Steering Rack Installation

CAUTION: Proper service and repair procedures are essential for safe and reliable installation of chassis parts, and require experience and tools specially designed for the purpose.  These parts must be installed by a qualified mechanic; otherwise an unsafe vehicle and/or personal injury could result.

Instructions:

1. Disconnect negative battery cable from battery and turn ignition key on.  Raise vehicle and support by frame.
2. Remove both front wheel and tire assemblies.
3. Disconnect outer tie rod ends from steering knuckles using a suitable tool.
4. Remove pinch bolt and nut connecting the left lower ball joint stud to the steering knuckle.  Disconnect lower control arm from steering knuckle using a suitable tool.
5. Some vehicles are equipped with a worm clamp which fastens the plastic steering column coupling shield to the rack and pinion lower housing.  This clamp must be removed prior to removal of old gear.  Save clamp for reinstallation.
6. Support front suspension cross member and remove all four (4) attaching bolts.
7. Lower cross member 4-5 inches in order to gain access to steering gear.
8. Remove splash shields and bellow shields.
9. Remove power steering pump lines at gear.
10. Remove bolts and brackets attaching gear to front suspension cross member.
11. If the steering coupling did not separate when cross member was lowered, grasp gear housing and pull downward.  Lower universal steering joint is removed with steering gear.

NOTE: On some vehicles, the plastic steering column coupling shield will also be removed with the gear.  This shield should be saved for reinstallation.

12. Remove gear from left side of vehicle.
13. Drive out roll pin attaching pinion shaft to lower universal joint and remove steering coupling from stub shaft of old gear.
14. Install lower universal joint on stub shaft of new unit and drive roll pin into universal joint in order to secure pinion shaft.
15. Transfer outer tie rod ends and jam nuts from old gear to new unit.
16. Install new gear through left (driver's) side of vehicle and position on cross member.
17. Install original brackets on mounting bushing or bushings.  Install original attaching bolts and torque to 28 N.-m (21 ft. lbs.).

NOTE: Before connecting pump hoses or lines to gear, it is suggested that all power steering fluid in hoses.  Lines and pump be flushed out if fluid is suspected of being contaminated.  Using contaminated fluid could result in premature failure of new gear and the possibility of the warranty becoming null and void.

18. Connect pump pressure and return lines to gear using new O-rings supplied Torque fittings to 20 N-m (15 ft. lbs.) to 27 N-m (20 ft. lbs.).

CAUTION: Threads in aluminum housing can be damaged by cross threading or over-tightening.

19. Secure splash shields and bellows shields previously removed Reinstall plastic steering column coupling shield and clamp (if removed).
20. Properly align D-shaped flats of female steering coupling, now located on new steering gear. With mating flats of male steering column coupling.  Make sure that the steering column spring clip is in place before rising cross member.

NOTE: The steering column spring clip may have fallen out during removal of the old gear from the vehicle.  This clip is to be used as a shim on the flat portion of the mating D-shaped steering couplings.

21. Raise cross member and install four (4) attaching bolts.  Tighten right rear cross member bolts first as this is a pilot bolt which correctly locates the cross member.  Tighten all four (4) attaching bolts to 122 N-m (90 ft. lbs.).
22. Raise left lower control arm into place and install pinch bolt and nut connecting the lower ball join stud to the steering knuckle.  On 1983 and earlier vehicles, tighten pinch bolt and nut to 68 N-m (50 ft. lbs.).  On 1984 and later vehicles, tighten pinch bolt and nut to 94 N-m (70 ft. lbs.).
23. Attach outer tie rod ends to steering knuckles.  Torque tie rod nuts to 47 N-m (35 ft. lbs.) and insert cotter pins.

NOTE: After reaching torque required, nut must always be tightened (up to 1/16 turns) further.  Never back nut off to insert cotter pin.

24. Install wheel and tire assemblies.
25. Lower vehicle to floor, turn ignition key off, and install negative batter cable.
26. Check and adjust power steering pump fluid and bleed air from system.
27. Check toe and adjust as necessary.

NOTE: The parts in this kit are designed to replace the worn or non-functioning original equipment parts in the vehicle as produced by the car factory.  These parts are not designed for installation on vehicles where the suspension and/or steering systems have been modified for racing, competition, or any other purpose.

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