Special Tools

J 42640 Steering Column Lock Pin

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Place a drain pan under the vehicle.



3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.




Warning: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage may cause loss of steering control which could result in an accident and possible personal injury.

Caution: Set steering shaft so the block tooth on the upper steering shaft is at the 12 o'clock position, the wheels on the vehicle are straight ahead and set the ignition switch to the LOCK position. Failure to follow these procedures could result in damage to the coil.

Caution: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.

4. Remove the lower pinch bolt from the power steering gear stub shaft (2).



5. Insert J 42640 into the steering column access hole in order to lock the steering column. This will maintain the correct orientation.
6. Remove the intermediate steering shaft (1) from the power steering gear stub shaft (2).
7. Remove both of the tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.



8. Support the rear of the frame (3) using jackstands.
9. Remove the frame bolts from the rear of the frame. Refer to Frame Replacement.

Caution: Do not lower the rear of the frame too far as damage to the engine components nearest to the cowl may result.

10. Lower the rear of the frame (3).
11. Remove the power steering pressure hose from the power steering gear. Refer to Power Steering Pressure Pipe/Hose Replacement.
12. Remove the power steering return hose from the power steering gear. Refer to Power Steering Return Hose Replacement.
13. Remove the power steering gear mounting bolts and nuts (1, 4).
14. Remove the power steering gear through the left wheel opening.

1. Install the power steering gear through the left wheel opening.

Caution: Refer to Fastener Caution in the Preface section.




2. Install the power steering gear mounting bolts and nuts (1, 4).

Tighten
Tighten the power steering gear mounting bolts to 90 N·m (66 lb ft).

3. Inspect the threads on the power steering pressure hose and the power steering return hose.
4. Inspect the O-ring seals on the power steering hoses.
5. Replace the seals if damaged, lubricate the seals before installation.
6. Install the clamp that holds the power steering hoses to the power steering gear.
7. Install the power steering pressure hose to the power steering gear. Refer to Power Steering Pressure Pipe/Hose Replacement.
8. Install the power steering return hose to the power steering gear. Refer to Power Steering Return Hose Replacement.
9. Raise the frame into position (3).
10. Install rear frame bolts. Refer to Frame Replacement.
11. Remove the jackstands.
12. Install the tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.




Caution: Set steering shaft so the block tooth on the upper steering shaft is at the 12 o'clock position, the wheels on the vehicle are straight ahead and set the ignition switch to the LOCK position. Failure to follow these procedures could result in damage to the coil.

Note: During the installation of the intermediate steering shaft, ensure the steering shaft is seated before you install the pinch bolt. The two mating shafts may disengage if the pinch bolt is inserted into the coupling before the steering shaft installation.

13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
14. Install the intermediate steering shaft (1) to the power steering gear stub shaft (2).
15. Install the lower pinch bolt to the intermediate steering shaft at the power steering gear stub shaft.

Tighten
Tighten the pinch bolt to 48 N·m (35 lb ft).




16. Install the intermediate steering shaft seal onto the power steering gear.
17. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
18. Remove the drain pan from under the vehicle.
19. Lower the vehicle.
20. Remove the J 42640 from the steering column.
21. Fill the power steering system with power steering fluid. Refer to Checking and Adding Power Steering Fluid.
22. Bleed the power steering system. Refer to Power Steering System Bleeding.
23. Inspect the power steering system for leaks. Refer to Power Steering Fluid Leaks.
24. Preform a front end alignment. Refer to Wheel Alignment Measurement.