Buick Encore: Repair instructions

Steering linkage inner tie rod inspection

Special Tools

GE-8001 Dial Indicator Set

For equivalent regional tools, refer to Special Tools.

NOTE: This inspection procedure does not supersede local government required inspections that have more stringent requirements.

1. Turn the ignition key to the ON position with the engine OFF.

Fig. 4: Measuring Lash Between Inner Tie Rod & Steering Gear Housing

2. With the aid of an assistant, turn the steering wheel to the full stop position and hold the steering wheel in that position until the test is complete. Part of the steering linkage inner tie rod (2) being tested should be inside the steering gear housing. The inner tie rod housing (1) being tested should be inside the steering gear housing and seated against the steering stop.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. If there is not a good location for the GE-8001 dial indicator pointer at the steering gear housing, install a large worm gear hose clamp (3) to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the GE-8001 dial indicator pointer.
5. Install the GE-8001 dial indicator between the inner tie rod and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing.

   The lash between the inner tie rod and the steering gear housing is equal to the lash between the inner tie rod and the inner tie rod housing because the inner tie rod housing is inside the steering gear housing during this procedure.

Fig. 5: Identifying Tire Grasping Positions

NOTE: Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack.

6. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire in order to remove any lash.
7. Zero the GE-8001 dial indicator.
8. On the same side of the tire previously pushed in, gently pull out and measure the lash.
9. Record the measurement shown on the GE-8001 dial indicator.
10. If the measured value exceeds 0.5 mm (0.02 in), replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement (N40), Steering Linkage Inner Tie Rod Replacement (NJ1).
11. Repeat the procedure for the other side.

STEERING LINKAGE OUTER TIE ROD INSPECTION

Special Tools

GE-8001 Dial Indicator Set

For equivalent regional tools, refer to Special Tools.

NOTE: This inspection procedure does not supersede local government required inspections that have more stringent requirements.

1. Inspect the outer tie rod seal. If the outer tie rod seal is torn, replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement.
2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle .

Fig. 6: Measuring Outer Tie Rod Lash

3. Install the GE-8001 dial indicator between the outer tie rod and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the GE-8001 dial indicator position.

Fig. 7: Identifying Tire Grasping Positions

4. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash.
5. Zero the GE-8001 dial indicator.
6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash.
7. Record the measurement shown on the GE-8001 dial indicator.
8. If the measured value exceeds 0.5 mm (0.02 in), replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement.
9. Repeat the procedure for the other side.

Power steering system bleeding

NOTE:

• Use clean, new power steering fluid only. Refer to Adhesives, Fluids, Lubricants, and Sealers.
• Hoses touching the frame, body or engine may cause system noise.

  Ensure the hoses do not touch any other part of the vehicle.

• Loose connections may not leak, but could allow air into the steering system. Ensure all hose connections are tight.
• Maintain the power steering fluid level throughout the bleeding procedure.

1. Fill the power steering fluid reservoir with fluid to the minimum system level, the FULL COLD level, or the middle of the hash mark on the cap stick fluid level indicator, as applicable.
2. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the Vehicle .
3. With the key in the ON position and with the engine OFF, turn the steering wheel from stop to stop 12 times.

   If the vehicle is equipped with longer length power steering hoses, turn the steering wheel from stop to stop 15 to 20 times.

4. Verify the power steering fluid level. Refer to Checking and Adding Power Steering Fluid.
5. Start the engine. Rotate the steering wheel from left to right. Inspect the power steering system for signs of cavitation or fluid aeration, like pump noise or whining.
6. Verify the fluid level. Repeat the bleed procedure, if necessary.
7. Lower the vehicle.

CHECKING AND ADDING POWER STEERING FLUID

1. Run the engine until the power steering fluid reaches about 80ºC (170ºF).
2. Turn the engine OFF.
3. If the power steering fluid reservoir is covered by a shield or a cover, remove the shield or the cover, as applicable.
4. Clean the power steering fluid reservoir and the reservoir cap.
5. Remove the reservoir cap.

NOTE: Inspect the power steering pump fluid level at regular intervals.

6. Inspect the power steering fluid level in the reservoir or on the cap stick, as applicable. Ensure that the fluid level is at the HOT/FULL/MAX mark on the cap stick or on the reservoir, as applicable.

CAUTION: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.

7. Add power steering fluid if necessary. Refer to Adhesives, Fluids, Lubricants, and Sealers.
8. Install the reservoir cap.
9. If you removed a shield or a cover, install the shield or the cover, as applicable.

POWER STEERING SYSTEM FLUSHING

NOTE: Do not reuse any drained power steering fluid regardless of appearance or condition.

1. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the Vehicle .
2. Place a large drain pan under the vehicle in order to collect the draining fluid.
3. Remove the fluid return hose at the power steering fluid reservoir or the pump inlet connection, as applicable.
4. Plug the reservoir return hose inlet connection on the power steering fluid reservoir or the pump, as applicable.

NOTE: This step may require 4 L (4 qt) of power steering fluid until the draining fluid appears clear.

5. Have an assistant maintain the minimum fluid level in the reservoir using clean, new power steering fluid.

   Refer to Checking and Adding Power Steering Fluid.

6. With the key in the ON position and with the engine OFF, turn the steering wheel fully to the left and to the right. Continue until the fluid from the return hose runs clear.
7. Remove the plug and install the fluid return hose to the power steering fluid reservoir or the pump inlet connection, as applicable.
8. Bleed the power steering system. Refer to Power Steering System Bleeding.
9. Inspect the power steering fluid for the following indications of contamination:

• Milky fluid - water
• Brown fluid - burnt
• Plastic debris or dirt chunks

10. If the fluid is contaminated, repeat steps 3-9.
11. Remove the drain pan.
12. Lower the vehicle.

POWER STEERING FLUID RESERVOIR REPLACEMENT

Fig. 8: Power Steering Fluid Reservoir

Power Steering Fluid Reservoir Replacement

POWER STEERING PUMP PULLEY REPLACEMENT

Fig. 9: Power Steering Pump Pulley

Power Steering Pump Pulley Replacement

Power steering pump replacement

Removal Procedure

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the power steering fluid reservoir as possible.
3. Remove the air cleaner assembly.
4. Remove the power steering pump belt.

Fig. 10: Power Steering Fluid Reservoir Outlet Hose

5. Loosen the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the power steering pump.
6. Remove the power steering gear inlet hose (3) and seal (4) from the power steering pump. Discard the seal.
7. Remove the air conditioning evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement (LUJ, LUV) , Air Conditioning Evaporator Hose Assembly Replacement (2H0) .

Fig. 11: Power Steering Pump And Bolts

NOTE: The power steering pump pulley does not need to be removed on vehicle.

The pulley is shown off for clarity. Remove the power steering pump bolts through the holes in the pulley.

8. Remove the power steering pump bolts (1) from the power steering pump (2) and remove the pump from the vehicle.
9. Transfer any components as needed.

Installation Procedure

Fig. 12: Power Steering Pump And Bolts

1. Position the power steering pump (2) in the vehicle.

CAUTION: Refer to Fastener Caution .

2. Install the power steering pump bolts (1) and tighten to 22 N.m (16 lb ft).
3. Install the air conditioning evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement (LUJ, LUV) , Air Conditioning Evaporator Hose Assembly Replacement (2H0) .

Fig. 13: Power Steering Fluid Reservoir Outlet Hose

4. Connect the power steering gear inlet hose (3) and NEW seal (4) to the power steering pump.

CAUTION: Refer to Component Fastener Tightening Caution .

5. Tighten the power steering gear inlet hose (3) to 34 N.m (25 lb ft).
6. Connect the power steering fluid reservoir outlet hose (2) to the power steering pump and secure with the power steering fluid reservoir outlet hose clamp (1).
7. Clean any excess power steering fluid from the vehicle and remove the drain pans.
8. Install the power steering pump belt.
9. Install the air cleaner assembly.
10. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

Power steering pump bracket replacement

Fig. 14: Power Steering Pump Bracket

Power Steering Pump Bracket Replacement

POWER STEERING PUMP REAR BRACE REPLACEMENT

Fig. 15: Power Steering Pump Rear Brace

Power Steering Pump Rear Brace Replacement

STEERING LINKAGE OUTER TIE ROD REPLACEMENT

Fig. 16: Steering Linkage Outer Tie Rod

Steering Linkage Outer Tie Rod Replacement

STEERING GEAR BOOT REPLACEMENT

Fig. 17: Steering Gear Boot

Steering Gear Boot Replacement

POWER STEERING FLUID COOLER REPLACEMENT

Removal Procedure

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the power steering fluid reservoir as possible.
3. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Encore) , Front Bumper Fascia Replacement (Encore) .

Fig. 18: Power Steering Gear Outlet Hose And Clamp

4. Release the power steering gear outlet hose clamp (1) and disconnect the power steering gear outlet hose from the power steering fluid cooler (2).
5. Remove the plastic push pin (3) from the power steering fluid cooler bracket.

Fig. 19: P/S Fluid Reservoir Inlet Pipe

6. Release the power steering fluid reservoir inlet pipe clamp (1) and disconnect the power steering fluid reservoir inlet pipe (2) from the power steering fluid cooler.

Fig. 20: Power Steering Fluid Cooler

7. Remove the power steering fluid cooler nuts (1).
8. Remove the power steering fluid cooler (2) from the vehicle.

Installation Procedure

Fig. 21: Power Steering Fluid Cooler

1. Position the power steering fluid cooler (2) on the vehicle.

CAUTION: Refer to Fastener Caution .

2. Install the power steering fluid cooler nuts (1) and tighten to 9 N.m (80 lb in).

Fig. 22: P/S Fluid Reservoir Inlet Pipe

3. Connect the power steering fluid reservoir inlet pipe (2) to the power steering fluid cooler and secure with the power steering fluid reservoir inlet pipe clamp (1).

Fig. 23: Power Steering Gear Outlet Hose And Clamp

4. Connect the power steering gear outlet hose to the power steering fluid cooler (2) and secure with the power steering gear outlet hose clamp (1).
5. Secure the power steering fluid cooler bracket with the plastic push pin (3).
6. Clean any excess power steering fluid from the vehicle and remove the drain pans.
7. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Encore) , Front Bumper Fascia Replacement (Encore) .
8. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

Power steering fluid reservoir outlet hose replacement

Removal Procedure

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the power steering fluid reservoir as possible.

Fig. 24: Steering Fluid Reservoir Outlet Hose And Clamp

3. Release the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the power steering fluid reservoir.

Fig. 25: Power Steering Fluid Reservoir Outlet Hose

4. Loosen the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the power steering pump.
5. Remove the power steering fluid reservoir outlet hose from the vehicle.

Installation Procedure

1. Position the power steering fluid reservoir outlet hose on the vehicle.

Fig. 26: Power Steering Fluid Reservoir Outlet Hose

2. Connect the power steering fluid reservoir outlet hose (2) to the power steering pump and secure with the power steering fluid reservoir outlet hose clamp (1).

Fig. 27: Steering Fluid Reservoir Outlet Hose And Clamp

3. Connect the power steering fluid reservoir outlet hose (2) to the power steering fluid reservoir and secure with the power steering fluid reservoir outlet hose clamp (1).
4. Clean any excess power steering fluid from the vehicle and remove the drain pans.
5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

POWER STEERING FLUID RESERVOIR INLET PIPE REPLACEMENT

Removal Procedure

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the power steering fluid reservoir as possible.

Fig. 28: Steering Fluid Reservoir Inlet Pipe

3. Release the power steering fluid reservoir inlet pipe clamp (1) and disconnect the power steering fluid reservoir inlet pipe (2) from the power steering fluid reservoir.

Fig. 29: Power Steering Fluid Reservoir Inlet Hose

4. Release the power steering fluid reservoir inlet hose (1) from the plastic clip (2) and remove the plastic push pin retainer (3).

Fig. 30: P/S Fluid Reservoir Inlet Pipe

5. Release the power steering fluid reservoir inlet pipe clamp (1) and disconnect the power steering fluid reservoir inlet pipe (2) from the power steering fluid cooler.
6. Remove the power steering fluid reservoir inlet pipe from the vehicle.

Installation Procedure

1. Position the power steering fluid reservoir inlet pipe on the vehicle.

Fig. 31: P/S Fluid Reservoir Inlet Pipe

2. Connect the power steering fluid reservoir inlet pipe (2) to the power steering fluid cooler and secure with the power steering fluid reservoir inlet pipe clamp (1).

Fig. 32: Power Steering Fluid Reservoir Inlet Hose

3. Install the plastic push pin retainer (3) and secure the power steering fluid reservoir inlet pipe clamp (1) in the plastic clip (2).

Fig. 33: Steering Fluid Reservoir Inlet Pipe

4. Connect the power steering fluid reservoir inlet pipe (2) to the power steering fluid reservoir and secure with the power steering fluid reservoir inlet pipe clamp (1).
5. Clean any excess power steering fluid from the vehicle and remove the drain pans.
6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

Power steering gear inlet pipe/hose replacement

Removal Procedure

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the power steering fluid reservoir as possible.

Fig. 34: Power Steering Gear Inlet Hose And Seal

3. Remove the power steering gear inlet hose (1) and seal (2) from the power steering pump. Discard the seal.

Fig. 35: Steering Gear Inlet Hose

4. Remove the power steering gear inlet hose bracket bolt (1) and separate the power steering gear inlet hose (2) from the vehicle engine.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 36: Power Steering Gear Inlet Hose And Bracket

6. Remove the power steering gear inlet hose bracket bolt (1) and the plastic push pin (2) and separate the power steering gear inlet hose (3) from the vehicle frame.

Fig. 37: Power Steering Gear Inlet And Outlet Hoses

7. Remove the power steering gear inlet and outlet hose bolt (1) and release the power steering gear inlet and outlet hoses (2,3) and seals (4) from the steering gear. Discard the seals.
8. Remove the power steering gear inlet hose from the vehicle.

Installation Procedure

1. Position the power steering gear inlet hose on the vehicle.

Fig. 38: Power Steering Gear Inlet And Outlet Hoses

2. Connect the power steering gear inlet and outlet hoses (2,3) and NEW seals (4) to the steering gear.

CAUTION: Refer to Fastener Caution .

3. Install the power steering gear inlet and outlet hose bolt (1) and tighten to 11 N.m (97 lb in).

Fig. 39: Power Steering Gear Inlet Hose And Bracket

4. Secure the power steering gear inlet hose (3) to the vehicle frame using the power steering gear inlet hose bracket bolt (1) and the plastic push pin (2).
5. Tighten the power steering gear inlet hose bracket bolt (1) to 9 N.m (80 lb in).

Fig. 40: Steering Gear Inlet Hose

6. Secure the power steering gear inlet hose (2) to the vehicle engine using the power steering gear inlet hose bracket bolt (1).
7. Install the power steering gear inlet hose bracket bolt (1) and tighten to 22 N.m (16 lb ft).

Fig. 41: Power Steering Gear Inlet Hose And Seal

8. Install the power steering gear inlet hose (1) and NEW seal (2) to the power steering pump.

CAUTION: Refer to Component Fastener Tightening Caution .

9. Tighten the power steering gear inlet hose (1) to 34 N.m (25 lb ft).
10. Clean any excess power steering fluid from the vehicle and remove the drain pans.
11. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

Power steering gear outlet pipe/hose replacement

Removal Procedure

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the power steering fluid reservoir as possible.
3. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation

Fig. 42: Steering Gear Outlet Hose Clamp

4. Release the power steering gear outlet hose clamp (1) and disconnect the power steering gear outlet hose (2) from the power steering fluid cooler.

Fig. 43: Power Steering Gear Outlet Hose Bracket

5. Remove the power steering gear outlet hose bracket bolt (1) and the plastic push pin (2) and separate the power steering gear inlet hose (3) from the vehicle frame.

Fig. 44: Power Steering Gear Inlet And Outlet Hoses

6. Remove the power steering gear inlet and outlet hose bolt (1) and release the power steering gear inlet and outlet hoses (2,3) and seals (4) from the steering gear. Discard the seals.
7. Remove the power steering gear outlet hose from the vehicle.

Installation Procedure

1. Position the power steering gear outlet hose on the vehicle.

Fig. 45: Power Steering Gear Inlet And Outlet Hoses

2. Connect the power steering gear inlet and outlet hoses (2,3) and NEW seals (4) to the steering gear

CAUTION: Refer to Fastener Caution .

3. Tighten the power steering gear inlet and outlet hose bolt (1) to 11 N.m (97 lb in).

Fig. 46: Power Steering Gear Outlet Hose Bracket

4. Secure the power steering gear outlet hose (3) to the vehicle frame using the power steering gear inlet hose bracket bolt (1) and the plastic push pin (2).
5. Tighten the power steering gear outlet hose bracket bolt (3) to 9 N.m (80 lb in).

Fig. 47: Steering Gear Outlet Hose Clamp

6. Connect the power steering gear outlet hose (2) to the power steering fluid cooler and secure using the power steering gear outlet hose clamp (1).
7. Clean any excess power steering fluid from the vehicle and remove the drain pans.
8. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
9. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

STEERING GEAR PIPE REPLACEMENT

Fig. 48: Steering Gear Pipe

Steering Gear Pipe Replacement

Steering gear replacement (N40)

Removal Procedure

1. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement (N40) .
2. Remove the intermediate steering shaft upper seal. Refer to Intermediate Steering Shaft Upper Seal Replacement .
3. Remove as much power steering fluid from the power steering fluid reservoir as possible.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Disconnect the steering linkage outer tie rods from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
6. Disconnect the stabilizer shaft links from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .
7. Disconnect the exhaust isolators from the drivetrain and front suspension frame. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
8. Remove the rear transmission mount bracket through bolt. Refer to Transmission Mount Bracket Replacement - Rear (AWD) , Transmission Mount Bracket Replacement - Rear (FWD) .

Fig. 49: Power Steering Gear Inlet Hose And Bracket

9. Remove the power steering gear inlet hose bracket bolt (1) and the plastic push pin (2) and separate the power steering gear inlet hose (3) from the vehicle frame.

Fig. 50: Power Steering Gear Outlet Hose Bracket

10. Remove the power steering gear outlet hose bracket bolt (1) and the plastic push pin (2) and separate the power steering gear inlet hose (3) from the steering gear.
11. Place drain pans under the vehicle.

Fig. 51: Power Steering Gear Inlet And Outlet Hoses

12. Remove the power steering gear inlet and outlet hose bolt (1) and release the power steering gear inlet and outlet hoses (2,3) and seals (4) from the steering gear. DISCARD the seals.
13. Position adjustable jack stands underneath the left and right sides of the rear of the drivetrain and front suspension frame.
14. Loosen, but do not remove, the drivetrain and front suspension frame front bolts. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
15. Remove the drivetrain and front suspension frame upper and rear bolts. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
16. Partially lower the rear of the drivetrain and front suspension frame to gain clearance for the steering gear.
17. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement .

Fig. 52: Steering Gear And Mounting Bolts

18. Remove the steering gear nuts (1), washers (2) and steering gear bolts (3). DISCARD the bolts.
19. Remove the steering gear (4) from the vehicle.

Installation Procedure

Fig. 53: Steering Gear And Mounting Bolts

1. Position the steering gear (4) on the vehicle.
2. Install the NEW steering gear bolts (3), washers (2) and nuts (1).

CAUTION: Refer to Fastener Caution .

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners.

Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

3. Tighten the steering gear bolts (3) to 100 N.m (74 lb ft) + (90-105 degrees).
4. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement .
5. Install all drivetrain and front suspension frame bolts. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .

Fig. 54: Power Steering Gear Inlet And Outlet Hoses

6. Connect the power steering gear inlet and outlet hoses (2,3) and NEW seals (4) to the steering gear.
7. Tighten the power steering gear inlet and outlet hose bolt (1) to 11 N.m (97 lb in).

Fig. 55: Power Steering Gear Outlet Hose Bracket

8. Secure the power steering gear outlet hose (3) to the steering gear using the power steering gear inlet hose bracket bolt (1) and the plastic push pin (2).
9. Tighten the power steering gear outlet hose bracket bolt (1) to 9 N.m (80 lb in).

Fig. 56: Power Steering Gear Inlet Hose And Bracket

10. Secure the power steering gear inlet hose (3) to the vehicle frame using the power steering gear inlet hose bracket bolt (1) and the plastic push pin (2).
11. Tighten the power steering gear inlet hose bracket bolt (1) to 9 N.m (80 lb in).
12. Clean any excess power steering fluid from the vehicle and remove the drain pans.
13. Install the rear transmission mount bracket through bolt. Refer to Transmission Mount Bracket Replacement - Rear (AWD) , Transmission Mount Bracket Replacement - Rear (FWD) .
14. Connect the exhaust isolators to the drivetrain and front suspension frame. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
15. Connect the stabilizer shaft links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .
16. Connect the steering linkage outer tie rods to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
17. Install the intermediate steering shaft upper seal. Refer to Intermediate Steering Shaft Upper Seal Replacement .
18. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (N40) .
19. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.

Steering gear replacement (NJ1)

Removal Procedure

1. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement (NJ1) .
2. Remove the intermediate steering shaft upper seal. Refer to Intermediate Steering Shaft Upper Seal Replacement .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Disconnect the steering linkage outer tie rods from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
5. Disconnect the stabilizer shaft links from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .
6. Disconnect the exhaust isolators from the drivetrain and front suspension frame. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
7. Remove the rear transmission mount bracket through bolt. Refer to Transmission Mount Bracket Replacement - Rear (AWD) , Transmission Mount Bracket Replacement - Rear (FWD) .
8. Position adjustable jack stands underneath the left and right sides of the rear of the drivetrain and front suspension frame.
9. Loosen, but do not remove, the drivetrain and front suspension frame front bolts. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
10. Remove the drivetrain and front suspension frame upper and rear bolts. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
11. Partially lower the rear of the drivetrain and front suspension frame to gain clearance for the steering gear.
12. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement .

Fig. 57: Steering Gear Bolts

13. Remove the steering gear nuts (1), washers (2) and steering gear bolts (3). DISCARD the bolts.
14. Remove the steering gear (4) from the vehicle.

Installation Procedure

Fig. 58: Steering Gear Bolts

1. Position the steering gear (4) on the vehicle.
2. Install the NEW steering gear bolts (3), washers (2) and nuts (1).

CAUTION: Refer to Fastener Caution .

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners.

Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

3. Tighten the NEW steering gear bolts (3) to 100 N.m (74 lb ft) + (90-105 degrees).
4. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement .
5. Install all drivetrain and front suspension frame bolts. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
6. Install the rear transmission mount bracket through bolt. Refer to Transmission Mount Bracket Replacement - Rear (AWD) , Transmission Mount Bracket Replacement - Rear (FWD) .
7. Connect the exhaust isolators to the drivetrain and front suspension frame. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
8. Connect the stabilizer shaft links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .
9. Connect the steering linkage outer tie rods to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
10. Install the intermediate steering shaft upper seal. Refer to Intermediate Steering Shaft Upper Seal Replacement .
11. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (NJ1) .

STEERING LINKAGE INNER TIE ROD REPLACEMENT (N40)

Fig. 59: Steering Linkage Inner Tie Rod

Steering Linkage Inner Tie Rod Replacement (N40)

STEERING LINKAGE INNER TIE ROD REPLACEMENT (NJ1)

Fig. 60: Steering Linkage Inner Tie Rod

Steering Linkage Inner Tie Rod Replacement (NJ1)

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