Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Manual Steering Gear

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REMOVAL & INSTALLATION



Samurai Models
  1. Remove the steering shaft coupler bolt, then disconnect the coupler from the gear.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and support the vehicle safely.
  4.  
  5. Remove the radiator under cover and disconnect the Pitman arm from the drag link.
  6.  
  7. Disconnect the steering damper from the Pitman arm.
  8.  
  9. Support the steering gear and remove the mounting bolts.
  10.  
  11. Remove the steering gear from the vehicle.
  12.  

To install:
  1. Install the steering gear in the vehicle and tighten the mounting nuts to 51-65 ft. lbs. (70-1 Nm).
  2.  
  3. Install the steering damper to the Pitman arm, then tighten the nut to 30 ft. lbs. (40 Nm).
  4.  
  5. Connect the drag link to the Pitman arm, and tighten the nut to 50 ft. lbs. (70 Nm).
  6.  
  7. Install the radiator under cover.
  8.  
  9. Connect the steering coupler to the steering box, and tighten the bolt to 15-21 ft. lbs. (20-30 Nm).
  10.  
  11. Lower the vehicle.
  12.  

Sidekick and Tracker Models

See Figures 1, 2, 3 and 4

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the lower skid plate.
  4.  
  5. Disconnect the steering lower shaft mounting bolts.
  6.  
  7. Using special tool J2207 or equivalent, disconnect the center link end from the Pitman arm.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the lower steering shaft mounting bolt and disconnect the shaft from the gear box



Click image to see an enlarged view

Fig. Fig. 2: Remove the center link-to-Pitman arm attaching nut and, using a tie rod end remover, press out the link from the arm

  1. Remove the 3 steering gear box mounting bolts.
  2.  
  3. Disconnect the steering lower shaft joint and remove the steering gear.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the three steering gear box attaching bolts and remove the box from the vehicle

  1. If replacing the steering gear, remove the nut connecting the Pitman arm to the steering gear. Use a Pitman arm puller to remove the Pitman arm from the steering gear.
  2.  

To install:
  1. Connect the Pitman arm to the steering gear, then install the nut. Tighten the nut to 101-129 ft. lbs. (140-180 Nm).
  2.  
  3. Install the steering gear box by connecting to the lower shaft joint.
  4.  

Align the flat part of the steering gear worm shaft with the bolt hole of the lower shaft joint.

  1. Install the steering gear box mounting bolts, then tighten them to 51-72 ft. lbs. (70-100 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 4: When installing the steering gear box, note the position of the guide bolt

  1. Attach the center link to the Pitman arm, then tighten the nut to 22-50 ft. lbs. (30-70 Nm).
  2.  
  3. Connect the lower steering shaft mounting bolts, then tighten them to 15-22 ft. lbs. (20-30 Nm).
  4.  
  5. Install the lower skid plate.
  6.  
  7. Lower the vehicle.
  8.  

 
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