Hydraulic Power Steering Gearbox Installation

NOTE: The illustrations show LHD model, RHD model is symmetrical. Before installing the steering gearbox, make sure that no power steering fluid is on the mating surface of the gearbox and front suspension subframe. To prevent the gearbox mounting bolts from loosening after installation, remove the power steering fluid from the mount cushions and bolt holes. Apply a mild soap and water solution to both side of the mount cushion mating surfaces (A). Pass the cylinder of the steering gearbox (B) through the wheelwell opening on the driver's side. Carefully move the steering gearbox toward the passenger's side until the pinion shaft clears the wheelwell opening in the body. |

Rotate the steering gearbox so the pinion shaft (A) points upward. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. Make sure the power steering return line and feed line are routed above the gearbox. |

Remove the vinyl tape from pinion shaft, and install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the valve housing. |

Position the cutout (A) on the mounting cushion (B) as shown, and install it securely on the cylinder of the gearbox. Install the gearbox mounting bracket (C) over the mounting cushion, and loosely install the two flange bolts. |

Install the steering stiffener plate (A) and gearbox mounting bolts on the driver's side of the gearbox, then tighten them to the specified torque. Tighten the flange bolts on the passenger's side of the gearbox to the specified torque alternately in two or more steps. Loosely connect the return line and feed line securely by hand. |

For LHD model, install the feed line holder (A) and return hose (B) on the gearbox mounting bracket (C). Install the feed line holder (D) on the front suspension subframe. Make sure that there is no interference between the feed and return lines and any other parts. | LHD model RHD model

Retighten the return line flare nut (A) to the specified torque. Retighten the feed line flare nut (B) to the specified torque. |

Connect the stabilizer links (A) to the stabilizer bar (B) on the right and left. Install the front suspension subframe driver's side mid mount (C). |

Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms. Install the tie-rod end ball joint nut, and tighten it to the specified torque. Then install the new cotter pin (B), and bend it as shown (C) or (D). |

Install the new cover seal (A) all the way around in the steering joint cover B. Make sure there are no wrinkles in the seal, then install the steering joint cover B. Center the steering rack within its stroke. |

Position the steering column joint (A) so the bolt (B) opposite to the notch (C) is within the range shown. With the rack in the straight ahead driving position, cut the wire (D) and slip the lower end of the steering joint on to pinion shaft (E). |

Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Make sure the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure the steering joint is fully seated. Tighten the steering joint bolt to the specified torque. |

Install the steering joint cover A. Install the front wheel, then set the wheels in the straight ahead position. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about three full turns) until the arrow mark on the label points straight up. Reinstall the steering wheel. Fill the system with power steering fluid, and bleed air from the system. After installation, do the following checks. Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up to the fluid. Check the gearbox for leaks. Do the front toe inspection. Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then if necessary, adjust the front toe by turning the tie-rod ends. |