the steering knuckle by using a tie rod end remover.
- Remove the rod ends from the tie rod shafts.
- Remove the steering rack mounting brackets and rubber mounting insulators.
- Separate the intermediate shaft from the input shaft.
- With some help, slowly move the steering rack to one side of the vehicle through the tie rod access hole. The rack may have to be twisted to allow the steering rod to clear the hole.
- Position the gear through the splash panel and into the body opening.
- Work the intermediate shaft into the input shaft. Secure with the nut and bolt, but do not tighten at this time.
- Install the steering gear mounting rubber and brackets, tightening to 40-55 ft. lbs. (54-75 Nm).
- Tighten the intermediate shaft and input shaft nut and bolt to 20-37 ft. lbs. (28-50 Nm).
- Rotate the steering wheel so the tie rod ends move back and forth. Connect the tie rods to the spindle and tighten the nuts to 27-32 ft. lbs. (36-43 Nm).
- Install the tie rod ends on to each steering knuckle, using new nuts. Tighten nuts to 27-32 ft. lbs. (36-43 Nm). Install new cotter pins
- Install the lower access panel and secure with the hardware.
- Connect the negative battery cable.
- Turn ignition switch on and check for proper operation.
- Lower vehicle. Have alignment checked.
- Disconnect the negative battery cable.
- Turn the ignition key to the RUN position.
- Remove the access trim panel from below the steering column.
- Remove the intermediate shaft bolts at the rack and pinion input shaft and the steering column shaft.
- Spread the slots enough to loosen the intermediate shaft at both ends. They cannot be separated at this time.
- Raise the vehicle and support it safely.
- Separate the tie rod ends from the steering knuckles, using a suitable tool. Turn the right wheel to the full left turn position.
- Disconnect the speedometer cable at the transaxle on automatic transaxles only.
- Disconnect the secondary air tube at the check valve. Disconnect the exhaust system at the manifold and remove the system.
- Remove the gear mounting brackets and insulators. Keep separated as they are not interchangeable.
- Turn the steering wheel full left so the tie rod will clear the shift linkage during removal.
- Separate the gear intermediate shaft, with an assistant pulling upward on the shaft from the inside of the vehicle.
Care should be taken during steering gear removal and installation to prevent tearing or damaging the steering gear bellows.
- Rotate the gear forward and down to clear the input shaft through the dash panel opening.
- With the gear in the full left turn position, move the gear through the right (passenger side) apron opening until the left tie rod clears the shift linkage and other parts so it may be lowered.
- Lower the left side of the gear assembly and remove from the vehicle.
- Rotate the input shaft to a full left turn stop. Position the right wheel to a full left turn.
- Start the right side of the gear through the opening in the right apron. Move the gear in until the left tie rod clears all parts so it may be raised up to the left apron opening.
- Raise the gear and insert the left side through the apron opening. Rotate the gear so the joint shaft enters the dash panel opening.
- With an assistant guiding the intermediate shaft from the inside of the vehicle, insert the input shaft into the intermediate shaft coupling. Insert the intermediate shaft clamp bolts finger-tight. Do not tighten at this time.
Install the gear mounting insulators and brackets in their proper places. Ensure the flat in the left mounting area is parallel to the dash panel. Tighten the bracket bolts to 40-55 ft. lbs. (54-75 Nm) in the sequence as described below:
- Tighten the left (driver's side) upper bolt halfway.
- Tighten the left side lower bolt.
- Tighten the left side upper bolt.
- Tighten the right side bolts.
- Do not forget that the right and left side insulators and brackets are not interchangeable side to side.
- Attach the tie rod ends to the steering knuckles. Tighten the castellated nuts to 27-32 ft. lbs. (36-43 Nm), then tighten the nuts until the slot aligns with the cotter pin hole. Insert a new cotter pin.
- Install the exhaust system. Install the speedometer cable, if removed.
- Tighten the gear input shaft to intermediate shaft coupling clamp bolt first. Then, tighten the upper intermediate shaft clamp bolt. Tighten both bolts to 20-37 ft. lbs. (28-50 Nm).
- Install the access panel below the steering column. Turn the ignition key to the OFF position.
- Check and adjust the toe. Tighten the tie rod end jam nuts, check for twisted bellows.
- Lower vehicle. Have toe alignment check. Road test the vehicle, checking for correct operation.
Tie Rod Articulation Effort
The yoke clearance is not adjustable except when overhauling the steering gear assembly. Pinion bearing preload is not adjustable. Tie rod articulation is preset and is not adjustable. If articulation is out of specification, replace the tie rod assembly. To check tie rod articulation, proceed as follows:
- With the tie rod end disconnected from the steering knuckle, loop a piece of wire through the hole in the tie rod end stud.
- Insert the hook of spring scale T74P-3504-Y or equivalent, through the wire loop. Effort to move the tie rod after initial breakaway should be 0.7-5.0 lbs.
Do not damage tie rod neck.
- Replace ball joint/tie rod assembly if effort falls outside this range. Save the tie rod end for use on the new tie rod assembly.
Rack Preload/Support Yoke
- Remove the rack and pinion assembly from the vehicle and mount it in a suitable vice.
- Loosen the locknut.
- Tighten the adjusting bolt using yoke adjustment adapter T90P-3504-JH in the yoke plug to 8.7 inch lbs. (1 Nm), then loosen the adjusting bolt 10-40 degrees from that position.
- Measure the pinion turning torque using pinion shaft adapting tool T86P-3504-K. The correct torque at the neutral position plus or minus 90 degrees should be 9-12 inch lbs. (1.0-1.3 Nm). At any other position the torque should be 14.7 inch lbs. (1.6 Nm) or less.
- If the pinion torque is not within specification, re-adjust the adjusting bolt to achieve the correct pinion torque. Tighten the adjusting bolt locknut.