Tracker 2000-2004

Removal & Installation

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  1. Turn the key to the LOCK position and remove the key.
    NOTE
    The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become un-centered which will cause damage to the coil assembly.

  2.  
  3. Lock the steering column in the straight ahead position.
  4.  
  5. Attempt to turn the steering wheel in order to verify the steering column is locked.
  6.  
  7. Disable the supplemental inflatable restraint system.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the skid plate, if equipped.
  12.  
  13. Remove the left outer tie rod nut from the knuckle.
  14.  
  15. Remove the tie rod end from the knuckle.
  16.  
  17. Remove the right outer tie rod nut from the knuckle.
  18.  
  19. Remove the tie rod end from the knuckle.
  20.  
  21. Place a drain pan or a suitable container under the steering gear.
    NOTE
    The first design banjo bolt style fitting utilizes 2 gaskets. The second design flare nut style fitting utilizes seals.

  22.  
  23. Remove the power steering gear inlet hose fitting from the power steering gear.
  24.  
  25. Remove the power steering gear inlet hose and the 2 gaskets, if equipped, from the steering gear.
  26.  
  27. Loosen the hose clamp and remove the power steering fluid reservoir hose from the steering gear.
  28.  
  29. Plug the hoses in order to prevent the fluid from escaping.
  30.  
  31. Using paint, place match marks on the lower steering shaft and on the steering gear housing.
  32.  
  33. Remove the clamp bolt from the lower steering shaft.
  34.  
  35. Disconnect the lower steering shaft from the steering gear.
  36.  
  37. Using paint, place match marks on the pinion shaft and on the steering gear housing.
    NOTE
    Do NOT disassemble the power steering gear.

  38.  
  39. Remove the 4 steering gear mounting bolts.
  40.  
  41. Remove the steering gear with the insulators and the brackets from the vehicle.
  42.  
  43. Remove the 2 brackets from the steering gear.
  44.  
  45. Remove the 2 insulators from the steering gear.
  46.  
  47. Place a match mark on the left inner tie rod thread and the right inner tie rod thread, indicating the positions of the tie rod lock nuts.
  48.  
  49. Loosen the 2 tie rod lock nuts and remove the 2 outer tie rod ends from the inner tie rods.

    Click image to see an enlarged view

    Fig. Steering gear centering marks

  50.  

To install:


NOTE
If you are replacing the steering gear, measure the location of the match mark made on the original inner tie rods. Use this measurement in order to make a corresponding mark on the replacement steering gear.

  1. Using paint, place match marks on the inner tie rods in order to position the 2 lock nuts during assembly.
  2.  
  3. Install the 2 tie rod lock nuts to the inner tie rods. Position the lock nuts at the match marks. Do NOT tighten the lock nuts.
  4.  
  5. Install the 2 outer tie rod ends to the inner tie rods. Do NOT tighten the outer tie rod ends or the lock nuts.
    NOTE
    If you are replacing the steering gear, measure the location of the match mark made on the pinion shaft and the steering gear housing. Make corresponding marks on the replacement steering gear in order to set the rack in the straight-ahead position.

  6.  
  7. Place match marks on the pinion shaft and on the steering gear housing.
  8.  
  9. Verify the steering wheel and the front wheels are in the straight-head position.
  10.  
  11. Install the 2 insulators to the steering gear.
  12.  
  13. Install the 2 brackets to the 2 insulators.
    NOTE
    Do NOT tighten the bracket bolts before tightening the lower steering shaft clamp bolt.

  14.  
  15. Install the steering gear and the 4 bolts to the vehicle.
  16.  
  17. Align the match mark on the pinion shaft with the match mark on the steering gear housing.
  18.  
  19. Connect the lower steering shaft to the steering gear. Install the clamp bolt to the lower steering shaft. Tighten the bolt to 18 ft. lbs. (25 Nm).
  20.  
  21. Tighten the mounting bolts on the steering gear. Tighten the bolts to 40 ft. lbs. (55 Nm).
  22.  
  23. Remove the plugs from the disconnected pipes and hoses.
  24.  
  25. Install the power steering fluid reservoir hose and the hose clamp to the steering gear.
    NOTE
    The first design banjo bolt style fitting uses 2 gaskets. The second design flare nut style fitting uses seals. The first design power steering components are not interchangeable with the second design power steering components.

  26.  
  27. Install the following components to the steering gear:

    The power steering gear inlet hose
     
    The 2 gaskets, if equipped
     
    The power steering gear inlet hose fitting
     

  28.  
  29. Tighten the fitting to 25.5 ft. lbs. (35 Nm).
  30.  
  31. Install the left outer tie rod end to the knuckle.
  32.  
  33. Install a NEW nut to the ball stud. Tighten the nut to 31.5 ft. lbs. (43 Nm).
  34.  
  35. Install the right outer tie rod end to the knuckle.
  36.  
  37. Install a NEW nut to the ball stud. Tighten the nut to 31.5 ft. lbs. (43 Nm).
  38.  
  39. Install the skid plate, if equipped.
  40.  
  41. Lower the vehicle.
  42.  
  43. Add fluid to the reservoir.
  44.  
  45. Bleed the power steering system.
  46.  
  47. Enable the SIR.
  48.  
  49. Measure the wheel alignment.
  50.  
  51. Adjust the front toe, if necessary.
  52.  
  53. Tighten the tie rod lock nuts. Tighten the nuts to 47 ft. lbs. (65 Nm).
  54.  

 
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