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Home >> Mazda >> 2002 >> B4000 Base, Automatic >> Repair and Diagnosis >> Steering >> Power Steering >> Steering Gear Removal/Installation >> 4X4 Installation

4X4 Installation

  1. Using the special tool, install new seals on the power steering return hose and power steering pressure hose.
    Fig 1: Installing Seals On The Power Steering Hoses
    G02673407Courtesy of MAZDA MOTORS CORP.
    2. NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached.

    Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in tie-rod boots.

    NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle.
  2. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.
  3. Install the steering gear into the RH opening of the crossmember.
    Fig 2: Installing Steering Gear
    G02673408Courtesy of MAZDA MOTORS CORP.
  4. Move the steering gear as far to the RH side of the vehicle as possible.
    Fig 3: Moving Steering Gear To Right Side
    G02673409Courtesy of MAZDA MOTORS CORP.
  5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position.
    Fig 4: Moving Left Front Wheel Spindle Tie-Rod Into The Opening
    G02673410Courtesy of MAZDA MOTORS CORP.
  6. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously.
  7. Rotate the steering gear control valve housing toward the rear of the vehicle.
    Fig 5: Rotating Steering Gear Control Valve Housing
    G02673411Courtesy of MAZDA MOTORS CORP.
  8. Install the steering gear to crossmember insulator bushings as shown.
    1. The large end of the metal sleeve must be positioned downward.
    2. Check that the mounting surfaces on the crossmember are clean and free of foreign material.
    Fig 6: Installing Steering Gear To Crossmember Insulator Bushings
    G02673412Courtesy of MAZDA MOTORS CORP.
  9. Install the steering gear to crossmember washers and stud bolts.
    1. The dished side of the washer faces downward.
    Fig 7: Installing Steering Gear To Crossmember Washers & Stud Bolts
    G02673413Courtesy of MAZDA MOTORS CORP.
    10. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
    Fig 8: Installing Steering Gear To Crossmember Stud Bolt Nuts
    G02673414Courtesy of MAZDA MOTORS CORP.
    CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result.
  10. Install the nuts.
  11. Install the lines and tighten the nut.
    Fig 9: Installing Lines & Retainer Nut
    G02673415Courtesy of MAZDA MOTORS CORP.
    12. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information see CLOCKSPRING .
    Fig 10: Installing Lower Steering Column Pinch Bolt
    G02673416Courtesy of MAZDA MOTORS CORP.
  12. Connect the intermediate shaft to the steering gear input shaft. Install a new lower steering column pinch bolt.
  13. Install the power steering fluid cooler. See POWER STEERING FLUID COOLER REMOVAL/INSTALLATION .
  14. Install the front stabilizer bar. See BAR AND LINK .
    15. NOTE: Orientate the front stabilizer bar as noted during removal.
    Fig 11: Installing Left Tie-Rod End
    G02673417Courtesy of MAZDA MOTORS CORP.
  15. Install the LH tie-rod end on the front wheel spindle tie-rod.
    1. Rotate the tie-rod end the number of turns recorded during removal.
  16. Position the tie-rod ends on the steering knuckles. Install the castellated nuts and new cotter pins.
    1. Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals.
    Fig 12: Installing Tie-Rod Ends On Steering Knuckles
    G02673418Courtesy of MAZDA MOTORS CORP.
  17. Tighten the tie-rod end jam nuts.
    Fig 13: Tightening Tie-Rod End Jam Nuts
    G02673419Courtesy of MAZDA MOTORS CORP.
  18. Position the air deflector, and install the retaining screws.
    Fig 14: Installing Air Deflector
    G02673420Courtesy of MAZDA MOTORS CORP.
  19. Install the front wheel and tire assemblies, see WHEEL & TIRE REMOVAL/INSTALLATION .
  20. Fill, purge and leak check the system.
  21. Check and, if necessary, adjust the wheel alignment.
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