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Home › Mazda › 2003 › B4000 Base, Standard › Repair and Diagnosis › Steering › Power Steering › Power Steering System › Steering Gear Removal/Installation › 4x4 Installation

4x4 Installation

  1. Using the special tool, install new seals on the power steering return hose and power steering pressure hose.
    Fig 1: Installing Seals On Power Steering Return Hose And Power Steering Pressure Hose
    G01924834Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Make sure the steering gear input shaft is turned to the left until the stop is reached.
      1. Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in tie-rod boots.
  2. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.
    NOTE:
    • Make sure the steering gear control valve housing is turned toward the front of the vehicle.
  3. Install the steering gear into the RH opening of the crossmember.
    Fig 2: Installing Steering Gear
    G01924835Courtesy of MAZDA MOTORS CORP.
  4. Move the steering gear as far to the RH side of the vehicle as possible.
    Fig 3: Moving Steering Gear As Far To RH Side
    G01924836Courtesy of MAZDA MOTORS CORP.
  5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position.
    Fig 4: Moving LH Front Wheel Spindle Tie-Rod
    G01924837Courtesy of MAZDA MOTORS CORP.
  6. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously.
  7. Rotate the steering gear control valve housing toward the rear of the vehicle.
    Fig 5: Rotating Steering Gear Control Valve Housing
    G01924838Courtesy of MAZDA MOTORS CORP.
  8. Install the steering gear to crossmember insulator bushings as shown.
    1. The large end of the metal sleeve must be positioned downward.
    2. Check that the mounting surfaces on the crossmember are clean and free of foreign material.
    Fig 6: Installing Steering Gear To Crossmember Insulator Bushings
    G01924839Courtesy of MAZDA MOTORS CORP.
  9. Install the steering gear to crossmember washers and stud bolts.
    1. The dished side of the washer faces downward.
    Fig 7: Installing Steering Gear To Crossmember Washers And Stud Bolts
    G01924840Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
  10. Install the nuts.
    Fig 8: Installing Nuts
    G01924841Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result.
  11. Install the lines and tighten the nut.
    Fig 9: Installing Lines
    G01924842Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clock-spring can result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and re-centered. For additional information see AIR BAG SLIDING CONTACT REMOVAL/INSTALLATION .
  12. Connect the intermediate shaft to the steering gear input shaft. Install a new lower steering column pinch bolt.
    Fig 10: Installing Lower Steering Column Pinch Bolt
    G01924843Courtesy of MAZDA MOTORS CORP.
  13. Install the power steering fluid cooler; see POWER STEERING FLUID COOLER REMOVAL/INSTALLATION  .
  14. Install the front stabilizer bar; see BAR AND LINK - 4X2 .
    NOTE:
    • Orientate the front stabilizer bar as noted during removal.
  15. Install the LH tie-rod end on the front wheel spindle tie-rod.
    1. Rotate the tie-rod end the number of turns recorded during removal.
    Fig 11: Installing LH Tie-Rod End On Front Wheel Spindle Tie-Rod
    G01924844Courtesy of MAZDA MOTORS CORP.
  16. Position the tie-rod ends on the steering knuckles. Install the castellated nuts and new cotter pins.
    1. Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals.
    Fig 12: Installing Castellated Nuts And Cotter Pins
    G01924845Courtesy of MAZDA MOTORS CORP.
  17. Tighten the tie-rod end jam nuts.
    Fig 13: Tightening Tie-Rod End Jam Nuts
    G01924846Courtesy of MAZDA MOTORS CORP.
  18. Position the air deflector, and install the retaining screws.
    Fig 14: Installing Retaining Screws
    G01924847Courtesy of MAZDA MOTORS CORP.
  19. Install the front wheel and tire assemblies, see WHEEL & TIRE REMOVAL/INSTALLATION .
  20. Fill, purge and leak check the system.
  21. Check and, if necessary, adjust the wheel alignment.
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