Power Steering Gear Box

REMOVAL & INSTALLATION

Pick-up and Montero

1. Disconnect the negative battery cable.
2. Raise the vehicle and support it safely on jackstands. Remove the front wheels.
3. Fold back the dust boot covering the steering shaft joint; remove the pinch bolt that holds the steering column shaft to the steering gear box.
4. Remove the cotter pin, castle nut and disconnect the steering linkage from the Pitman arm. Use a screw-type puller to separate the joint.
5. Disconnect and plug the fluid lines from the steering gear box.
6. Remove the steering gear mounting nuts and remove the gear from the vehicle. New mounting nuts will be needed for installation.

   Fig. 1: Power steering gear box removal and installation components — Monteros and some Pick-up trucks

7. To install, fit the steering gearbox into position on the vehicle frame and tighten the mounting bolts to 40–47 ft. lbs. (55–65 Nm).
8. Connect the pressure and return lines to the steering gearbox. Tighten the pressure hose the 9–13 ft. lbs. (12–18 Nm).
9. Connect the Pitman arm to the relay rod (center link) and tighten the nut to 33 ft. lbs. (44 Nm). Install a new cotter pin.
10. Connect the steering column shaft to the steering gearbox and tighten the pinchbolt to 22–25 ft. lbs. (30–35 Nm) for 4-wheel drive vehicles, and to 11–14 ft. lbs. (15–20 Nm) for rear wheel drive vehicles.
11. Install the front wheels and lower the vehicle to the ground.
12. Pour power steering fluid into the reservoir to the lower mark.
13. With the coil high tension line disconnected at the coil, operate the starter intermittently (15 or 20 seconds each time) and turn the steering wheel all the way from left to right and back several times. Do this 5 or 6 times while an assistant keeps watch on the fluid level in the reservoir.

    WARNING
    Do not be tempted to bleed the system with the engine idling. The air in the system will be broken up and absorbed into the fluid, resulting in a noisy, foamy mess. During the bleeding procedure, replenish the fluid so that the level never falls below the lower level on the reservoir.

14. Once the preliminary bleeding is done, the fluid level should stay fairly constant as the wheel is turned while cranking the motor. When this is true, the coil wire may be reconnected and the engine started. Only run the engine at idle; high rpm will not help.
15. With the engine running, turn the wheel from lock to lock several times and observe the fluid level in the reservoir. The level should not change more than about 0.20 in. (5mm) throughout the full travel of the wheel. The fluid should not look cloudy or milky.

    NOTE: If the system still contains air, the pump will be noisy during operation. This noisy operation can damage the pump. If the fluid level changes markedly during steering wheel movement, the system still contains air. If the fluid level rises suddenly after the engine has been shut off, the system still contains air.

16. Inspect all the fluid line connections for any sign of leakage.
17. Have the front alignment checked and adjusted by a reputable repair facility.