B
FRONT SUSPENSION AND STEERING
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
33
Repair and Service Manual
634756
grease specified in tool list.
Assemble rack and pinion unit by installing pinion in
reverse order of removal making sure to lubricate pinion
seal lip prior to installing seal. See “Pinion Seal Replace-
ment” on page 31. Insert rack into rack and pinion unit.
Turn pinion clockwise to help pull rack in if necessary.
Install bellows and secure to rack extension with wire tie
(8).
Do not
secure large end of bellows to rack and pinion
unit until instructed to do so after setting proper rack
extension-to-rack and pinion unit clearance. Install ten-
sioner and tighten bolts (13) to 100 - 120 in. lbs. (11 - 14
Nm) torque. Thread jam nut and rack ball joint to original
location on rack extension and set jam nut hand tight.
Install rack and pinion unit on vehicle. See “Rack and Pin-
ion Unit Replacement” on page 33.
After replacing or servicing steering components,
always verify that an 1/8" gap exists between large
hex of rack extension and rack and pinion unit when
steering is turned fully to the right forcing passen-
ger spindle arm against front axle.
Set proper rack extension-to-rack and pinion unit clear-
ance. See “Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance” on page 33.
Rack and Pinion Unit Replacement
Tool List
Qty.
Socket, 13 mm ............................................................ 1
Ratchet ........................................................................ 1
Needle Nose Pliers...................................................... 1
Wrench, 11/16" ............................................................ 1
Ball Joint Separator ..................................................... 1
Plastic Faced Hammer ................................................ 1
Wrench, 5/8"................................................................ 1
Socket, 5/8" ................................................................. 1
Ratchet ........................................................................ 1
Torque Wrench, ft. lbs. ................................................ 1
Socket, 11/16" ............................................................. 1
Torque Wrench, in. lbs................................................. 1
To remove rack and pinion unit (12) (Ref. Fig. 14), loosen
front wheels and lift and support front of vehicle per
SAFETY section. Remove front wheels.
Remove bolt (13) and washer (14) securing intermediate
shaft (15) to rack and pinion unit (12).
Remove cotter pin (2) and loosen castellated nut (3) until
rack ball joint (1) threads are protected. Using a ball joint
separator as a lever, apply pressure to ball joint and tap
nut with plastic faced hammer to release ball joint from
passenger side spindle arm. Remove nut from ball joint
and ball joint from spindle arm.
Remove the three lock nuts (18) securing rack and pinion
unit to front axle and discard nuts. Remove rack and pin-
ion unit from vehicle. Retain washers (19), spacers (20)
and the two bolts (16) for assembly.
Replace rack and pinion unit in reverse order of removal.
Use new lock nuts (18) and tighten them to 35 - 50 ft. lbs.
(50 - 70 Nm) torque.
Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque
and continue to tighten as needed to insert new cotter
pin. Maximum torque is 50 ft. lbs. (70 Nm).
Tighten bolt (13) securing intermediate shaft to pinion to
155 - 215 in. lbs. (18 - 24 Nm) torque.
After replacing or servicing steering components,
always verify that an 1/8" gap exists between large
hex of rack extension and rack and pinion unit when
steering is turned fully to the right forcing passen-
ger spindle arm against front axle.
Set proper rack extension-to-rack and pinion unit clear-
ance. See “Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance” on page 33.
Install front wheels per WHEELS AND TIRES section.
Lower vehicle per SAFETY section.
Check front wheel alignment and adjust if necessary. See
Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance
Tool List
Qty.
Wrench, 11/16" ............................................................1
Wrench, 3/4" ................................................................1
Wrench, 1/2" ................................................................1
Wire Cutter...................................................................1
Washer, 1/8" Thick.......................................................1
Crowfoot Socket, 3/4" ..................................................1
Torque Wrench, ft. lbs..................................................1
Wire Tie, 10" long ........................................................1
Check for proper rack extension-to-rack and pinion unit
clearance by first turning steering wheel fully to the right.
The rear spindle arm on the passenger side
must rest
against
the front axle (Ref. Fig. 22). If it does not, all
adjustment is made at the rack ball joint (6) (Ref. Fig. 21).
Loosen jam nut (5) at rack ball joint and use wrench to
thread shaft of rack extension (7) further into rack ball
joint. This will provide more travel for the steering wheel
to be turned to the right.
