1. Outer Tie Rod
2. Tie Rod End Rock Nut
3. Rack and Pinion Boot
4. Inner Tie Rod
5. Bulkhead Retaining Ring
6. Bushing & Cylinder Bulkhead
7. Steering Rack Gear
8. Rack Inner Seal
9. Bearing
10. Pinion Gear
11. Pinion Shaft Seal
12. Bushing
13. Cylinder Liner Kit
14. Cylinder Liner Kit
15. Rack Bearing
16. Adjuster Spring
17. Adjuster Plug
18. Grommet
19. Pinion Bearing
20. Retaining Ring

Check	Action
Check the intermediate shaft joints for looseness.	Tighten the intermediate shaft joints.
Check the power steering hose for contact with other components.	Be sure the power steering hose is correctly fitted into the hose clips.

Check	Action
Check the power steering hose for contact with the body.	Be sure the power steering hose is correctly fitted into the hose clips.
Check the steering gear for insufficient lubrication.	Lubricate the steering gear.
Check the steering gear mounting for improper installation.	Tighten the steering gear mounting bracket nuts and bolts.
Check the outer tie rods for improper installation.	Tighten the outer tie rod joints. Replace the outer tie rods.

Check	Action
Check the steering wheel for contact with the turn signal housing.	Adjust the turn signal housing.
Check the intermediate shaft joints for binding or looseness.	Replace the intermediate shaft.
Check the power steering pump flow control valve for sticking and improper alignment.	Replace the power steering pump.
Check the wheel alignment.	Align the wheels.
Check the wheel bearings for wear or damage.	Replace the wheel bearings.
Check the intermediate shaft joints for improper installation.	Adjust the intermediate shaft between the steering gear and the steering column. Replace the intermediate shaft.
Check the outer tie rods and the ball joints for binding or looseness.	Tighten the tie rods and the ball joints. Replace the tie rods and the ball joints.
Check the steering gear adjustments.	Perform a straight-ahead check.
Check the steering column shaft seal for rubbing on the shaft.	Replace the dash seal.
Check the steering shaft bearings for binding.	Replace the stub shaft bearings.

Check	Action
Check the power steering pump for internal leaks.	Replace the power steering pump.
Check the hoses for damage or restricted flow.	Replace the power steering hoses and/or pipes.
Check the power steering fluid level.	Fill the power steering fluid reservoir.
Check the power steering pump flow control valve for sticking and improper operation.	Replace the power steering pump.

Check	Action
Check the power steering pump for insufficient pressure.	Replace the power steering pump.
Check the power steering pump flow control valve for sticking and improper operation.	Replace the power steering pump.
Check the power steering pump serpentine belt for slippage.	Tighten the power steering serpentine belt.
Check for air contamination in the power steering system.	Bleed the power steering system.

Check	Action
Check for air contamination in the power steering system.	Bleed the power steering system.
Check the power steering pump serpentine belt for looseness.	Tighten the power steering serpentine belt.

Check	Action
Check for air contamination in the power steering system.	Bleed the power steering system.
Check the wheel bearings for wear or damage.	Replace the wheel bearings.
Check the steering gear mounting for improper installation.	Tighten the steering gear mounting bracket nuts and bolts.
Check the intermediate shaft joints for improper Installation Note.	Adjust the intermediate shaft between the steering gear and the steering column. Replace the intermediate shaft.
Check the outer tie rods and the ball joints for looseness.	Tighten the tie rods and the ball joints. Replace the tie rods and the ball joints.

Check	Action
Check the intermediate shaft joints for improper installation.	Adjust the intermediate shaft between the steering gear and the steering column. Replace the coupling flange.
Check the power steering pump flow control valve for sticking and improper installation.	Replace the power steering pump.
Check the power steering pump for insufficient pressure.	Replace the power steering pump.
Check the power steering pump for internal leaks.	Replace the power steering pump.
Check for a loose or a worn intermediate shaft.	Tighten the intermediate shaft. Replace the intermediate shaft, as needed.
Check the power steering pump serpentine belt tension.	Tighten the power steering serpentine belt.

1. Disconnect and remove the power steering gear. Refer to "Rack and Pinion Assembly" in this section.
2. Place the power steering gear on a bench next to the vehicle.
3. Disconnect the pressure line at the point where the hose connects to the pipe. Extend this line to reach the power steering gear on the bench.
4. Disconnect the return line from the power steering fluid reservoir. Extend this line to reach the power steering gear on the bench.
5. Connect the power steering pipes to the power steering gear.
6. Start the engine and allow it to idle for 10 seconds.
7. Check the power steering fluid level. Refer to Section 6A, Power Steering System.
8. Start the engine and turn the rack and pinion stub shaft a full turn in each direction. Hold the shaft against each stop for 5 seconds.
9. Inspect for possible leak points. Refer to Section 6A, Power Steering System.

1. Stop the engine.
2. Disconnect the power steering pipes from the power steering gear.
3. Remove the extensions and reconnect the pressure and return lines.
4. Install and connect the power steering gear. Refer to "Rack and Pinion Assembly" in this section.
5. Start the engine and allow it to idle for 10 seconds.
6. Check the power steering fluid level. Refer to Section 6A, Power Steering System.

Step	Action	Value(s)	Yes	No
1	Place the steering wheel in the straight-ahead position. Is the wheel in the correct position?	-	Go to Step 2	-
2	Is the lower intermediate shaft pinch bolt lying parallel to the steering gear?	-	Go to Step 3	Go to Step 4
3	Is the steering wheel off center by more than 5 degrees?	-	Go to Step 5	Go to Step 6
4	The pinion is displaced on the rack. The steering pinion position must be corrected. Is the repair complete?	-	Go to Step 2	-
5	Remove steering wheel and center on the spindle splines. Is the repair complete?	-	Go to Step 3	-
6	Turn the steering wheel all the way to the right. Measure the inner and the outer angles of the tire centerline compared to the straight-ahead centerline. Are the angles within specifications?	Inner angle: 37° 15′ Outer angle: 32° 40′	System OK	Go to Step 7
7	The rack assembly was not assembled correctly. Repair as needed. Is the repair complete?	-	Go to Step 6	-

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1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires and Wheels.
3. Remove the outer tie rod nuts and disconnect the tie rod ends from the knuckle using the ball joint remover KM-507-B. Refer to "Outer Tie Rod" in this section.
Installation Notice

Tightening Torque

50 N•m (37 lb-ft)




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4. Remove the lower pinch bolt from the intermediate shaft. Refer to "Intermediate Shaft And Dash Seal" in this section.
5. Remove the return line bracket bolt from the cross-member. Refer to Section 6A, Power Steering System.
Installation Notice

Tightening Torque	Intermediate Shaft Lower Pinch Bolt	26 N•m (19 lb-ft)
Tightening Torque	Crossmember-to-Return Line Bracket Bolt	8 N•m (6 lb-ft)




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6. Disconnect the return line pipe from the power steering gear outlet. Place a drain pan under the steering gear to catch the power steering fluid.
7. Disconnect the pressure line pipe from the power steering gear inlet.
8. Remove the rack and pinion assembly mounting bolt and nut.
Installation Notice

Tightening Torque	Power Steering Gear Inlet-to-Pressure Line Fitting Nut	28 N•m (21 lb-ft)
Tightening Torque	Power Steering Gear Outlet-to-Return Line Fitting Nut	28 N•m (21 lb-ft)
Tightening Torque	Rack and Pinion Assembly Mounting Bolt	60 N•m (44 lb-ft)
Tightening Torque	Rack and Pinion Assembly Mounting Nut	60 N•m (44 lb-ft)

• After installing the pipes, bleed the power steering system. Refer to "Bleeding the Power Steering System" in this section.



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9. Remove the rack and pinion assembly U-clamp mounting bolt and nut.
10. Remove the U-clamp and the bushing.
Installation Notice

Tightening Torque	Rack and Pinion Assembly U-clamp Mounting Bolt	60 N•m (44 lb-ft)
Tightening Torque	Rack and Pinion Assembly U-clamp Mounting Nut	60 N•m (44 lb-ft)




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11. Remove the rack and pinion assembly.
Installation Notice
• Do a straight-ahead check. Refer to "Straight-Ahead Check" in this section.
• When adding fluid or marking a complete fluid change, always use DEXRON®-III power steering fluid.

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1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires and Wheels.
3. Remove the outer tie rod nuts and disconnect the tie rod ends from the knuckle using the ball joint remover KM-507-B.
Installation Notice

Tightening Torque

50 N•m (37 lb-ft)




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4. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut.
5. Loosen the outer tie rod adjusting nut and remove the outer tie rod by twisting it off the inner tie rod.
Installation Notice

Tightening Torque

64 N•m (47 lb-ft)

• After Installation, perform a front toe adjustment. Refer to Section 2B, Wheel Alignment.

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1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and wheels.
3. Remove the outer tie rod. Refer to "Outer Tie Rod" in this section.
4. Remove the dust boot retaining clamps.



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5. Remove the dust boot.
Installation Notice
• After Installation, perform a front toe adjustment. Refer to Section 2B, Wheel Alignment.

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1. Turn the steering wheel until it is horizontal. This is the straight-ahead position. Make a mark on the steering column shaft that lines up with a mark on the intermediate shaft upper universal joint.
2. Remove the upper pinch bolt from the universal joint on the intermediate shaft.
Installation Notice

Tightening Torque

22 N•m (16 lb-ft)

• When attaching the upper universal joint, the marks on the intermediate shaft and on the steering column shaft should line up.



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3. Raise and suitably support the vehicle.
4. Make a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower universal joint.
5. Remove the lower pinch bolt from the universal joint on the intermediate shaft.
6. Remove the nuts from the dash seal.
7. Remove the intermediate shaft.
Installation Notice

Tightening Torque	Dash Seal Nut	6 N•m (4 lb-ft)
Tightening Torque	Intermediate Shaft Lower Pinch Bolt	25 N•m (18 lb-ft)

• When attaching the lower universal joint, the marks on the intermediate shaft and on the stub shaft should line up.
• When attaching the lower and the upper universal joint, the steering wheel must be placed in the straight-ahead position with the spokes pointing down.

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1. Siphon the power steering fluid from the power steering fluid reservoir.
2. Raise and suitably support the vehicle.
3. Disconnect the power steering gear hydraulic cylinder pipes from the power steering gear at the valve end. Replace the O-ring seals as needed.
Installation Notice

Tightening Torque

18 N•m (13 lb-ft)




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4. Disconnect the power steering gear hydraulic cylinder pipes from the power steering gear at the cylinder end.
5. Remove the steering gear hydraulic cylinder pipes from the vehicle.
Installation Notice

Tightening Torque

27 N•m (20 lb-ft)

• When adding power steering fluid or making a complete change, always use DEXRON®-III power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
• Fill the reservoir with power steering fluid.
• Inspect for leaks. If there are leaks, correct the cause of the leaks and bleed the system. Refer to Section 6A, Bleeding the Power Steering System.

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1. Remove the rack and pinion assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section.
2. Remove the valve and pinion assembly from the rack and pinion steering assembly. Refer to "Valve and Pinion" in this section.
3. Remove the rack bearing assembly from the rack and pinion steering assembly. Refer to "Rack Bearing" in this section.



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4. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie rod nut and the adjusting nut.
Installation Notice
• When installing the outer tie rod nut, the mark on the inner tie rod and adjusting nut should line up.
• After installation, perform a front toe adjustment. Refer to Section 2B, Wheel Alignment.
6. Remove the dust boot retaining clamps and remove the dust boot.



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7. Remove the cylinder-side inner tie rod and the pinion-side inner tie rod.
Installation Notice

Tightening Torque

100 N•m (74 lb-ft)

• To prevent the inner tie rods from loosening, use Loc-tite® 242 (or equivalent) on both inner tie rod connections to secure them to the rack shaft.
• The right and left inner tie rods are unequal in length. Be sure to install the correct inner tie rod on the proper side of the power steering gear.



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Important : The retaining ring can be released by inserting a small screwdriver through the hole in the side of the housing.
6. Remove the bulkhead inner cylinder retaining ring, the bulkhead inner cylinder, and the rack.
Installation Notice
• Coat all the seals with power steering fluid to ensure proper sealing.



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1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section.
2. Remove the adjuster plug locknut from the adjuster plug, and remove the adjuster plug from the housing with the rack guide spring cap wrench J-42459.
3. Remove the adjuster spring and the rack bearing.
Installation Notice
• Coat the rack bearing, the adjuster spring and the adjuster plug with lithium-based grease.
• With the rack centered, turn the adjuster plug clockwise until a torque of 12 N•m (9 lb-ft) is obtained, then back it off by 50 to 70 degrees.

Tightening Torque

12 N•m (9 lb-ft)

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1. Raise and suitably support the vehicle.
2. Center the steering wheel.
3. Remove the power steering gear. Refer to "Rack and Pinion Assembly" in this section.
4. Loosen the locknut and turn the adjuster plug clockwise until a torque of 12 N•m (9 lb-ft) is obtained, then loosen it by 50 to 70 degrees.
5. Tighten the locknut on the adjuster plug while holding the adjuster plug stationary.
6. Install the power steering gear. Refer to "Rack and Pinion Assembly" in this section.
7. Be sure to check the return ability of the steering wheel to center position after adjustment.
Installation Notice

Tightening Torque

12 N•m (9 lb-ft)

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1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section.
2. Remove the dust cover and the retaining ring from the lower end of the housing.
Notice : If the stub shaft is not held, damage to the pinion teeth will occur.
3. While holding the stub shaft with a wrench, remove the locknut from the pinion.
Installation Notice

Tightening Torque

30 N•m (22 lb-ft)




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4. With the gear centered, mark the location of the stub shaft notch on the housing to aid in properly installing the pinion and valve assembly.
5. Remove the dust cover and the upper housing retaining ring.



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6. Remove the valve and pinion assembly from the stub shaft housing.



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7. Remove the stub shaft dust seal, the stub shaft bearing annulus assembly.



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8. Remove the pinion bearing from the stub shaft housing.
Installation Notice
• Install the bushing and a new lower pinion valve seal.
• Coat all the seals with power steering fluid to ensure proper sealing.
• When the valve and pinion assembly is fully seated in the housing, be sure the notch in the stub shaft and the mark on the housing line up. If this is not done the vehicle will not pass the straight-ahead check and will have poor steering performance.

Application			Description
Power Steering Fluid			Power Steering Fluid DEXRON®-III
Capacity			1.1 Liter
Type			Rack and Pinion
Overall Gear Ratio			16:1
Power Steering Angle	185 Tire	Inside	37.4
		Outside	32.1
	195 Tire	Inside	37.4
		Outside	32.1
Grease	Rack		Grease No. 2 Lithium
	Ball Joint		Nerita 0460 ＆ Retinax or Crown #2

Application	N•m	Lb-Ft	Lb-In
Knuckle-to-Outer Tie Rod Nut	50	37	-
Intermediate Shaft Lower Pinch Bolt	26	19	-
Intermediate Shaft Upper Pinch Bolt	22	16	-
Crossmember-to-Return Line Bracket Bolt	8	6	71
Power Steering Gear Inlet-to-Pressure Line Fitting Nut	28	21	-
Power Steering Gear Outlet-to-Return Line Fitting Nut	28	21	-
Rack and Pinion Assembly Mounting Bolt	60	44	-
Rack and Pinion Assembly Mounting Nut	60	44	-
Rack and Pinion Assembly U-clamp Mounting Bolt	60	44	-
Rack and Pinion Assembly U-clamp Mounting Nut	60	44	-
Inner Tie Rod Adjusting Nut	64	47	-
Dash Seal Nut	6	4	53
Power Steering Gear Hydraulic Cylinder Pipe-to-Valve End Fitting Nut	18	13	-
Power Steering Gear Hydraulic Cylinder Pipe-to-Cylinder End Fitting Nut	27	20	-
Inner Tie Rod Nut	100	74	-
Adjuster Plug Locknut	12	9	106
Valve and Pinion Locknut	30	22	-

	KM-507-B Ball Joint Remover
	J-42459 Rack Guide Spring Cap Wrench
	KM-J-22610 Dust Boot Clamp Installer