Steering Gearbox Removal and Installation

Special Tools Required
Ball joint remover, 28 mm (  07MAC-SL00201)
 



Removal


Note these items during removal:

1.Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.

2.Raise the front of the vehicle, and support it with safety stands in the proper locations.

3.Remove the front wheels.

4.Remove the steering wheel.

5.Remove the driver's dashboard lower cover.

6.Remove the steering joint cover (A).

 

7.Remove the steering joint bolt (A), and disconnect the steering joint by moving the steering joint (B) toward the column. Hold the lower slide shaft (C) on the column with a piece of wire (D) between the joint yoke (E) on the lower slide shaft to the joint yoke on the upper shaft.

 

8.Remove the center guide (A) (if equipped), and discard it. The center guide is for factory assembly only.

 

9.Remove the engine under cover.

10.Remove the cotter pin (A) from the 12 mm nut (B), and loosen the nut.

 

11.Separate the tie-rod ball joint and the knuckle using the special tool.

12.For with HID model: Disconnect the head light adjuster front leveling sensor connector.

13.Remove the lower arm ball joint from the knuckle.

14.Remove the stabilizer link from the stabilizer bar.

15.RHD type: Disconnect the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C) and motor 2P connector (D). Wrap the connectors with vinyl tape to avoid the contamination from grease or water.

 

16.LHD type: Disconnect the motor 1P connector (A), and motor 2P connector (B). Wrap the connectors with vinyl tape to avoid the contamination from grease or water.

 


17.LHD type: Disconnect the torque sensor 4P connector (A), and motor-angle sensor 6P connector (B) then remove them from the harness clamp bracket (C). Wrap the connectors with vinyl tape to avoid the contamination from grease or water.

 

18.Remove the two 12 mm flange bolts (A) from the lower torque rod bracket, and discard them.

 

19.Place the transmission jack at the center of the front subframe and support it securely.

20.Remove the front subframe mounting bolts (A), and discard them.

 

21.Lower the front subframe (B) and steering gearbox as an assembly by lowering the jack slowly.

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

 

23.Remove the stiffener plate (A) and mounting bracket B, then remove the steering gearbox from the front subframe.

RHD: 

LHD: 

Installation


1.Center the steering rack within its stoke.

2.Place the steering gearbox on the front subframe.

RHD: 

LHD: 

3.Position the cutout (A) on the mounting cushion (C) as shown, and install it on the gearbox securely.

NOTE:
  • Make sure to align the tab (D) on the mounting cushion with paint mark (E) on the steering gearbox.
  • Apply water on the mounting cushion.

4.Align the tab on the mounting cushion with the locating hole (F) on the mounting bracket B, then install the stiffener plate (G) and new mounting bolts (H) loosely.

5.Install the mounitng bolts (I) and (J) loosely.

NOTE: Make sure to avoid interference with the subframe and the mounting bracket B.

6.Tighten the mounting bolts (H) to the specified torque.

7.Tighten the mounting bolt (I) to the specified torque.

8.Tighten the mounting bolts (J) to the specified torque.

9.Install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the top of the torque sensor. Turn out the lip (C) of the grommet to facilitate installation. Return the lip of the grommet after the operation of 11.

 

10.Set the front subframe (A) mounted with the steering gearbox on the transmission jack and support it.

 

11.Carefully raise the front subframe with the jack, and pass the pinion shaft into the cabin.

NOTE:
  • Be sure that the pinion shaft grommet is in place securely. 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.

12.Install the front subframe with new 14 mm flange bolts and tighten to the specified torque.

13.Install the new lower torque rod bracket bolts (A), and tighten to the specified torque.

 

14.RHD type: Remove the vinyl tape, then connect the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C), and motor 2P connector (D) to the steering gearbox. Make sure to push these connectors until you hear a click so that the connectors are secured.

 

15.LHD type: Remove the vinyl tape, and connect the torque sensor 4P connector (A) and motor-angle sensor 6P connector (B) to the steering gearbox, then install them to the harness clamp bracket (C). Make sure to push these connectors until you hear a click so that the connectors are secured.

 

16.LHD type: Remove the vinyl tape, then connect the motor 1P connector (A) and motor 2P connector (B) to the steering gearbox. Make sure to push these connectors until you hear a click so that the connectors are secured.

 

17.Connect the stabilizer link to the stabilizer bar.

18.Wipe off any grease contamination from the lower arm ball joint tapered section and threads. Then reconnect the lower arm to the knuckle.

19.For with HID lamp model: Connect the headlight adjuster front leveling sensor connector.

20.Wipe off any grease contamination from the ball joint tapered section and the threads. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it.

 

21.Install the new cotter pin (C) and bend it as shown.

22.Install the engine under cover.

23.Center the steering rack within its stroke in the steering joint connection.

24.With the rack in the straight ahead driving position, cut the wire (A) and slip the lower end of the steering joint onto pinion shaft (B) in the range shown.

 

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

 

26.Install the steering joint cover (A).

 

27.Install the driver's dashboard lower cover.

28.Install the front wheels, then set the wheels in the straight ahead position.

29.Install the steering wheel.

30.Holding the tyres raised off the ground (lifted up), 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. 

31.Reconnect the negative cable to the battery and do the following items:


32.After installation, perform the following checks:

  • Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
  • Start the engine, and let it idle. 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.
  • Check the front toe inspection.