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Steering Gearbox Removal and Installation

Special Tools Required

Ball joint remover, 28 mm
 07MAC-SL00201

Engine support hanger
 AAR-T1256-J00*
*: This special tool is available from Snap-on Tools    International, LLC.
Note these items during removal:
  • Use solvent and a brush, wash any oil and dirt off the end of the steering gearbox. Avoid any electrical parts. Blow dry with compressed air.
  • Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.
  • Lower the front subframe from the body and remove the steering gearbox through the gap produced by lowering the front subframe.
  • The illustrations show LHD model, RHD model is similar for items not shown in this section.
Removal
  1. Remove the front wheels.
  1. Release the lock lever, and adjust the steering column to the full tilt up position, and to the full telescopic in position.
  1. Tighten the lock lever.
  1. Remove the steering joint cover (A).

  1. Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and joint yoke (D) of the upper shaft to prevent the lower slide from pulling out.
  1. Release the lock lever, and adjust the steering column to the full telescopic out position, then tighten the lock lever.

  1. Remove the steering joint bolt (A).
  1. Disconnect the steering joint (B) by moving the steering joint toward the column.

  1. Remove the center guide (A) (if equipped) from top of the pinion shaft (B), and discard it. The center guide is for factory assembly use only.

  1. Remove the cotter pin (A) from the tie-rod ball joint, then remove the nut (B).

  1. Remove the clip (A) from the castle nut (B), and remove the nut.

  1. Install the hanger adapter (A) to the threaded hole (B) in the cylinder head using the 8 mm bolt.

  1. On the left side, remove the harness clip (A) from the harness clamp bracket (B).
  1. Place the cross arm foot (C) to the harness clamp bracket on both side.
  1. Install the engine support hanger (AAR-T1256-J00) to the vehicle, and attach the hook (D) to the hanger adapter (E). Tighten the wing nut (F) by hand, and lift and support the engine.
  1. Raise the vehicle on a lift.

  1. LHD model: Disconnect the motor 2P connector (A), and torque sensor 4P connector (B) from the torque sensor.

  1. RHD model: Disconnect the motor 2P connector (A), torque sensor 3P connector (B), and steering gearbox 1P connector (C) from the torque sensor.
  1. Wrap the connectors with the vinyl tape to avoid the contamination from grease or water.

  1. LHD model: Remove the secondary HO2S wire clamp (A) on steering gearbox. Do not disconnect secondary HO2S 4P connector and secondary HO2S.

  1. RHD model: Remove the secondary HO2S wire (A) from the clamp (B) on steering gearbox. Do not disconnect secondary HO2S 4P connector and secondary HO2S.

  1. Remove the lower torque rod (A).

  1. Attach a jack (A) to the center of the front subframe (B) and support the front subframe securely by raising the jack.
  1. Remove the front subframe mounting bolts (C).
  1. Lower the front subframe and steering gearbox as an assembly by lowering the jack slowly.

  1. Remove the steering gearbox (A) from the front subframe (B).

  1. Remove the pinion shaft grommet (A) from the top of the torque sensor.

Installation
  1. Before installing the steering gearbox, make sure that no grease is on the mating surface of the steering gearbox and the front subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove any grease from the bolt holes.
  1. Install the pinion shaft grommet (A). Align the cutout portion (B) in the pinion shaft grommet with the lug portion (C) on the torque sensor 3P connector. The grommet must not have a gap at the mating surface of the grommet and torque sensor.

  1. Place the steering gearbox (A) on the front subframe (B).
  1. Loosely install the stiffener plates, and new gearbox mounting bolts, then tighten the bolts to the specified torque in the sequence shown.
  1. Turn the lip (C) of the pinion shaft grommet to ease installation.
LHD model
RHD model

  1. Set the front subframe (A) mounting with the steering gearbox on the transmission jack and support it.
  1. Carefully raise the front subframe with the jack, and pass the pinion shaft into the cabin. Return the lip (B) of the pinion shaft grommet.
    NOTE:
    • Be sure that the pinion shaft grommet is securely in place. Check whether the pinion shaft grommet is not turning up. Incorrect installation can cause leakage of water, mud, or noise.
    • Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
  1. Loosely install new front subframe mounting bolts, then tighten the bolts to the specified torque in the sequence shown.

  1. Install the lower torque rod (A) with new mounting bolts and new mounting nut, and tighten them to the specified torque.
    NOTE: Make sure the stopper (B) of flange bolt securely installed.

  1. LHD model: Install the secondary HO2S wire clamp (A) to the steering gearbox.

  1. RHD model: Install the secondary HO2S wire (A) to the clamp (B) on steering gearbox.
  1. Remove the vinyl tape from the connectors.

  1. LHD model: Connect the motor 2P connector (A), and torque sensor 4P connector (B) to the torque sensor.

  1. RHD model: Connect the motor 2P connector (A), torque sensor 3P connector (B), and steering gearbox 1P connector (C) to the torque sensor.
  1. Lower the vehicle.
  1. Remove the engine support hanger (AAR-T1256-J00) from the vehicle.

  1. Remove the cross arm foot (A), then install the harness clip (B) to the harness clamp bracket (C) on the left side.

  1. Remove the hanger adapter (A) from the threaded hole (B) in the cylinder head.

  1. Wipe off any grease contamination from the tapered section and the threads of the ball joint. Connect the tie-rod ends (A) to the knuckles with a nut, then tighten it to the specified torque.
  1. Install the new cotter pin (B), and bend it as shown.

  1. Wipe off any grease contamination from the tapered section and threads of the lower arm ball joint. Then reconnect the lower arm (A) to the knuckle. Install the new castle nut (B) and tighten it.
    NOTE:
    • Be careful not to damage the lower ball joint boot (C). Check the ball joint boot for deformation before connecting the knuckle.
    • Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the joint pin clip hole. Do not align the castle nut by loosening it.
  1. Install the clip (D).
  1. Install the front wheels, then set the wheels in the straight ahead position.
    NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.

  1. Cut the wire (A).
  1. Slip the lower end of the steering joint (B) onto the pinion shaft (C) taking care to align the gap (D) within the angle shown.
  1. Release the lock lever, and adjust the steering column to the full tilt down position, and to the full telescopic out position, then tighten the lock lever.

  1. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower steering joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft.
  1. Pull on the steering joint to make sure that the steering joint is fully seated, then tighten the lower joint bolt to the specified torque.

  1. Install the steering joint cover (A).
  1. With the tyres raised off the ground, check for the following symptoms by turning the steering wheel fully to the right and left several times.
    Symptom
    Probable cause
    Rubbing sound coming from the lower steering column area.
    Steering column joint is contacting the cover.
    Grating sound from the lower steering column area, or a rough feeling during steering.
    Poor engagement of the pinion shaft serrations.
    Noise from around the steering wheel during steering.
    Poor engagement of the SRS cable reel with the steering wheel, or a damaged cable reel.

    • Turn the ignition switch to ON (II) and check that the SRS indicator should came on for about 6 seconds and then go off.
    • Make sure the horn and turn signal switches work properly.
    • Make sure the steering wheel switches work properly.
  1. After installation, do these checks:
    • Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times.
    • Check that the EPS indicator does not come on.
    • Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then adjust the front toe by turning the tie-rod ends, if necessary.