Gearbox Removal/Installation
NOTE: Before removing the steering gearbox, make
sure the front wheels are straight ahead.
1. Remove the steering joint cover.
STEERING JOINT COVER
CLAMPCLIP
2. Remove the steering joint bolts, and disconnect the
steering joint by moving the joint toward the
column.
STEERING JOINT
STEERING JOINT BOLTS
22 N.m (2.2 kg-m, 16 Ib-ft)
3. Lock the steering shaft with ignition key to keep
the steering shaft position.
4. Raise the car and place safety stands in the proper
locations (see section 1).
5. Remove the front wheels.
8 x 1.25 mm
BOLT WASHERS
25 N.m (2.5 kg-m, 18 Ib-ft)
Corrosion resistant bolt/nut
FLOOR UNDER
COVER
9. Remove the folding spare tire and spare tire holder
plate.
10. Disconnect the battery negative terminal, then
disconnect the positive terminal and remove the
battery.
11. Remove the spare tire holder and floor under cover.
10 N·m
(1.0 kg-m, 7 Ib-ft)
SPARE TIRE
HOLDER
(cont’d)
COTTER PIN
Replace.
On reassembly, bend
the cotter pin as shown.
Corrosion resistant bolt/nut
CASTLE NUT
44 N·m
(4.4 kg-m, 32 Ib-ft)
10 mm HEX NUT
NOTE: If necessary, apply penetrating type lubricant
to loosen the ball joint.
BALL JOINT REMOVER. 28 mm
07MAC-SL00200
6. Remove the cotter pin from the castel nut and
remove the nut.
7. Install the 10 mm hex nut on the ball joint. Be sure
that the 10 mm hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
might be damaged by the ball joint remover.
NOTE: Remove the ball joint using the Ball Joint
Remover, 28 mm (07MAC-SL00200). Refer to
page 18-21(’93-’96), 18-21(’91-’92) for how to use
8. Separate the tie-rod ball joint and knuckle using the
special tool.
CAUTION: Avoid damaging the ball joint boot.
TOOTHED LOCK
WASHERS
Manual Steering
Gearbox Removal/Installation (Cont’d)
12. Remove the flange bolts and nuts from the gearbox
and front crossbeam.
10 mm FLANGE NUTS
60 N·m
(6.0 kg-m, 43 Ib-ft)
FRONT CROSSBEAM
10 x 97 mm
FLANGE BOLT
FLANGE BOLT
Corrosion resistant bolt/nut
13. Remove the steering gearbox from the front cross-
beam by removing the flange bolts.
FLANGE BOLTS
60 N.m (6.0 kg-m, 43 Ib-ft)FRONT CROSSBEAM
Front
GEARBOX
ASSEMBLY
Corrosion resistant bolt/nut
14. Install the gearbox in the reverse order of removal.
CAUTION: Torque the castle nut of the tie-rod end
to the lower torque specification, then tighten it on-
ly far enough to align the slot with the pin hole. Do
not align the nut by loosening.
NOTE: When connecting the steering joint, make
sure that the cable reel of SRS is centered.
15. Set the steering rack in the center of its strokes.
16. Center the cable reel as follows:
Turn the steering wheel left approx. 150
degrees, to check the cable reel position with
indicator.
If the cable reel is centered, the yellow gear
tooth lines up with the alignment mark on the
cover.
Return the steering wheel right approx. 150
degrees to position the steering wheel in the
straight ahead position.
YELLOW GEAR TOOTH
ALIGNMENT MARK
17. Slip the lower of the steering joint onto the pinion
shaft (line up the bolt hole with the groove around
the shaft) and loosely install the lower bolt.
NOTE:
Be sure that the lower steering joint bolt is
securely in the groove in the steering gearbox
pinion.
If the steering wheel and rack are not aligned
centered, reposition the serrations at lower side
of the steering joint.
18. Adjust the front toe after installing the gearbox (see
section 18).