Steering System (Service Information): Gear: Installation: AWD

Fig 1: Steering Gear Mounting Bolts

Courtesy of DAIMLERCHRYSLER CORP.

1. If necessary, install outer tie rods from original gear to replacement inner tie rods. Install each outer tie rod same amount of threads as it was installed on original gear. This will get toe setting close, saving some time when toe is set later in this procedure.
2. Lift steering gear (1) into mounted position and install steering gear lower mounting bolts (2 and 3). Install upper mounting bolt (4) and nut. Tighten all bolts to 102 N.m (75 ft. lbs.) torque.
   Fig 2: Rack Assembly And Inner Tie Rod Bellows Heat Shields

   Courtesy of DAIMLERCHRYSLER CORP.
3. Install heat shield (3) above each inner tie rod bellows (2). Tighten screws to 10 N.m (89 in. lbs.) torque.
   Fig 3: Hoses at AWD Gear

   Courtesy of DAIMLERCHRYSLER CORP.
   NOTE: Always use a NEW O-ring on the ends of the steering hoses.
4. Lubricate NEW O-ring on end of pressure hose with clean power steering fluid.
5. Install pressure hose (3) to steering gear (2). Tighten tube nut to 47 N.m (35 ft. lbs.) torque.
6. Lubricate NEW O-ring on end of return hose with clean power steering fluid.
7. Install return hose (1) to steering gear (2). Tighten tube nut to 47 N.m (35 ft. lbs.) torque.
8. Align splines and install steering coupling to steering gear shaft. Install NEW pinch bolt. Tighten bolt to 54 N.m (40 ft. lbs.) torque.
   Fig 4: Tie Rod Attachment at Knuckle

   Courtesy of DAIMLERCHRYSLER CORP.
9. Install each outer tie rod (2) end to its knuckle (3). Install nut (1) and tighten to 85 N.m (63 ft. lbs.) torque.
   Fig 5: Tire And Wheel Mounting

   Courtesy of DAIMLERCHRYSLER CORP.
10. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.) torque. (Refer to TIRES/WHEELS - INSTALLATION)
11. Lower vehicle.
    Fig 6: Disconnecting/Connecting Battery Cables

    Courtesy of DAIMLERCHRYSLER CORP.
12. Connect battery negative cable (2) to battery post. It is important that this is performed properly. (Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
13. Fill pump reservoir with fluid and perform pump initial operation procedure. (Refer to STEERING/PUMP - STANDARD PROCEDURE) 
14. Perform wheel alignment setting toe to specifications. (Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)
    Fig 7: Removing/Installing Tie Rods (AWD)

    Courtesy of DAIMLERCHRYSLER CORP.
15. Tighten tie rod jam nuts (1) to 75 N.m (55 ft. lbs.) torque.