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Steering Gear - 4WD: Installation

NOTE:
  • Make sure the steering gear input shaft is turned to the left until the stop is reached.
NOTE:
  • Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in the steering gear bellows boot.
  1. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.
    Fig 1: Turning Steering Gear Input Shaft
    G04309577Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Make sure the steering gear control valve housing is turned toward the front of the vehicle.
  2. Install the steering gear into the RH opening of the crossmember.
    Fig 2: Installing Steering Gear Into RH Opening Of Crossmember
    G04309578Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Take care not to scuff or tear the steering gear bellows boots.
  3. Move the steering gear as far to the RH side of the vehicle as possible.
    Fig 3: Moving Steering Gear Into Position
    G04309579Courtesy of MAZDA MOTORS CORP.
  4. Move the LH inner tie rod into the opening in the crossmember and move the steering gear into position.
  5. To place the steering gear in the straight-ahead position, turn the steering gear input shaft to the left by 1/2 the number of turns previously recorded.
    Fig 4: Installing Pressure And Return Lines
    G04309580Courtesy of MAZDA MOTORS CORP.
  6. Rotate the steering gear control valve housing toward the rear of the vehicle.
  7. Install the 2 steering gear stud bolts.
    CAUTION:
    • Hold the tops of the steering gear-to-crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
  8. Install the 2 steering gear nuts.
    • Tighten to 150 N-m (15.3 kgf-m, 111 ft-lbf).
      NOTE:
      • O-ring seals must be installed any time the lines are disconnected from the steering gear.
  9. Position the pressure and return lines and install clamp plate nut.

    Tightening Torque: 25 Nm {2.5 kgf-m, 18 ft-lbf} (vehicles built through 12/2005) 35 Nm {3.6 kgf-m, 26 ft-lbf} (vehicles built after 12/2005) 

    CAUTION:
    • Do not allow the steering column 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 steering column shaft has rotated, the clockspring must be removed and re-centered. See CLOCKSPRING .
  10. Connect the steering column shaft to the steering gear and install a new bolt.
    • Tighten to 55N-m (5.6 kgf-m, 41 ft-lbf).
  11. Install the stabilizer bar and link. See STABILIZER BAR AND LINK .
  12. Install the outer tie-rod ends.
    • Rotate the outer tie-rod ends the number of turns recorded during removal.
  13. Position the outer tie rods and install the nuts and new cotter pins.
    • Make sure the brake disc shields are not bent and are not in contact with the outer tie-rod end boots.

      Tightening Torque: 70 Nm {7.1 kgf-m, 52 ft-lbf} (vehicles built through 12/2005) 80 Nm {8.2 kgf-m, 59 ft-lbf} (vehicles built after 12/2005) 

  14. Install the power steering fluid cooler. See POWER STEERING FLUID COOLER  .
  15. Tighten the tie-rod jam nuts.
    • Tighten to 80 N-m (8.2 kgf-m, 59 ft-lbf).
  16. Fill and leak check the system. See POWER STEERING SYSTEM FILLING .
  17. Check and, if necessary, align the front end. See WHEEL ALIGNMENT PREINSPECTION .
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