Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Power Steering Gear

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REMOVAL & INSTALLATION



Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 1 and 2

  1. Remove the coolant reservoir tank from the radiator.
  2.  
  3. Disconnect the steering column lower shaft from the gear box by removing the bolt.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the center link nut and lockwasher holding the Pitman arm to the center link. Using a Pitman arm puller, disconnect the center link from the Pitman arm.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: On power steering models, disconnect the fluid lines from the gear box. A small catch can should be placed beneath the open connection to catch any spilled fluid

  1. Lower the vehicle and place a fluid catch pan under the power steering gear box. Remove the pressure hose from the power steering gear assembly and plug the line.
  2.  
  3. Disconnect the return hose and plug the line.
  4.  
  5. Remove the three power steering gear mounting bolts.
  6.  
  7. Remove the power steering gear.
  8.  
  9. Remove the nut holding the Pitman arm to the power steering box. Place alignment marks on the Pitman arm and steering box. Using a Pitman arm puller, remove the Pitman arm from the steering box.
  10.  

To install:
  1. Align the matchmarks on the Pitman arm and the power steering gear sector shaft. Install the Pitman arm to the gear assembly and tighten the nut to 101-129 ft. lbs. (140-180 Nm).
  2.  
  3. Install the power steering gear assembly on the vehicle, then tighten the mounting bolts to 59-73 ft. lbs. (80-100 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 2: When install the power steering lines, make sure to route and position them as shown

  1. Connect the power steering pressure and return hoses. Using new gaskets, tighten the union bolt for the pressure line to 26 ft. lbs. (35 Nm).
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the center link to the Pitman arm and tighten the nut to 22-50 ft. lbs. (30-70 Nm). Lower the vehicle.
  6.  
  7. Connect the steering column lower shaft to the gear assembly, then tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
  8.  
  9. Install the coolant reservoir tank to the radiator.
  10.  
  11. Refill and bleed the power steering pump.
  12.  

 
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