Login- Download PDF Manual
-
designed to be serviced as an assembly; without wir- ing, switches, shrouds, steering wheel, etc. Most steering column components can be serviced without removing the steering column from the vehicle.
Fig.8STEERINGCOLUMN
1 - KEY CYLINDER 2 - GEAR SHIFT LEVER 3 - MOUNTING HOLES 4 - STEERING COLUMN 5 - IGNITION SWITCH
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag, Refer to Electrical Restraints and follow all WARN- INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS- CHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COAT- INGS AND ARE SPECIFICALLY DESIGNED FOR THE
Fig.9IGNITIONSWITCHWITHTILT
1 - IGNITION SWITCH 2 - TILT LEVER MECHANISM
(8) For columns without tilt remove the bracket to gain access to the ignition switch mounting screws. (Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
DR IGNITION SWITCH (Continued)
COLUMN
19 - 11
(3) Position switch to column and install
the mounting screw. Tighten screw to 3 N·m (26 in. lbs.). (4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N·m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N·m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
shrouds.
(7) Reconnect the lower clockspring connectors. (8) Install the key cylinder. (9) Install
steering column upper and lower
(10) Enable the airbag system. (Refer to 8 - ELEC- TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL- LATION).
Fig.10IGNITIONSWITCHWITHOUTTILT
1 - Ignition Switch Mounting Screws 2 - Non-Tilt Mounitng Bracket Screws
Fig.11IGNITIONSWITCH
1 - Ignition Switch 2 - Ignition Switch Mounting Screws
(10) Remove ignition switch mounting screw. (11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.
(2) Connect the electrical connector to rear of the ignition switch. Make sure that locking tabs are fully seated into wiring connector.
KEY-IN IGNITION SWITCH DESCRIPTION
The key-in ignition switch is integral to the igni- tion switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced, (Refer to 19 - STEERING/COLUMN/IG- NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to Ignition Switch in the appropriate section of Electri- cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
19 - 12
COLUMN
KEY CYLINDER REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
steering column.
(1) Disconnect negative cable from battery. (2) Remove upper and lower covers (shrouds) from
(3) Place shifter in PARK position. (4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.
Fig.12KEYCYLINDER
1 - KEY 2 - KEY CYLINDER 3 - RETAINING PIN HOLE
(a) Rotate key to RUN position. (b) Press in on retaining pin while pulling key
cylinder from ignition switch (Fig. 13).
DR
INSTALLATION
The ignition key must be in the key cylinder for
cylinder installation.
(1) Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch.
(2) Push the key cylinder in until it clicks. (3) Replace the upper and lower shrouds. (4) Reconnect the battery.
GEAR SHIFT LEVER REMOVAL
(1) Remove the kneeblocker. (Refer to 23 - BODY/ INSTRUMENT PANEL/KNEE BLOCKER - REMOV- AL).
(2) Remove the upper and lower column shroud. (3) Remove and discard the brake light switch. (4) Loosen the column bolts and lower the column enough to allow clearance for the gear shift lever removal.
(5) Disconnect
the overdrive switch harness (if
equipped).
(6) Disconnect the shift cable from the shift lever. (7) Remove the SKIM. (8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)
(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).
Fig.13KEYCYLINDER
1 - KEY CYLINDER 2 - PUNCH
Fig.14GEARSHIFTLEVER
1 - PARK INHIBIT BLOCKER SPRING 2 - GEAR SHIFT LEVER
INSTALLATION
(1) Install the lever assembly using care to install the pin in the blocker to slider slot (Fig. 15) and install the mounting screws and tighten to 12 N·m (105 in. lbs.).
DR GEAR SHIFT LEVER (Continued)
COLUMN
19 - 13
(2) Lock the steering wheel with the tire in the
straight position.
(3) Remove and discard the lower pinch bolt. (4) Lower the steering coupler shaft from the col-
umn.
(5) Remove the upper steering coupling shaft seal by pushing in the four tags securing it to the panel (Fig. 16).
Fig.15GEARSHIFTLEVERSPRING
1 - BLOCKER TO INHIBIT LINK SLOT 2 - GEAR SHIFT LEVER
(2) Cycle the key from ACC to RUN and ensure
that the blocker does not stick or bind.
(3) Turn the key to the OFF position and ensure that the shifter will not pull from the PARK position. the over drive switch harness (if
(4) Connect
equipped).
NOTE: Route and tie off harness to original loca- tion.
(5) Connect the shift cable to the lever. (6) Ensure the gear shift lever and transmission are in the PARK position and snap the cable adjust clip in place.
(7) Install a new brake light switch (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - INSTALLATION).
(8) Install the SKIM and halo. (9) Install the upper and lower column shroud. (10) Install
the column back into place and
tighten.
(11) Install the kneeblocker. (Refer to 23 - BODY/ INSTRUMENT PANEL/KNEE BLOCKER - INSTAL- LATION).
Fig.16RELEASETANGS
1 - RELEASE TANGS (4) 2 - UPPER STEERING COUPLER SHAFT
(6) Remove and discard the lower coupler pinch bolt from the lower steering coupling shaft (Fig. 17). (7) Remove the upper steering coupling shaft from
the vehicle (Fig. 17).
UPPER STEERING COUPLING REMOVAL
(1) Disconnect the negative battery cable.
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
Fig.17UPPERSTEERINGCOUPLERSHAFT
1 - LOWER STEERING COUPLER 2 - RELEASE TANGS (4) 3 - UPPER STEERING COUPLER SHAFT
COLUMN
19 - 14
UPPER STEERING COUPLING (Continued) INSTALLATIONDR
(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).
(2) Install the upper steering coupling shaft seal by pushing it in securing the four tangs to the panel (Fig. 16).
NOTE: Note: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used.
Fig.18LOWERSTEERINGCOUPLER
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly. (5) Remove and discard the upper coupler pinch
(6) Remove and discard the lower coupler pinch
bolt (Fig. 20).
bolt (Fig. 19).
(3) Install the steering coupler shaft to the column
(Fig. 17).
(4) Install the upper pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(5) Install the shaft to the lower coupler (Fig. 17). (6) Install the lower pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(7) Unlock the steering wheel. (8) Reconnect the negative battery cable.
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD
(1) Disconnect the negative battery cable. (2) Raise and support the vehicle.
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly. for proper (5) Mark both coupler
connections
installation.
(6) Remove and discard the upper coupler pinch
(7) Remove and discard the lower coupler pinch
(8) Remove the lower steering shaft coupler (Fig.
bolt.
bolt.
18).
REMOVAL - 4X4 HD
(1) Disconnect the negative battery cable. (2) Raise and support the vehicle.
Fig.19LOWERCOUPLERPINCHBOLT
1 - INTERMEDIATE STEERING SHAFT 2 - LOWER COUPLING BOLT 3 - STEERING GEAR
DR LOWER STEERING COUPLING (Continued)
(7) Remove the lower steering shaft coupler (Fig.
20).
COLUMN
19 - 15
(5) Install the left front tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STAN- DARD PROCEDURE).
(6) Lower the vehicle. (7) Reconnect the negative battery cable. (8) Unlock the steering wheel.
STEERING WHEEL REMOVAL
(1) Disable and remove the driver’s side air- - ELECTRICAL/RESTRAINTS/
bag.(Refer DRIVER AIRBAG - REMOVAL).
to
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
Fig.20INTERMEDIATESTEERINGSHAFT
1 - UPPER COUPLING BOOT AND BOLT 2 - INTERMEDIATE STEERING SHAFT 3 - LOWER COUPLING BOLT 4 - STEERING GEAR
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD(1) Install the coupler to the steering rack & pin-
ion using the marks made in the removal process.
(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla- tion.
(3) Install the lower pinch bolt and tighten to 57
(4) Install the upper pinch bolt and tighten to 57
N·m (42 ft. lbs.).
N·m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STAN- DARD PROCEDURE).
(6) Lower the vehicle. (7) Reconnect the negative battery cable. (8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear. (2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla- tion.
Fig.21STEERINGWHEELPULLER
1 - STEERING WHEEL 2 - SPECIAL TOOL CJ98-1
(4) Remove and discard the steering wheel bolt. (5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
(3) Install the driver’s side air bag. (Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(3) Install the lower pinch bolt and tighten to 28
bolt to 61 N·m (45 ft. lbs.).
N·m (250 in. lbs.).
N·m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
19 - 16
GEAR - INDEPENDENT FRONT SUSPENSION
GEAR - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page
GEAR - INDEPENDENT FRONT SUSPENSION
BUSHING
DR
page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 18
GEAR - INDEPENDENT FRONT SUSPENSION DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made up of two main components, the pinon shaft and the rack. The gear cannot be adjusted or internally ser- viced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18(2) Drain and siphon the power steering fluid from
the reservoir.
bolt.
& pinion.
(3) Raise the vehicle. (4) Remove and discard the steering coupler pinch
(5) Remove the power steering hoses from the rack
(6) Remove the tire and wheel assembly. (7) Remove the tie rod end nuts and separate tie rod ends from the knuckles with Special tool 8677
(Refer to 19 - STEERING/LINKAGE/TIE ROD END - REMOVAL).(8) Remove the skid plate (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - REMOV- AL).
(9) Remove the rack & pinion mounting bolts. (Fig.
2) & (Fig. 3)
(10) Remove the rack & pinion from the vehicle.
Fig.1STEERINGGEAR
1 - OUTER TIE ROD ENDS 2 - MOUNTING BUSHINGS 3 - BELLOWS
REMOVAL
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(1) Lock the steering wheel.
Fig.2STEERINGGEARMOUNTINGBOLTS
1 - STEERING GEAR MOUNTING BOLTS 4X4
DR GEAR - INDEPENDENT FRONT SUSPENSION (Continued)
GEAR - INDEPENDENT FRONT SUSPENSION
19 - 17
an additional 90°. (Refer to 19 - STEERING/LINK- AGE/TIE ROD END - INSTALLATION).
(5) Install the pressure power steering hose to the steering gear and tighten to 32 N·m (23 ft. lbs.). (Refer to 19 - STEERING/PUMP/HOSES - INSTAL- LATION).
(6) Install the return power steering hose to the steering gear and tighten to 71 N·m (52 ft. lbs.). (Refer to 19 - STEERING/PUMP/HOSES - INSTAL- LATION).
(7) Install the front skid plate (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(9) Remove the support and lower the vehicle. (10) Fill the system with fluid,
(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(11) Adjust the toe position. (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- DURE).
Fig.4STEERINGGEAR4X4
1 - FRONT AXLE 2 - STEERING GEAR MOUNTING NUTS & BUSHINGS
Fig.3STEERINGGEAR4X2
1 - SWAY BAR 2 - STEERING GEAR 3 - LEFT OUTER TIE ROD END 4 - LOWER CONTROL ARMS 5 - LEFT INNER & RIGHT OUTER (TIE ROD ENDS)
INSTALLATION
NOTE: Before installing gear inspect bushings and replace if worn or damaged.
NOTE: In the frame there is two holes for the mounting of the steering gear one is slotted and one is round, When tightening the gear to specifi- cations make sure to tighten the mounting bolt with the hole first to avoided movement of the steering gear.
(1) Install the gear on the front crossmember and tighten the mounting bolts to 319 N·m (235 ft. lbs.). (Fig. 4) & (Fig. 3).
(2) Slide the shaft coupler onto the gear. Install
new pinch bolt and tighten to 49 N·m (36 ft. lbs.).
(3) Clean and dry the tie rod end studs and the
knuckle tapers.
(4) Install the tie rod ends into the steering knuck- les and tighten the nuts to 61 N·m (45 ft. lbs.) then
GEAR - INDEPENDENT FRONT SUSPENSION
19 - 18
GEAR - INDEPENDENT FRONT SUSPENSION (Continued) SPECIFICATIONSDR
TORQUE CHART
DESCRIPTION
Rack and Pinion Steering
Gear
Gear to Frame Bolts
Rack and Pinion Steering
Gear
Coupler Bolt Tie Rod End Knuckle Nut
Tie Rod End
Jam Nut
Power Steering Line
Pressure Line
Power Steering Line
Return Line
Power Steering Line
Pressure Line To Pump
BUSHING REMOVAL
TORQUE SPECIFICATIONS
N·m 319
49
61
Ft. Lbs.
235
36
45
Then tighten an additional
Then tighten an additional
90° 75
32
71
37
90° 55
23
52
27
In. Lbs.
—
—
—
—
—
—
—
(1) Remove the steering gear
STEERING/GEAR - REMOVAL).
(Refer
to 19 -
CAUTION: Do not overtighten the vise on the gear case.
(2) Mount the steering gear in a soft jawed vise.
NOTE: If the bushings are seized a brass punch can be used to remove the bushings from the gear using care not to strike the gear.
(3) Remove the front mounting bushings. (4) Remove the rear mounting bushings. (5) Remove the steering gear from the vise and
place it on the bench.
INSTALLATION
NOTE: Coat all bushings with a thin rubber lubri- cate oil prior to installation.
NOTE: A rubber mallet can be used to assist in the installation of the bushings once lubricated.
(1) Coat the rear bushings with a thin rubber lubricate oil then install the rear bushings using a rubber mallet to seat the bushings in the gear.
(2) Coat the front bushings with a thin rubber lubricate oil then install the front bushings using a rubber mallet to seat the bushings in the gear.
(3) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(4) Adjust the toe position (if necessary) (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - STAN- DARD PROCEDURE).DR
GEAR - LINK/COIL
19 - 19
GEAR - LINK/COIL
TABLE OF CONTENTS
page
page
GEAR - LINK/COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . 21
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 22SPECIAL TOOLS
REMOVAL - DIESEL
. . . . . . . . . . . . . . . . . . . 24
INSTALLATION
INSTALLATION - GAS ENGINE . . . . . . . . . . . 24
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . 25STEERING GEAR INPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28PITMAN SHAFT
REMOVAL
REMOVAL - GAS . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . 30
REMOVAL - DIESELPOWER STEERING GEAR . . . . . . . . . . . . . . 22
INSTALLATION
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE . . . . . . . . . . . . . . . 23
INSTALLATION - GAS . . . . . . . . . . . . . . . . . . 30
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . 30GEAR - LINK/COIL DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio’s used are 12.5:1.
OPERATION
The gear acts as a rolling thread between the worm shaft and rack piston. The worm shaft is sup- ported by a thrust bearing at the lower end and a bearing assembly at the upper end. When the worm shaft is turned from input from the steering column the rack piston moves. The rack piston teeth mesh with the pitman shaft. Turning the worm shaft, turns the pitman shaft, which turns the steering linkage.
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(2) Lock the steering wheel. (3) Siphon out as much power steering fluid as
possible.
Fig.1STEERINGGEAR
1 - INPUT SHAFT 2 - OUTLET 3 - INLET 4 - VALVE ASSEMBLY HOUSING 5 - PITMAN SHAFT COVER BOLTS 6 - STEERING GEAR 7 - MESHLOAD ADJUSTER NUT 8 - PITMAN SHAFT
GEAR - LINK/COIL
19 - 20
GEAR - LINK/COIL (Continued)DR
(4) Disconnect and cap the fluid hoses from steer- ing gear (Refer to 19 - STEERING/PUMP/HOSES - REMOVAL).
(5) Remove coupler pinch bolt at the steering gear
and slide shaft off gear (Fig. 2).
Fig.4STEERINGGEARREMOVAL/INSTALLATION 1 - STEERING GEAR 2 - MOUNTING BOLTS (3)
INSTALLATION
Fig.2COLUMNSHAFT
1 - STEERING COUPLER 2 - STEERING GEAR INPUT SHAFT
(6) Mark the pitman shaft and pitman arm for installation reference. Remove the pitman arm from the shaft with Puller C-4150A (Refer to 19 - STEER- ING/LINKAGE/PITMAN ARM - REMOVAL), (Fig. 3).
(1) Position the steering gear on the frame rail and install the three mounting bolts (Fig. 4). Tighten the mounting bolts to 196 N·m (145 ft. lbs.).
(2) Align steering coupler on gear shaft. Install pinch bolt and tighten to 49 N·m (36 ft. lbs.) torque. (3) Align and install the pitman arm (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - INSTALLA- TION).
(4) Install the washer and retaining nut on the pit- man shaft. Tighten the nut to 305 N·m (225 ft. lbs.). (5) Connect fluid hoses to steering gear (Refer to 19 - STEERING/PUMP/HOSES - INSTALLATION), tighten to 31 N·m (23 ft. lbs.).
(6) Add fluid, (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE).
(7) Reset the toe and center the steering wheel (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
Fig.3PITMANARMREMOVAL
1 - PITMAN ARM 2 - C-4150A PULLER
(7) Remove steering gear three mounting bolts (Fig. 4). Remove the steering gear from the vehicle.
ADJUSTMENTS
ADJUSTMENT
CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result.
NOTE: Adjusting the steering gear in the vehicle is not recommended. Remove gear from the vehicle and drain the fluid. Then mount gear in a vise to perform adjustments.
DR GEAR - LINK/COIL (Continued)
GEAR - LINK/COIL
19 - 21
(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
(2) Mount the gear carefully into a soft-jawed vise.
CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment
(3) Hold the steering gear upside down over a drain pan and rotate the input shaft back and forth several times lock-to-lock to discharge the fluid from the steering gear
(4) Rotate the input shaft to the left stop and then back-off approximately 45 degrees. Using an inch- pound torque wrench on the input shaft, record the peak torque required to slowly and evenly rotate the input shaft clockwise 1â„2 turn (180 degrees) starting from the 45 degree position. This peak torque read- ing is the preload torque. The preload torque must be within 2 - 10 in-lbs.
(5) Rotate the input shaft to its center of travel (approximately 1.5 turns from either stop). Place the torque wrench on the input shaft with the handle in the vertical position. Rotate the torque wrench slowly and evenly 1â„4 turn (90 degrees) each side of center and record the peak torque measure on or near cen- ter. This total on-center torque reading must be 5 - 9
in-lbs higher than the previously measured preload torque without exceeding a total of 17 in-lbs. The value of the total on-center minus the preload torque is defined as the meshload torque(6) If required, adjust the on-center torque by loos- ening the adjuster screw lock nut and turning the adjuster screw until the total on-center and meshload torque readings fall within the specified values. Turn the adjuster screw clockwise to increase and counter- clockwise to decrease the torque reading. While hold- ing the adjuster screw in place, tighten the lock nut to 31 N·m (23 ft. lbs.).
(7) Re-check the preload and on-center torque
readings.
(8) Install pitman arm on the steering gear (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - INSTALLATION).
(9) Reinstall steering gear to the vehicle (Refer to
19 - STEERING/GEAR - INSTALLATION).
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Steering Gear Type Gear Code & Ratio
Recirculating Ball
12.5:1
TORQUE SPECIFICATIONS
DESCRIPTION
Preload Torque
Meshload Torque
N·m
0.23-1.13
0.56-1.02
Ft. Lbs.
—
—
In. Lbs.
2-10
5-9
+ Preload (17 Max)
GEAR - LINK/COIL
19 - 22
GEAR - LINK/COIL (Continued) TORQUE CHARTTORQUE SPECIFICATIONS
DR
N·m 196
32
71
37
31
305
68
54
2.26
97
DESCRIPTION
Steering Gear Mounting
Frame Bolts
Power Steering Line
Pressure
Power Steering Line
Return
Power Steering Line
Pressure Line To Pump
Steering Gear
Adjustment Screw Locknut
Steering Gear
Pitman Shaft Nut
Steering Gear
Pitman Shaft Cover Bolts
Steering Gear
Valve Housing to Gear
Bolts
Steering Gear
Retainer Ring Screw
Steering Gear Retainer Ring
SPECIAL TOOLS
POWER STEERING GEAR
Ft. Lbs.
145
23
52
27
23
225
50
40
—
72
In. Lbs.
—
—
—
—
—
—
—
—
20
—
HANDLEC-4171
INPUTSHAFTSEALINSTALLER-8987
DR GEAR - LINK/COIL (Continued)
GEAR - LINK/COIL
19 - 23
PULLER,SLIDEHAMMER-C-3752
PITMANSHAFTSEALPROTECTOR-8993
SEALREMOVERADAPTER-8990
PITMANSHAFTSEALINSTALLER-8989
INPUTSHAFTSEALPROTECTOR-8986
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE
(1) Seperate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the steering wheel from stop to stop and
count the number of turns.
(4) Center the steering wheel by rotating it from the stop back 1 1/2 turns to achieve center position.
(5) Remove the pitman shaft cover bolts.
RETAINERRINGWRENCH-8988
NOTE: The pitman shaft will not clear the housing if it is not centered.
(6) Remove the pitman shaft from the gear. (7) Remove dust seal from the housing with a spe-
cial tool (Fig. 5).
CAUTION: Use care not to score the housing bore when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
GEAR - LINK/COIL
19 - 24
PITMAN SHAFT SEAL (Continued)DR
Fig.5SLIDEHAMMER
Fig.6CENTERINGSTEERINGGEAR
1 - STEERING GEAR 2 - SLIDE HAMMER C-3752 USED WITH SPECIAL TOOL ADAPTER 8990
(9) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to remove.
(10) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752.
REMOVAL - DIESEL
(1) Seperate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
with a wire brush.
(4) Clean exposed end of pitman shaft and housing
(5) Rotate the input shaft with a 12 point socket from stop to stop and count the number of turns (Fig. 6).
(6) Center the input shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 6).
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if it is not centered.
(8) Remove the pitman shaft from the gear. (9) Remove dust seal from the housing with a spe-
cial tool 8990 (Fig. 5).
1 - STEERING GEAR 2 - 12 POINT SOCKET 3 - RATCHET 4 - INPUT SHAFT
CAUTION: Use care not to score the housing bore when prying out seals.
(10) Remove retaining ring with snap ring pliers. (11) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to remove.
(12) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752. (Fig. 5).
INSTALLATION
INSTALLATION - GAS ENGINE
NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring.
(1) Coat the oil seal and washer with high temp
grease.
NOTE: Install the oil seal with the lip facing inward. Flat side of the washer.
the oil seal should be against
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7). (3) Install backup washer. (4) Install the retainer ring with snap ring pliers.
DR PITMAN SHAFT SEAL (Continued)
Fig.7SEALINSTALLATION
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8989
3 - STEERING GEAR(5) Coat the dust seal with high temp grease. (6) Install the dust seal with a driver and handle
(7) Install protective seal protector 8993 over the
(Fig. 7).
shaft (Fig. 8).
GEAR - LINK/COIL
19 - 25
INSTALLATION - DIESEL
NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring.
(1) Coat the oil seal and washer with high temp
grease.
NOTE: Install the oil seal with the lip facing inward. Flat side of the washer.
the oil seal should be against
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7). (3) Install backup washer. (4) Install the retainer ring with snap ring pliers. (5) Coat the dust seal with high temp grease. (6) Install the dust seal with special tool 8989
driver and C-4171 handle (Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(10) Install
the steering gear
(Refer
to 19 -
STEERING/GEAR - INSTALLATION).
(11) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(12) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
STEERING GEAR INPUT SHAFT SEAL REMOVAL
(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment
(2) Mount the steering gear upside down over a
drain pan in a soft jawed vise.
(3) Place a drain pan under the gear and rotate the input shaft back and forth several times lock-to- lock to discharge the fluid from the steering gear (4) Drain all the remaining fluid from the gear. (5) Rotate the input shaft from stop to stop and count the number of turns using a 12 point socket (Fig. 9).
Fig.8PITMANSHAFTSEALPROTECTOR
1 - STEERING GEAR 2 - SPECIAL TOOL 8993
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(10) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
GEAR - LINK/COIL
19 - 26
STEERING GEAR INPUT SHAFT SEAL (Continued)DR
NOTE: The pitman shaft will not clear the housing if it is not centered.
(6) Center the input shaft by rotating it from the stop back 1 1/2 turns to achieve center position (Fig. 9).
(10) Remove the valve housing and wormshaft assembly from the steering gear housing and place the valve housing in a soft jawed vise (Fig. 11).
Fig.9CENTERINGSTEERINGGEAR
1 - VALVE HOUSING 2 - SET SCREW 3 - RETAINER RING
Fig.11VALVEHOUSINGANDWORMSHAFT
1 - STEERING GEAR 2 - 12 POINT SOCKET 3 - RATCHET 4 - INPUT SHAFT
(11) Remove the retainer ring set screw from the
valve housing (Fig. 12).
(7) Remove the pitman shaft
(Refer
to 19 -
STEERING/GEAR/PITMAN SHAFT - REMOVAL).
(8) Remove the four bolts securing the valve hous-
(9) Remove the valve housing from the steering
ing.
gear (Fig. 10).
Fig.12SETSCREWFORTHERETAINERRING
1 - SET SCREW 2 - 3/32 ALLEN HEAD SOCKET 3 - RETAINER RING
Fig.10VALVEASSEMBLY
1 - VALVE HOUSING 2 - WORMSHAFT BALLS 3 - STEERING GEAR HOUSING
DR STEERING GEAR INPUT SHAFT SEAL (Continued)
GEAR - LINK/COIL
19 - 27
(12) Using special tool reatainer ring wrench to remove the steering gear worm thrust bearing reatainer ring (Fig. 13).
(14) Remove the dust seal with a pick (Fig. 15).
Fig.13REATINERRINGREMOVAL
1 - SPECIAL TOOL 8988
2 - RATCHET(13) Separate the wormshaft assembly from the valve housing, Then remove the wormshaft assembly from the vise (Fig. 14).
Fig.15DUSTSEALREMOVAL
1 - PICK 2 - VALVE HOUSING 3 - SEAL
CAUTION: Use care not to score the housing bore when removing seals.
(15) Remove the snap ring with snap ring pliers
(Fig. 16).
Fig.14WORMSHAFTANDVALVEASSEMBLY
Fig.16SNAPRINGREMOVAL
1 - PISTON TEFLON SEALS 2 - RETAINER RING
1 - SNAP RING PLIERS 2 - SNAP RING 3 - VALVE HOUSING
GEAR - LINK/COIL
19 - 28
STEERING GEAR INPUT SHAFT SEAL (Continued)(16) Using special tool slide hammer C-3752 with
adapter 8990 remove the oil seal (Fig. 17).
DR
Fig.17OILSEALREMOVAL
1 - VALVE HOUSING 2 - SPECIAL TOOL 3 - TORQUE WRENCH
Fig.18RETAINERRINGINSTALLATION
1 - SPECIAL TOOL 8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSINGINSTALLATION
(1) Inspect the piston teflon seals for damage.
Replace if needed.
NOTE: To replace the teflon seals, use a pick to remove the teflon o-ring and the rubber o-ring underneath. Install a new rubber o-ring in the piston seal grove and a new teflon o-ring over the top of it.
(2) Install the valve into the valve housing. (3) Thread the retainer ring into the valve housing
(Fig. 18). Tighten to 97 N·m (72 ft. lbs.)
NOTE: It is very important to make sure to compen- sate for the added length of the torque wrench when torquing to proper specifications.
(4) Install the retainer ring set screw. Tighten to
2.26 N·m (20 in. lbs.)
(5) Clean the steering gear housing.
CAUTION: Valve assembly must be centered to the housing (Fig. 19).
(6) Install the valve assembly into the steering gear (Fig. 19). Tighten the new bolts to 54 N·m (40 ft. lbs.)
(7) Install the input shaft seal protector 8986 (Fig.
20).
(8) Coat the new seal in high temp grease and Install the new oil seal using special tool 8987 driver and C-4171 handle (Fig. 21).
Fig.19CENTEREDGEARTEETH
1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN HOLE 2 - VALVE HOUSING
NOTE: Drive the oil seal into the housing until the outer edge does not quite clear the snap ring groove.
(9) Insert the snap ring into the housing. Using special tool 8987 driver and C-4171 handle push the snap ring and oil seal together until the snap ring seats in the groove.
NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring.
DR STEERING GEAR INPUT SHAFT SEAL (Continued)
GEAR - LINK/COIL
19 - 29
(14) Install the steering gear to the vehicle (Refer
to 19 - STEERING/GEAR - INSTALLATION).
(15) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
PITMAN SHAFT
REMOVAL
REMOVAL - GAS
Fig.20INPUTSHAFTSEALPROTECTOR
1 - INPUT SHAFT 2 - SPECIAL TOOL 8986
Fig.21INPUTSHAFTSEALINSTALLATION
1 - VALVE HOUSING 2 - SPECIAL TOOL 8987
3 - SPECIAL TOOL C-4171(10) Install the new dust seal using high temp grease, special tool C-4171 (driver) and 8987 (han- dle).
(11) Check to make sure the gear is centered in the middle tooth before installing the pitman shaft (Fig. 19).
(12) Install the pitman shaft into the steering gear (Refer to 19 - STEERING/GEAR/PITMAN SHAFT - INSTALLATION).
(13) Perform over-center meshload adjustment (Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(1) Separate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the steering wheel from stop to stop and
count the number of turns.
(4) Center the steering wheel by rotating it from the stop back 1 1/2 turns to achieve center position.
(5) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if it is not centered.
(6) Remove the pitman shaft from the gear (Fig.
22).
Fig.22PITMANSHAFT
1 - PITMAN SHAFT 2 - O-RING SEAL 3 - COVER 4 - ADJUSTING NUT
(7) Remove the cover if needed by loosing the adjuster nut, Then removing the cover from the pit- man shaft.
GEAR - LINK/COIL
19 - 30
PITMAN SHAFT (Continued) REMOVAL - DIESELDR
(1) Separate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
with a wire brush.
(4) Clean exposed end of pitman shaft and housing
(5) Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns (Fig. 23).
(6) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 23).
Fig.24PITMANSHAFT
1 - PITMAN SHAFT 2 - O-RING SEAL 3 - COVER 4 - ADJUSTING NUT
INSTALLATION
INSTALLATION - GAS
(1) Coat the seal with power steering fluid. (2) Install pitman shaft into the steering gear until
it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(4) Perform over-center meshload
adjustment, (Refer to 19 - STEERING/GEAR - ADJUSTMENTS). (5) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(6) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - DIESEL
(1) Coat the seal with power steering fluid. (2) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(4) Perform over-center meshload
adjustment (Refer to 19 - STEERING/GEAR - ADJUSTMENTS). (5) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(6) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(7) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
Fig.23CENTERINGSTEERINGGEAR
1 - STEERING GEAR 2 - 12 POINT SOCKET 3 - RATCHET 4 - INPUT SHAFT
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if it is not centered.
(8) Remove the pitman shaft from the gear (Fig.
24).
(9) Remove the cover if needed by loosing the adjuster nut, Then removing the cover from the pit- man shaft.
DR
LINKAGE - INDEPENDENT FRONT SUSPENSION
19 - 31
LINKAGE - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page
page
LINKAGE - INDEPENDENT FRONT
TIE ROD END
SUSPENSION DIAGNOSIS AND TESTING - OUTER TIE ROD
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LINKAGE - INDEPENDENT FRONT SUSPENSION DIAGNOSIS AND TESTING - OUTER TIE ROD END
NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
(2) Remove the front tires. (3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.
(4) Position indicator plunger on the topside of the
outer tie rod end.
NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the outer tie rod end.
(5) Position a pry bar in order to pry downwards
on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace the outer tie rod end (Refer to 19 - STEERING/ LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall tires (Refer to 22 - TIRES/WHEELS/
the front WHEELS - STANDARD PROCEDURE).
REMOVAL - OUTER TIE ROD END . . . . . . . . . . 31
INSTALLATION - OUTER TIE ROD END . . . . . . 32TIE ROD END REMOVAL - OUTER TIE ROD END
NOTE: Do not twist removal or installation.
the boot anytime during
(1) Loosen the jam nut. (2) Remove the outer tie rod end nut from the ball
(3) Separate the tie rod ball stud from the knuckle
with Remover 8677 (Fig. 1).
(4) Unthread the outer tie rod end from the inner
stud.
tie rod.
Fig.1TIERODSEPARATION
1 - TIE ROD END 2 - SPECIAL TOOL 8677
LINKAGE - INDEPENDENT FRONT SUSPENSION
19 - 32
TIE ROD END (Continued) INSTALLATION - OUTER TIE ROD ENDDR
NOTE: Do not removal or installation.
twist
the boot at anytime during
(1) Thread the outer tie rod end onto the inner tie
rod, to it’s original position (Fig. 2).
(2) Install the outer tie rod end into the steering
knuckle (Fig. 2).
(3) Tighten the ball stud nut on the ball stud to 61
N·m (45 ft. lbs.) then an additional 90°.
(4) Set wheel toe pattern, (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- DURE).
(5) Tighten jam nut to 75 N·m (55 ft. lbs.) (Fig. 2).
Fig.2TIERODEND
1 - JAM NUT 2 - TIE ROD - INNER 3 - TIE ROD END - OUTER
DR
LINKAGE - LINK/COIL
19 - 33
LINKAGE - LINK/COIL
TABLE OF CONTENTS
page
page
LINKAGE - LINK/COIL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
STANDARD PROCEDURE - LUBRICATION . . . . 34
SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 34
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . 35
DAMPER
PITMAN ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36TIE ROD END
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37TRACK BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37DRAG LINK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LINKAGE - LINK/COIL DESCRIPTION
The steering linkage is comprised of a tie rod end, tie rod, drag link, steering damper and pitman arm (Fig. 1).
CAUTION: If any steering components are replaced or serviced an alignment must be performed.
NOTE: To avoid damaging ball stud seals, use Puller C-3894–A or an appropriate puller to remove tie rod ends (Fig. 2).
Fig.1LINK/COILFRONTSUSPENSION
1 - STABILIZER BAR 2 - PITMAN ARM 3 - STEERING GEAR 4 - STABILIZER LINK 5 - TIE ROD ENDS 6 - LOWER SUSPENSION ARMS 7 - DRAG LINK 8 - TRACK BAR 9 - DAMPER 10 - UPPER SUSPENSION ARM
LINKAGE - LINK/COIL
19 - 34
LINKAGE - LINK/COIL (Continued)DR
STANDARD PROCEDURE - LUBRICATION
Periodic lubrication of the steering system compo- nents is required. Refer to Lubrication And Mainte- nance for the recommended maintenance schedule.
The following components must be lubricated: †Tie rod †Tie rod end †Drag link
Fig.2BallStudPuller
1 - CLAMP 2 - ADJUSTMENT SLEEVE 3 - PULLER TOOL C-3894–A 4 - SEAL 5 - TIE-ROD END
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
Pitman Arm
Gear Shaft Nut
Drag Link Pitman Arm Drag Link Tie Rod Drag Link
Adjuster Clamp
Tie Rod End
Knuckle
Tie Rod End
Adjuster Clamp
Stabilizer Bar Link to Axle
Steering Damper
Axle
Steering Damper
Tie Rod
TORQUE SPECIFICATIONS
N·m 300
88
108
61
108
61
68
9581
Ft. Lbs.
225
65
80
45
80
45
50
7060
In. Lbs.
—
—
—
—
—
—
— —
—
LINKAGE - LINK/COIL
19 - 35
(2) Remove the drag link nut from the knuckle
side.
(3) Remove the drag link from the right knuckle
and pitman arm with Puller C-3894A (Fig. 3).
DR LINKAGE - LINK/COIL (Continued) SPECIAL TOOLS
STEERING LINKAGE
RemoverBallStudMB-991113
PullerTieRodC-3894-A
Fig.3DRAGLINKREMOVAL
1 - PITMAN ARM 2 - DRAGLINK 3 - C -3894-A PULLER
INSTALLATION
(1) Install the drag link to the pitman arm. Install
the nut and tighten to 88 N·m (65 ft. lbs.).
(2) Install
the drag link to the right steering knuckle. Install the nut and tighten to 108 N·m (80
ft. lbs.).(3) Install tie rod to the left steering knuckle and drag link. Install the nuts and tighten to 108 N·m (80 ft. lbs.).
(4) Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain- ing bolt is located on the bottom side of the sleeve.
PITMAN ARM REMOVAL
(1) Remove the drag link from the right knuckle
and pitman arm with Puller C-4150A (Fig. 4).
(2) Mark the pitman arm and shaft positions for installation reference. Remove the nut and washer from the pitman arm (Fig. 5). Remove the pitman arm with Puller C-4150A.
RemoverBallJointC-4150A
DAMPER REMOVAL
(1) Remove the steering damper mounting nuts
and bolts.
(2) Slide the damper from the isolation bushing. (3) Remove the damper.
INSTALLATION
(1) Install the steering damper on the axle and iso-
lation bushing. Tighten nut to 95 N·m (75 ft. lbs.).
(2) Install the steering damper on the tie rod.
Tighten nut to 81 N·m (60 ft. lbs.).
DRAG LINK REMOVAL
(1) Remove the draglink nut from the pitman arm
side.
19 - 36
LINKAGE - LINK/COIL PITMAN ARM (Continued)DR
Fig.4PITMANARMREMOVAL
Fig.6PITMANARMINSTALLED
1 - PITMAN ARM 2 - C-4150A PULLER
1 - DRAGLINK 2 - STEERING GEAR 3 - SWAYBAR 4 - NUT/WASHER 5 - PITMAN ARM
NOTE: Position the clamp on the sleeve so retain- ing bolt is located on the bottom side of the sleeve.
TIE ROD END REMOVAL
(1) Remove tie rod nuts (Fig. 7). (2) Remove tie rod from drag link and left knuckle
with Puller C-4150A.
Fig.5PITMANARMREMOVAL/INSTALLATION
1 - STEERING GEAR 2 - PITMAN ARM 3 - NUT 4 - WASHER
INSTALLATION
(1) Align reference marks and install pitman arm. (2) Install the lock washer and retaining nut on the pitman shaft and tighten nut to 251 N·m (185 ft. lbs.).
(3) Install the drag link to the pitman arm (Fig. 6). Install the nut and tighten to 108 N·m (80 ft. lbs.). (4) Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).
Fig.7TIERODENDS
1 - NUT 2 - TIE ROD ENDS
DR TIE ROD END (Continued) INSTALLATION
LINKAGE - LINK/COIL
19 - 37
(1) Install tie rod to the left steering knuckle and drag link. Install the nuts and tighten to 108 N·m (80 ft. lbs.).
(2) Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(3) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain-
