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Power Steering Gear: Installation

  1. If necessary, install outer tie rods onto inner tie rod threads. As outer tie rods are installed, count out same amount of rotations as were counted on tie rod removal. This will get toe setting somewhat close to specifications before vehicle is aligned at end of this procedure.
  2. Carefully install power steering gear through left wheel opening using the reverse of how it was removed. Use care not to cut tie rod boots on shields as gear is installed  .
    NOTE: When installing steering gear mounting bolts, note driver's side mounting bolt is longer than passenger's side bolt.
  3. Center gear mounting bosses over mounting holes in cradle and install two power steering gear mounting bolts. Tighten mounting bolts to 163 N.m (120 ft. lbs.) torque.
    NOTE: Before installing power steering hoses on power steering gear, wipe clean connections with a lint-free cloth and replace O-rings. Lubricate O-rings using clean power steering fluid.
  4. Install pressure hose into gear port (Figure ). Thread pressure hose tube nut into gear and tighten to 31 N.m (275 in. lbs.) torque.
  5. Install return hose into gear port (Figure ). Thread return hose tube nut into gear and tighten to 31 N.m (275 in. lbs.) torque.
  6. Find power steering gear's center of travel, then match splines inside intermediate shaft extension with that on steering gear shaft. Slide extension onto shaft (Fig 1 ).
  7. Install roll pin fastening intermediate shaft extension to power steering gear shaft as follows (Fig 1 ):
    1. Insert Installer, Special Tool 6831A, extension and steering gear shaft.
    2. Slide roll pin onto Remover shaft.
    3. Thread knurled nut all way onto end of Installer.
    4. While holding Installer head stationary, turn hex nut pulling roll pin into shafts. Stop installing roll pin once it is centered intermediate shaft extension.
    5. Remove tool.
  8. Slide shaft cover down over top of steering gear.
    Fig 1: Installing Roll Pin
    G03572899Courtesy of DAIMLERCHRYSLER CORP.
  9. Install outer tie rods to steering knuckles. Start NEW nut onto stud of each outer tie rod. While holding stud stationary using a socket, tighten nut. Using a crowfoot wrench on a torque wrench, tighten nut to 47 N.m (35 ft. lbs.) torque. Then, tighten nut an additional 1/2 (180°) turn after that torque is met.
  10. Snug tie rod jam nuts on both sides of vehicle. Do not torque at this time. Tighten tie rod jam nuts to 75 N.m (55 ft. lbs.) torque while performing wheel alignment at end of this procedure  .
  11. Install tire and wheel assemblies (Refer to INSTALLATION ). Tighten wheel mounting nuts to 135 N.m (100 ft. lbs.) torque.
  12. Lower vehicle.
  13. Connect negative (-) battery cable on negative battery post.
  14. Remove steering wheel holder.
  15. Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. (Refer to STANDARD PROCEDURE )
  16. Inspect for leaks.
  17. Perform wheel alignment setting toe to specifications. (Refer to STANDARD PROCEDURE )
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