Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Power Steering Gear

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REMOVAL & INSTALLATION



Except 929 and RX-7
  1. Raise the vehicle and support it on axle stands. Remove the bolt attaching the steering shaft universal joint to the gearbox.
  2.  
  3. Remove the cotter pin from the tie rod end ballstud and then loosen the nut. Press the ballstud out of the steering knuckle with a vice-like tool such as MB991113 or equivalent. Remove the nut and pull the stud out of the knuckle.
  4.  
  5. Place a drain pan under the gearbox and the disconnect the pressure and return hose connectors with a flare nut wrench, and allow the fluid to drain.
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  7. Unbolt and remove the two bolts in each gearbox mounting clamp with a ratchet and long extension, working from the engine compartment side.
  8.  
  9. Pull the gearbox out the right side of the vehicle, working carefully to keep the unit from being damaged.
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  11. Install in reverse order, noting the following points: Make sure the rubber mounting sleeve is positioned so the flat side faces the crossmember and apply adhesive to the rounded side so the slit will not open up when the unit is clamped in place. Torque the gearbox mounting bolts to 43-58 ft. lbs. (58-79 Nm) and the ballstud nut to 17 ft. lbs. (23 Nm), then turn farther to align castellations with the cotter pin hole and install a new cotter pin.
  12.  
  13. Have someone keep the power steering reservoir filled with Dexron®II automatic transmission fluid as you perform this procedure. Disconnect the high tension wire and use the starter to spin the engine while you turn the steering wheel from stop-to-stop several times. Lower the vehicle, reconnect the ignition wire and start the engine, letting it idle. Have someone continue to turn the steering wheel from lock-to-lock continuously until there are no more bubbles in the power steering fluid reservoir and the level remains constant as the wheel is turned back and forth. Stop the procedure. Make sure the fluid reservoir is full. Check for leaks. Adjust the toe-in.
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929
  1. Disconnect the negative battery cable. Raise and support the vehicle safely. Remove the wheel and tire assemblies.
  2.  
  3. Remove the lower steering gear assembly cover. Remove the steering damper.
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  5. Place a drain pan under the gearbox and the disconnect the pressure and return hose connectors with a flare nut wrench, and allow the fluid to drain. Disengage the electrical wire from the control valve assembly. Remove the control valve assembly with the pressure switch attached.
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  7. Separate the tie rod ends from their mountings. Remove the steering gear from the vehicle.
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  9. To install, maneuver the steering gear assembly into position, then install the clamp mounting bolts to hold it in place. Torque the mounting bolts to 23-34 ft. lbs. (31-46 Nm).
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  11. Connect the tie rod ends to the steering knuckle and torque the ball stud nut to 22-33 ft. lbs. (30-45 Nm). Install a new cotter pin.
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  13. Bolt the control valve/pressure switch assembly into place and engage the electrical wires.
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  15. Connect the pressure and return pipes to the gear housing and the control valve assembly. Install new copper crush washers where the pipes connect to the control valve.
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  17. Install the lower cover and lower the vehicle. Bleed the system.
  18.  

RX-7
  1. Disconnect the battery cables and remove the battery and cover. Drain the cooling system.
  2.  
  3. Remove the radiator cooling fan, shroud and radiator.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Place a drain pan under the gearbox and the disconnect the pressure and return hose connectors with a flare nut wrench, and allow the fluid to drain.
  8.  
  9. Disconnect the front stabilizer bar from the steering rack assembly.
  10.  
  11. Remove the cotter pin and tie rod end castle nut. Separate the tie rod from the steering knuckle.
  12.  
  13. Remove the pinch bolt at the steering column U-joint.
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  15. Remove the steering rack mounting bolts and power steering hoses.
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  17. Remove the rack and separate the steering column U-joint.
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  19. Installation is the same as described for 1986-89 RX-7s with manual steering gear. Bleed the system as described in the following portion of this section. Check the front end alignment.
  20.  

 
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