For 1990-2009 cars

## Steering Gear Replacement ZF

#### Special Tools

• | J 22610 /KMJ-22610 Keystone Clamp Pliers

• | KM-6004-2 Tie Rod Wrench

### Removal Procedure

Important: Only the front axle body is released. The guide joints remain attached to the steering knuckle.

1. Turn the steering wheel as far as the stop.

• | Turn the steering wheel and front wheels to the straight-ahead position.

• | Remove the ignition key.

• | Allow the steering lock to engage.

Important: The bolt is accessible from the passenger compartment.

2. Remove the intermediate shaft from the steering gear.

• | Remove the clamp bolt (1) from the intermediate shaft.

• | Remove the intermediate shaft from the steering wheel.

3. Remove the rubber sleeve from the steering gear (2).

Important: Mark the position relative to the wheel hub.

4. Remove the 2 front wheels.

Remove the 10 wheel bolts.

5. Release the 2 tie rod ends. Refer to Steering Linkage Outer Tie Rod Replacement .
6. Remove the lower engine compartment cover.

Release the 8 bolts (1).

7. Remove the front exhaust pipe.

| Important: The flexible part of the pipe must not be bent by more than 5 degrees.

• | Remove the 3 nuts for connecting the front pipe to the particle filter/rear catalytic converter (1).

• | Remove the 3 nuts for connecting the pipe to the front catalytic converter (2).

• | Remove the bracket from the oil pan (3).

• | Remove the exhaust pipe.

8. Remove the rear engine damping block from the transmission.

Remove the 3 bolts (1).

9. Place the vehicle jack in a position under the front frame.
10. Remove the triangular plate.

Remove the 6 bolts (1, 2).

11. Remove the center 2 bolts from the axle housing (1).
12. Remove the engine damping block bracket (1) at the rear of the engine damping block.
13. Remove the rear engine damping block (2).

Remove the bolt connection.

Important: Oil will run out use a drain pan.

14. Remove the supply line (3) and return line (4) from the steering gear.
15. Remove the electro-hydraulic supply unit from the front frame.

• | Release the 2 wiring harness plugs (1, 2) and remove from the electro-hydraulic supply unit.

• | Remove the 3 nuts (3, 4) from the steering gear and the front frame.

• | Remove the electro-hydraulic supply unit with supply and return line from the steering gear and the front frame.

16. Remove the tie rods on both sides of the steering gear.

• | Remove the 2 retaining straps (1, 2).

• | Remove the 2 boots from the steering gear.

• | Remove the 2 tie rods (4) from the steering gear with KM-6004-2 .

17. Remove the steering gear from the front axle body.

• | Remove the 2 nuts (2) from the front axle body.

• | Remove the 2 bolts.

• | Remove the steering gear.

### Installation Procedure

Notice: Refer to Fastener Notice in the Preface section.

1. Install the steering gear to the front frame.

Insert the 2 new bolts.

Tighten
Tighten the 2 new nuts to 45 N·m (33 lb ft) plus 45 degrees plus 15 degrees.

Important: Clean the thread on the rack and coat with locking compound.

2. Install the 2 tie rods to the steering gear with KM-6004-2 .

Counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side.

Tighten
Tighten the 2 tie rods to the steering gear to 90 N·m (67 lb ft).

Important: Ensure that the boot sits in the grooves of the tie rod and steering gear.

3. Install the 2 boots to the steering gear.

• | Place the 2 boots on the steering gear.

• | Install the 2 new retaining clamps to the steering gear with J 22610 /KMJ-22610 .

• | Install the 2 boots to the tie rod using new retaining strap.

Important: Note the steering wiring harness.

4. Install the electro-hydraulic supply unit with bracket to the front frame.

Tighten
Tighten to 22 N·m (16 lb ft).

5. Place the electro-hydraulic supply unit with the holder on the steering gear and front frame .

Tighten
Tighten the 3 nuts.

6. Connect the 2 wiring harness plugs to the electro-hydraulic supply unit.
7. Install the supply and return line to the steering gear .

Tighten
Tighten to 16 N·m (12 lb ft).

8. Use the 2 new seal rings.
9. Install the supply and return line holder to the steering gear.
10. Install the rear engine damping block bracket to the engine damping block.

Tighten
Tighten to 55 N·m (40 lb ft).

11. Install the bolts for the front frame.

Install the triangular plates, insert the following new bolts and leave loose.

Tighten

• | Tighten the 2 bolts (2) for the front axle housing to 90 N·m (67 lb ft) plus 45 degrees plus 15 degrees .

• | Tighten the 4 bolts (1) for the triangular plates to the vehicle underbody 65 N·m (48 lb ft).

12. Insert the center bolts for the front frame and leave slack.

Tighten
Tighten the 2 bolts for front axle housing (1) to 90 N·m (67 lb ft) plus 45 degrees plus 15 degrees .

13. Lower the vehicle.
14. Place the engine support underneath, at the back on the transmission.

Tighten
Tighten the bolt to 80 N·m (59 lb ft) .

Important: The flexible part of the pipe must not be bent by more than 5 degrees.

15. Install the front exhaust pipe.

• | Lubricate the bolts with bolt paste and install the pipe between the front and rear catalytic converters.

• | Use new gaskets and new nuts.

Tighten
Tighten to 25 N·m (18 lb ft).

• | Install the bracket to the oil pan .

Tighten
Tighten to 25 N·m (18 lb ft).

16. Install the lower engine compartment cover.

Tighten
Tighten the 8 bolts to 5 N·m (44 lb in).

17. Bleed the power steering system. Refer to Front Frame Replacement .
18. Inspect the straight-ahead position, adjust if necessary. Refer to Straight Ahead Inspection .
19. Inspect the toe-in, adjust if necessary. Refer to Front Toe Adjustment .
20. Install the front wheels.

Tighten
Tighten the 10 wheel bolts to 110 N·m (81 lb ft).

## Steering Gear Replacement TRW without NR1, NS1, NS2

#### Special Tools

• | KM-6004-2 Tie Rod Wrench

• | J 22610 Keystone Clamp Pliers

### Removal Procedure

Important: To remove the steering gear, the front frame must be removed.

1. Remove the front frame. Refer to Front Frame Replacement .
2. Remove the engine damping block bracket (1) at the rear of the engine damping block.
3. Remove the holder (2).

Important: Oil runs out, use drain pan.

4. Place a drain pan under the power steering line connections and remove the supply line (3) and return line (4) from the steering gear.

Important: Note the wiring route.

5. Disconnect the wiring harness for the steering from the front frame.
6. Remove the electro-hydraulic supply unit from the front frame.

• | Remove the 3 nuts (1, 2) from the steering gear and the front frame.

• | Remove the electro-hydraulic supply unit with supply and return line from the steering gear and the front frame.

7. Remove the tie rods on both sides of the steering gear.

• | Remove the 2 retaining straps (1, 2).

• | Remove the 2 boots from the steering gear.

• | Remove the 2 tie rods (4) from the steering gear with KM-6004-2 .

• | Counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side.

8. Remove the steering gear from the front frame.

• | Remove the 2 nuts (2) from the front frame.

• | Remove the 2 bolts.

• | Remove the steering gear from the front frame.

### Installation Procedure

Notice: Refer to Fastener Notice in the Preface section.

1. Install the steering gear to the front frame.

Insert 2 new bolts.

Tighten
Tighten the 2 new nuts 45 N·m (33 lb ft) plus 45 degrees plus 15 degrees.

Important:

• | Clean the thread on the rack and coat with locking compound.

• | Counterholding is no longer necessary in vehicles from model year 2006.

2. Install the 2 tie rod to the steering gear with KM-6004-2 .

Counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side.

Tighten
Tighten to 90 N·m (66 lb ft).

Important:

• | Ensure that the boot sits in the grooves of the tie rod and the steering gear.

• | Ensure that the boot sits in the grooves of the tie rod.

3. Install the 2 boots to the steering gear.

• | Place the 2 boots on the steering gear.

• | Install the 2 new retaining clamps to the steering gear with J 22610 .

• | Install the 2 boots to the tie rod using the new retaining strap.

Important: Note the steering wiring harness.

4. Install the electro-hydraulic supply unit with bracket to the front frame .

Tighten
Tighten to 22 N·m (16 lb ft).

5. Place the electro-hydraulic supply unit with the holder on the steering gear and front frame.

Tighten
Tighten 3 nuts to 22 N·m (16 lb ft).

Important: Ensure that the wiring is routed properly.

6. Install the wiring harness for the steering to the front frame.
7. Install the supply and return line to steering gear .

Use the 2 new seal rings.

Tighten
Tighten to 30 N·m (22 lb ft).

8. Install the supply and return line holder to the steering gear.
9. Install the rear engine damping block bracket to the engine damping block.

Tighten
Tighten to 55 N·m (41 lb ft).

10. Install the front frame. Refer to Front Frame Replacement .
11. Charge and bleed the hydraulic system. Refer to Hydraulic Brake System Bleeding .
12. Inspect the straight-ahead position, adjust if necessary. Refer to Straight Ahead Inspection .
13. Check the toe-in, adjust if necessary. Refer to Front Toe Adjustment .