For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 21867-02 Tie Rod End Remover

1. Pull back the forward section of the driver's side floor carpet.
2. Remove the steering shaft coupling cover (1).
3. Loosen the bolt (2) that retains the upper steering shaft coupling.

Do not remove the bolt (2).

4. Remove the bolt (1) that retains the lower steering shaft coupling. Separate the steering shaft from the pinion.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
7. Remove the cotter pin (5) and the castle nut (4) from each outer tie rod (3).
8. Use the J 21867-02 in order to separate the outer tie rods from the steering knuckles.
9. Remove the front exhaust pipe. Refer to Front Pipe Replacement in Engine Exhaust.
10. If the vehicle has a manual transmission, remove the gearshift control shaft and the extension rod. Refer to Gearshift Control Shaft and Extension Rod Replacement in Manual Transmission - M42 and M58.

If the vehicle has an automatic transmission, remove the rear torque rod bracket from the automatic transmission.

Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system.

11. Remove the steering gear outlet pipe (1) from the steering gear.
12. Remove the steering gear inlet pipe (2) from the gear steering gear.
13. Remove the 2 pipes (3, 4) from the steering gear.
14. Remove the following components in order to remove the steering gear (2) from the bulkhead:

• | The 4 bolts (1)

• | The 2 steering gear mounting brackets

15. Perform the following steps in order to remove the steering gear from the vehicle:

15.1. | Slide the steering gear slightly to the driver's side.

15.2. | Rotate the steering gear in order to position the pinion gear between the transmission case and the frame rail.

15.3. | Slide the steering gear to the passenger's side in order to slide the left outer tie rod through the frame opening.

15.4. | Lower the left side of the steering gear in order to position the steering gear at an angle of 45 degrees.

15.5. | Remove the steering gear from the vehicle.

### Installation Procedure

1. Perform the following steps in order to install the steering gear to the vehicle:

1.1. | Position the steering gear below the engine compartment.

1.2. | Position the pinion shaft away from the vehicle.

1.3. | Raise the right side of the steering gear in order to position the steering gear at an angle of 45 degrees.

1.4. | Slide the right side of the steering gear through the right side frame opening.

1.5. | Raise the left side of the steering gear so that the steering gear is parallel to the vehicle.

1.6. | Slide the left outer tie rod through the left side frame opening.

1.7. | Rotate the steering gear in order to position the pinion shaft against the transaxle case.

1.8. | Slide the steering gear slightly to the driver's side.

Continue to rotate the steering gear.

1.9. | Slide the pinion shaft through the floor opening.

2. Install the 2 mounting brackets on the steering gear.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Secure the steering gear to the bulkhead with the 4 bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

4. Unplug the steering gear inlet pipe.
5. Unplug the steering gear outlet pipe.

Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage.

6. Install the 2 pipes (3, 4) to the steering gear.
7. Install the inlet pipe (2) to the steering gear.
8. Install the outlet pipe (1) to the steering gear.

Tighten

• | Tighten the 2 flare nuts (6, 7) to 27 N·m (19.5 lb ft).

• | Tighten the 2 flare nuts (5) to 17 N·m (12.5 lb ft).

• | Tighten the flare nut for the inlet pipe (2) to 40 N·m (28.5 lb ft).

• | Tighten the flare nut for the outlet pipe (1) to 40 N·m (28.5 lb ft).

9. If the vehicle has a manual transmission, install the gearshift control shaft and the extension rod. Refer to Gearshift Control Shaft and Extension Rod Replacement in Manual Transmission - M42 and M58.

If the vehicle has an automatic transmission, install the rear torque rod bracket to the automatic transmission.

10. Install the front exhaust pipe to the engine. Refer to Front Pipe Replacement in Engine Exhaust.
11. Install the outer tie rods (3) to the steering knuckles.

Important: Do not loosen the castle nuts in order to insert the cotter pins.

12. Install the castle nuts (4) to the outer tie rods.

Tighten
Tighten the castle nuts to 43 N·m (32 lb ft). Tighten the castle nut in order to align the cotter pin slot with the ball stud hole. Do not turn the castle nut more than 1/6 of a turn beyond the tightening specifications.

13. Install the cotter pins (5).

Bend the pin ends in order to secure the castle nuts.

14. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
15. Lower the vehicle.
16. Install the pinion shaft to the steering shaft coupling.
17. Secure the pinion shaft to the lower steering shaft coupling with the bolt (1).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

18. Tighten the bolt for the upper steering shaft coupling (2).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

19. Install the steering shaft coupling cover (1).
20. Reposition the driver's side floor carpet.

Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.

21. Fill the power steering fluid reservoir with new power steering fluid, if necessary. Refer to Checking and Adding Power Steering Fluid .

Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time.

22. Bleed the power steering system. Refer to Power Steering System Bleeding .
23. Measure the wheel alignment. Refer to Wheel Alignment Measurement in Wheel Alignment.
24. Adjust the front toe, if necessary. Refer to Front Toe Adjustment in Wheel Alignment.