Steering Gear Replacement RWD

Tools Required

J 42640 Steering Column Anti-Rotation Pin

Notice: Do not rotate steering shaft after steering column has been removed. Damage to SIR components may occur.

1. Lock the steering column through the access hole in the steering column lower trim cover using the J 42640 .
2. Remove the air cleaner assembly.



3. Remove the intermediate shaft shield from the steering gear.



4. Place a drain pan below the steering gear.
5. Remove the pressure and the return hoses from the power steering gear.

Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt from entering the system.




6. Remove the lower intermediate shaft coupling bolt.
7. Draw alignment marks on the lower intermediate shaft coupling and the steering shaft.
8. Remove the lower intermediate shaft coupling from the steering shaft.
9. Remove the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.



10. Remove the steering gear mounting bolts and the washers from the frame.
11. Remove the steering gear.

1. Install the steering gear.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the power steering gear to the frame washers and the mounting bolts.

Tighten
Tighten the power steering gear to frame mounting bolts to 75 N·m (55 lb ft).

3. Install the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.



4. Install the lower intermediate shaft to the power steering gear.

Ensure that the alignment marks line up.

5. Install the lower intermediate shaft coupling bolt.

Tighten
Tighten the lower intermediate shaft coupling bolt to 35 N·m (26 lb ft).




6. Install the pressure and the return hoses to the power steering gear.

Tighten

•	Tighten the pressure hose to 25 N·m (18 lb ft) for the vehicle equipped with the 2.2L engines.

•	Tighten the pressure hose to 30 N·m (22 lb ft) for the vehicle equipped with the 4.3L engines.

•	Tighten the return hose to 25 N·m (18 lb ft).




7. Install the intermediate shaft shield to the power steering gear.
8. Install the air cleaner assembly.



9. Unlock the steering column by removing the J 42640 from the steering column lower steering column trim cover access hole.
10. Bleed the power steering system. Refer to Power Steering System Bleeding .

Steering Gear Replacement 4WD

Tools Required

Notice: Do not rotate steering shaft after steering column has been removed. Damage to SIR components may occur.

1. Lock the steering column through the access hole in the steering column lower trim cover using J 42640 .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L.



3. Remove the intermediate shaft shield from the steering gear.



4. Place a drain pan below the steering gear.
5. Disconnect the wiring harness clip from the power steering return hose at the power steering gear.
6. Remove the pressure and the return hoses from the power steering gear.

Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt from entering the system.




7. Remove the lower intermediate shaft coupling bolt.
8. Draw alignment marks on the lower intermediate shaft coupling and the steering shaft.
9. Remove the lower intermediate shaft coupling from the steering shaft.
10. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
11. Remove the steering linkage shield. Refer to Steering Linkage Shield Replacement in Steering Linkage.



12. Remove differential carrier shield mounting bolts.
13. Remove the differential carrier shield.



14. Remove the pitman arm ball stud cotter pin and nut at the relay rod.



15. Disconnect pitman arm from relay rod using J 24319-B .



16. Remove the steering gear mounting bolts and the washers from the frame.
17. Remove the steering gear.
18. Remove the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.

1. Install the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.
2. Install the steering gear.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the power steering gear to the frame washers and mounting bolts.

Tighten
Tighten the power steering gear to frame mounting bolts to 75 N·m (55 lb ft).




4. Connect the relay rod to the pitman arm ball stud.

Ensure the seal is on the stud.

5. Seat the taper using J 29193 or J 29194 .

Tighten
Tighten J 29193 or J 29194 to 62 N·m (48 lb ft).

6. Remove J 29193 or J 29194 from the pitman arm ball stud.
7. Install the new nut and cotter pin to the pitman arm ball stud at the relay rod.

Tighten
Tighten the pitman arm ball stud nut at the relay rod to 83 N·m (61 lb ft).




8. Install differential carrier shield.
9. Install the differential carrier shield mounting bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

10. Install the steering linkage shield. Refer to Steering Linkage Shield Replacement in Steering Linkage.
11. Lower the vehicle.



12. Install the lower intermediate shaft to the power steering gear.
13. Ensure that the alignment marks line up.
14. Install the lower intermediate shaft coupling bolt.

Tighten
Tighten the lower intermediate shaft coupling bolt to 35 N·m (26 lb ft).




15. Install the pressure and return hoses to the power steering gear.

Tighten

•	Tighten the pressure hose to 30 N·m (22 lb ft).

•	Tighten the return hose to 25 N·m (18 lb ft).

16. Connect the wiring harness clip to the power steering return hose at the power steering gear.



17. Install the intermediate shaft shield to the power steering gear.
18. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L.



19. Unlock the steering column by removing the J 42640 from the steering column lower steering column trim cover access hole.
20. Bleed the power steering system. Refer to Power Steering System Bleeding .