ION, L-Series, S-Series 1999-2005

Removal & Installation

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  1. Raise and support the vehicle.
  2.  
  3. Remove the front wheel.
  4.  
  5. Loosen the outer tie rod to inner tie rod jam nut.
  6.  
  7. Remove the tie rod to steering knuckle nut and discard.
  8.  
  9. Using the special tool SA91100C, separate the tie rod from the steering knuckle.
  10.  
  11. Remove the outer tie rod from the inner tie rod. Record the number of turns used in removal to aid in the installation.
  12.  
  13. Remove the outer to inner tie rod jam nut and discard.
  14.  

To install:

  1. Thoroughly clean the inner tie rod threads.
  2.  
  3. Install a new outer to inner tie rod jam nut.
  4.  
  5. Thread the outer tie rod onto the inner tie rod using the previously recorded thread count.
  6.  
  7. Install the outer tie rod to the steering knuckle.
  8.  
  9. Install a new outer tie rod nut, and tighten the nut to 18 lb ft+90 degrees (25 Nm+90 degrees).
  10.  
  11. Install the front wheel.
  12.  
  13. Set the toe.
  14.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the front wheel.
  4.  
  5. Loosen the outer tie rod to inner tie rod jam nut.
  6.  
  7. Remove the tie rod to steering knuckle nut and discard.
  8.  
  9. Using the special tool SA91100C, separate the tie rod from the steering knuckle.
  10.  
  11. Remove the outer tie rod from the inner tie rod. Record the number of turns used in removal to aid in the installation.
  12.  
  13. Remove the outer to inner tie rod jam nut and discard.
  14.  

To install:

  1. Thoroughly clean the inner tie rod threads.
  2.  
  3. Install a new outer to inner tie rod jam nut.
  4.  
  5. Thread the outer tie rod onto the inner tie rod using the previously recorded thread count.
  6.  
  7. Install the outer tie rod to the steering knuckle.
  8.  
  9. Install a new outer tie rod nut, and tighten the nut to 18 lb ft+90 degrees (25 Nm+90 degrees).
  10.  
  11. Install the front wheel.
  12.  
  13. Set the toe.
  14.  

Inner Tie Rod



  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the outer tie rod.
  6.  
  7. Remove the steering gear.

    Click image to see an enlarged view

    Fig. Remove the inner tie rod to outer tie rod jam nut. Count the threads for installation

  8.  
  9. Remove the inner tie rod to outer tie rod jam nut. Count the threads for installation.
  10.  
  11. Remove the steering gear boot.
  12.  
  13. Slide the shock damper toward the steering gear.
    NOTE
    The steering gear rack must be held stationary during inner tie rod removal


    NOTE
    Protect the steering gear rack teeth when removing the inner tie rod end

  14.  
  15. Using two wrenches, remove the inner tie rod end from the steering gear.
  16.  

To install:

  1. Remove any old Loctite® from the threads of the rack and inner tie rod.
    NOTE
    The threads must be clean prior to thread locker application. Do not use too much thread locker, only enough to evenly coat the threads.



    Click image to see an enlarged view

    Fig. The threads must be clean prior to thread locker application

  2.  
  3. Apply Loctite 262® or equivalent to the inner tie rod threads.
    NOTE
    The steering gear rack must be held stationary during inner tie rod installation


    NOTE
    Protect the steering gear rack teeth when installing the inner tie rod end

  4.  
  5. Use the special tool SA9209C to install the inner tie rod to the steering gear.
  6.  
  7. Tighten the inner tie rod to 70 ft. lbs. (95 Nm).
  8.  
  9. Slide the shock damper into position.
  10.  
  11. Install the steering gear boot.
  12.  
  13. Install the tie rod jam nut on the inner tie rod end. Turn the nut on the same number of threads recorded in removal.
  14.  
  15. Install the steering gear.
  16.  
  17. Install the outer tie rod.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Set the front toe.
  22.  

Outer Tie Rod



  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Loosen the outer tie rod to inner tie rod jam nut.
  6.  
  7. Remove the outer tie rod to steering knuckle prevailing nut. Discard the nut.
    NOTE
    Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.



    Click image to see an enlarged view

    Fig. Using the special tool SA91100C, separate the tie rod from the steering knuckle

  8.  
  9. Using the special tool SA91100C, separate the tie rod from the steering knuckle.
  10.  
  11. Remove the outer tie rod from the inner tie rod.
  12.  

To install:


NOTE
The threads of the inner tie rod must be clean and free of debris.

  1. Install the outer tie rod to the inner tie rod.
  2.  
  3. Connect the outer tie rod to the steering knuckle.
  4.  
  5. Seat the ball stud taper in to the steering knuckle by tightening the special tool J44015 to 33 ft. lbs. (45 Nm).
    NOTE
    Hold the ball stud from turning during installation of the prevailing nut.

  6.  
  7. Install a new torque prevailing nut to the tie rod ball stud, and tighten the nut to 44 ft. lbs. (60 Nm).
  8.  
  9. Install the tire and wheel.
  10.  
  11. Set the front toe.
  12.  

 
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