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Home >> Mazda >> 2004 >> B4000 Base, Automatic >> Repair and Diagnosis >> Steering >> Power Steering >> Power Steering System >> 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: Locating Seal Position Of Power Steering Return Hose & Power Steering Pressure Hose
    G01936474Courtesy of MAZDA MOTORS CORP.
    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.

  2. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.
    NOTE:
    • Make sure the steering gear control valve housing is turned toward the front of the vehicle.
  3. Install the steering gear into the RH opening of the crossmember.
    Fig 2: Installing Steering Gear Into RH Opening Of Crossmember
    G01936475Courtesy of MAZDA MOTORS CORP.
  4. Move the steering gear as far to the RH side of the vehicle as possible.
    Fig 3: Placing Steering Gear To RH Side Of Vehicle
    G01936476Courtesy 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 LH Front Wheel Spindle Tie-Rod & Positioning Steering Gear
    G01936477Courtesy 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 Toward Rear Of Vehicle
    G01936478Courtesy 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 cross-member are clean and free of foreign material.
    Fig 6: Installing Steering Gear To Crossmember Insulator Bushings
    G01936479Courtesy 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
    G01936480Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
  10. Install the nuts.
    Fig 8: Installing Crossmember Nuts
    G01936481Courtesy 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.
  11. Install the lines and tighten the nut.
    Fig 9: Installing Lines & Tighten Nut
    G01936482Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clock-spring can result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information See CLOCKSPRING .
  12. Connect the intermediate shaft to the steering gear input shaft. Install a new lower steering column pinch bolt.
    Fig 10: Installing New Lower Steering Column Pinch Bolt
    G01936483Courtesy of MAZDA MOTORS CORP.
  13. Install the power steering fluid cooler; see POWER STEERING FLUID COOLER REMOVAL/INSTALLATION  .
  14. Install the front stabilizer bar; see BAR AND LINK REMOVAL - 4X2 .
    NOTE:
    • Orientate the front stabilizer bar as noted during removal.
  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.
    Fig 11: Locating LH Tie-Rod End
    G01936484Courtesy of MAZDA MOTORS CORP.
  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: Locating Castellated Nut
    G01936485Courtesy of MAZDA MOTORS CORP.
  17. Tighten the tie-rod end jam nuts.
    Fig 13: Locating Tie-Rod End Jam Nut
    G01936486Courtesy of MAZDA MOTORS CORP.
  18. Position the air deflector, and install the retaining screws.
    Fig 14: Locating Retaining Screws
    G01936487Courtesy of MAZDA MOTORS CORP.
  19. Install the front wheel and tire assemblies.
  20. Fill, purge and leak check the system.
  21. Check and, if necessary, adjust the wheel alignment.
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