REMOVAL & INSTALLATION
See Figure 1
- Remove the intermediate shaft cover.
- Loosen the upper pinch bolt. Remove the lower pinch bolt at the pinion shaft.
- Raise and safely support the vehicle. Remove the wheel assemblies.
- Remove both tie rod ends from the steering knuckles and the left inner tie rod from the rack.
- Remove the steering gear-to-body attaching nuts and the rack and pinion assembly from the vehicle.
- Install the rack and pinion assembly to the vehicle and tighten the steering gear-to-body attaching nuts.
- Install both tie rod ends to the steering knuckles and the left inner tie rod to the rack.
- Install the wheel assemblies. Safely lower the vehicle.
- Install the lower pinch bolt at the pinion shaft and tighten the upper pinch bolt.
- Install the intermediate shaft cover.
See Figures 2, 3 and 4
- Place the steering unit a vise.
- Remove the tie-rod end.
- Remove the boot.
- Straighten the bent part of the locking washer between the inner tie-rod and the rack. A new washer should be used when reassembled.
- Remove the tie-rod from the rack.
- Loosen the adjusting plug nut, remove the spring and plunger.
- Remove the pinion seal.
- Remove the snapring.
- Rotate the pinion gear shaft until the pinion flat is parallel or aligned with the rack. Then measure the length of the rack exposed from the assembly. This measurement will be used to reassemble the unit.
- Remove the pinion assembly. A plastic hammer can be used when withdrawing the pinion assembly.
- Remove the rack. Be careful not to damage the housing while remove the rack.
- With the steering housing mounted in a vise, install the rack into the housing.
- Set the rack to the dimension recorded during removal. Install the pinion with the flat side parallel to the rack.
- Install the pinion retaining snapring.
- Lubricate the plunger well and install. Install the spring, adjusting plug and the locknut.
- Tighten the adjusting plug to 4 ft. lbs. (5 Nm).
- Repeat step 5.
- Back off the adjusting plug up to 25 degrees.
- Install the pinion shaft seal. Tighten the locknut snug.
- Measure the pinion shaft preload. If the preload is not between 0.4-0.9 ft. lbs. (0.6-1.3 Nm), loosen the locknut and readjust the plug torque. When the acceptable preload is achieved, apply liquid thread lock to the locknut and tighten the locknut to 49 ft. lbs. (66 Nm).
- Install the inner tie rod and a new locking washer to the rack end. Tighten it to 65 ft. lbs. (88 Nm). Protect the rack from the vise. Stake the locking washer to the flat of the inner tie-rod. Apply grease to the inner surface of the small opening in the boot.
- Install a new boot over the inner tie-rod.
- Install the tie-rod nut and attach the tie-rod end.
- Adjust the tie-rod so the length from the outer side of the boot clamp to the outer side of the locknut is 7.5 in. (190.4 mm).
- Tighten the tie-rod locking nut to 40 ft. lbs. (54 Nm).
- Install the boot clamp and wire.