Installation Procedure
Power Steering Assist Motor Seal (1) @ Power Steering Assist Motor - Install NEW
- Power Steering Assist Motor (2) - Install
- CAUTION:
Steering Gear Bolt (1) - Install NEW and tighten [4x] - Fastener Specifications
Connect the electrical connectors. (1)
- Using a digital scale, weigh the NEW electric belt drive rack and pinion steering gear belt. Record the weight and use the chart to determine the tension of the electric belt drive rack and pinion steering gear belt. Refer to the Belt Tension Table for proper belt tension specification.
Electric Belt Drive Rack and Pinion Steering Gear Belt (1) - Install NEW
- NOTE:
With the steering linkage inner tie rods removed, there is no stop on the end of the steering rack travel.
Install an appropriate tool (1) on the input shaft (2) and rotate the input shaft as close to end to end travel as possible 3 times to manually break in the electric belt drive rack and pinion steering gear belt.
- Ensure the electric belt drive rack and pinion steering gear rotates freely.
Move the steering rack to centered position. The center position can be found by taking a measurement of the distance (a) from the end of the steering gear housing to the end of the steering gear rack (1). This measurement should be 61.1 mm (2.4 in).
To adjust the belt tension, loosen the steering gear idler pulley (4) and use the tool installed to adjust the belt tension as necessary. Tighten the steering gear idler pulley (4) when taking measurements.
- Install the CH-53104 Steering Gear Idler Pulley Holder (2).
- Install and tighten the 2 steering gear bolts (3) that were saved from the removal steps.
- Install an appropriate sized C-clamp (1) with a rubber pad on the tightening surface to tighten the steering gear idler pulley to the correct specification.
- Place the body of the GE-50576-A Acoustic Belt Tension Tester on a flat surface.
Position the microphone of the GE-50576-A Acoustic Belt Tension Tester (1) at the outboard location of the electric belt drive rack and pinion steering gear belt (2).
- Use an allen wrench or finger to strum the steering gear belt at the center location between the two pulleys three times to get an average belt tension reading.
- Record the average reading from the outboard frequency test.
Position the microphone of the GE-50576-A Acoustic Belt Tension Tester (1) at the inboard location of the electric belt drive rack and pinion steering gear belt (2).
- Use an allen wrench or finger to strum the steering gear belt at the center location between the two pulleys three times to get an average belt tension reading.
- Record the average reading from the inboard frequency test.
- Find the average of the inboard and outboard measurements and compare to the chart. If the frequency is within specification, continue. If not, repeat steps 14 - 20 until accurate frequency specification is achieved.
- Apply the final torque for the steering gear idler pulley before removing the tools. Fastener Specifications
- Remove the C-clamp used to tighten the idler pulley.
- Confirm the inboard and outboard measurements are still within specification. If not, repeat steps 15 - 21 until accurate frequency specification is achieved.
- Remove the GE-50576-A Acoustic Belt Tension Tester.
- Remove and DISCARD the 2 steering gear bolts used during the belt tension procedure.
- Remove the CH-53104 Steering Gear Idler Pulley Holder.
Power Steering Assist Motor Seal (3) @ Steering Gear Housing Cover - Install NEW
- Steering Gear Housing Cover (2) - Install
- Steering Gear Bolt (1) - Install NEW and tighten [6x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Steering Linkage Inner Tie Rod- Left Side and Right Side (1) - Install [2x]
- CAUTION:
Holding the steering gear rack bar with anything other than a non-serrated adjustable wrench will cause damage to the steering gear.
NOTE:Left side shown, right side similar.
Cover the electric belt drive rack and pinion steering gear bar (2) with a clean shop towel.
- Hold the electric belt drive rack and pinion steering gear bar (2) with a non-serrated adjustable wrench.
- Using a universal inner tie rod wrench, tighten the left and right side steering linkage inner tie rods (1). Fastener Specifications
- NOTE:
Left side shown, right side similar.
Position a NEW left and right side steering gear boot clamp-inner (1) on the left and right side steering gear boots (2).
- NOTE:
Left side shown, right side similar.
Steering Gear Boot- Left Side and Right Side (1) - Install [2x]
- NOTE:
Left side shown, right side similar.
Steering Gear Boot Clamp- Inner- Left Side and Right Side (1) - Tighten [2x]- use CH-22610 Keystone Clamp Pliers (2)
- NOTE:
Left side shown, right side similar.
Steering Gear Boot Clamp- Outer- Left Side and Right Side (1) - Install [2x]
- NOTE:
Left side shown, right side similar.
Install the left and right side steering linkage inner tie rod nuts (2) until aligned with the previously placed matched mark on the steering linkage inner tie rod.
- Steering Linkage Outer Tie Rod- Left Side and Right Side (1) - Install [2x]
Intermediate Steering Shaft (2) - Install
- If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Remove loose debris from internal and external threads using compressed air.
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
- Intermediate Steering Shaft Lower Bolt (1) - Install and tighten - Fastener Specifications
Electric Belt Drive Rack and Pinion Steering Gear (3) - Install
- Steering Gear Bolt- Upper (1) - Install and tighten [2x] - Fastener Specifications
- Steering Gear Bolt - Lower (2) - Install [2x]
- Steering Gear Nut (4) - Install [2x]
- Steering Gear Bolt - Lower (2) - Tighten [2x] - Fastener Specifications
Steering Linkage Outer Tie Rod Nut (1) - Install and tighten [2x] - Fastener Specifications
Instal the hose retainers as necessary.
- Connect the electrical connectors and install the wiring harness retainers as necessary.
- Install the front electric drive transmission module assembly to the front cradle (1).
- NOTE:
Some components not shown for graphic clarity.
Rear Drive Motor Rear Mount Bolt (2) - Install NEW [2x]
- Drive Motor Mount Nut (1) - Install
- Rear Drive Motor Rear Mount Bolt (2) - Tighten [2x] - Fastener Specifications
Drive Motor Rear Mount Bracket Bolt (1) - Install NEW and tighten [6x] - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Output Shaft Seal- Left Side and Right Side (1) - Install NEW [2x]
- Output Shaft Retaining Ring- Left Side and Right Side (2) - Install NEW [2x]
Front Wheel Drive Shaft Washer- Left Side and Right Side (1) - Install [2x]
- Apply a thin coating of grease to the splines of the front wheel drive half shafts and front electric drive transmission module output shafts. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Left side shown, right side similar.
Front Wheel Drive Half Shaft- Left Side and Right Side (1) - Install [2x]
- NOTE:
Left side shown, right side similar.
Front Wheel Drive Shaft Nut- Left Side and Right Side (1) - Install NEW and tighten [2x] - Fastener Specifications
Remove the following tools from the front electric drive transmission module:
- EN-52059 Engine Support Fixture Adapter Bolts - M10 (1)
- EN-36857 Engine Lift Bracket (2)
- Overhead Hoist Hooks (3)
- NOTE:
Left side shown, right side similar.
Battery Negative Cable Extension Cable- Left Side and Right Side (2) - Install [2x]
- Battery Negative Cable Ground Bolt- Left Side and Right Side (1) - Install and tighten [2x] - Fastener Specifications
Install the front electric drive transmission module positive and negative cable (2) to the wiring harness bracket.
- Battery Positive Cable Channel Nut (1) - Install and tighten [2x] - Fastener Specifications
Generator Control Module Coolant Pump Bracket Bolt- Right Side (1) - Install and tighten [2x] - Fastener Specifications
Generator Control Module Coolant Pump Bracket Bolt- Left Side (1) - Install and tighten [2x] - Fastener Specifications
Engine Wiring Harness Bolt (3) - Install and tighten - Fastener Specifications
- Engine Wiring Harness Ground Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Engine Wiring Harness Retainer (1) @ Front Cradle - Install [3x]
Install the air conditioning condenser, engine cooling fan and engine radiator as an assembly (1) to the front cradle.
- Connect the electrical connectors and install the wiring harness retainers as necessary.
Drive Motor Control Module Radiator Outlet Hose (2) @ Engine Radiator - Install
- Retainer (1) - Engage
Drive Motor Control Module Radiator Inlet Hose (1) - Install
- Retainer (2) - Engage
Front Cradle (2) - Install - Front Cradle Removal and Installation
- Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation
- Measure and adjust the front toe. Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment
- Calibrate the power steering control module. Power Steering Control Module Calibration
Install a rubber pad to the tightening surface to prevent damage to the idler pulley.
NEVER hold the tester by hand while taking measurements or the readings will be inaccurate.
Never use a sharp object to strum the belt as belt damage may occur. If the belt is damaged, the electric belt drive rack and pinion steering gear will need to be replaced.
Strum the electric belt drive rack and pinion steering gear belt as close as possible to the center position between the two electric belt drive rack and pinion steering gear pulleys to achieve the most accurate readings.
When testing frequency, there should be a difference of 10 - 40 Hz between the inboard and outboard measurements. If you are not seeing a difference in the measurements, rotate the electric belt drive rack and pinion steering gear 90 degrees and try again.
Increasing the belt tension increases the frequency. Reducing the belt tension reduces the frequency.
Refer to Component Fastener Tightening Caution .
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.