Steering Gearbox Removal and Installation - EPS

Special Tools Required
Ball joint remover, 28 mm (  07MAC-SL00201)
 

Removal

• Using solvent and a brush to wash any oil and dirt off the end of the steering gearbox. Avoid any electrical parts. Blow dry with compressed air.
  
• Make sure to remove the steering wheel before disconnecting the steering joint to avoid damaging the cable reel.
  
• The illustrations shows LHD type, RHD type is symmetrical.
  

1.	Make sure you have the anti-theft codes for the radio, then write down the audio presets.

2.	Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.

3.	Raise the front of vehicle, and support it with safety stands in the proper locations.

4.	Remove the front wheels.

5.	Remove the steering wheel.

6.	Remove the driver's dashboard under cover.

7.	Remove the steering joint cover A.

8.	Remove the steering joint bolt (A), and disconnect the steering joint by moving the steering joint (B) toward the column. Hold the lower slide shaft (C) on the column with a piece of wire (D) between the joint yoke (E) on the lower slide shaft to the joint yoke on the upper shaft.

9.	Remove the center guide (A) (if equipped), and discard it. The center guide is for factory assembly only.

10.	Remove the cotter pin (A) from the 12 mm nut (B), and loosen the nut.

11.	Separate the tie-rod ball joint and knuckle using the special tool.

12.	Remove the front splash shield.

13.	Disconnect the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C), and motor 2P connector (D) from the passenger's side of the steering gearbox. Wrap the connectors with vinyl tape to avoid the contamination from grease or water.

14.	Remove the lower ball joint mounting bolt (A) and flange nuts (B) from the lower arm.

15.	Disconnect the lower arm from the lower ball housing.

16.	Vehicle with K20Z2 engine model: Remove the exhaust hanger (A) from the three way catalytic converter (TWC)(B).

17.	Attach a wood block (A) to the lower center of the front subframe (B). Attach a jack to the center of the wood block and support the front subframe securely by raising the jack.

18.	Remove the front subframe middle mount bolt (A) from the driver's side.

19.	Remove the front subframe middle mount bolt (A) from the passenger's side.

20.	Vehicle with except K20Z2 engine model: Remove the two 12 mm flange bolts (A) from the lower torque rod bracket.

21.	Vehicle with K20Z2 engine model: Remove the lower torque rod mounting bolt (A) and discard it.

22.	Vehicle with K20Z2 engine model: Remove the lower radiator hose (A) from the radiator hose stay (B).

23.	Vehicle with K20Z2 engine model (A/T): Remove the ATF filter mounting bolt (A), then open the ATF cooler hose clamp (B) on the front subframe.

24.	Vehicle with K20Z2 engine model (M/T): Remove the lower engine mounting bolt (A) while holding the nut (B) with a wrench and discard it.

25.	Remove the front subframe front mounting bolts (A) from the right and left sides of the vehicle, and discard them.

26.	Remove the front subframe rear mounting bolts (A) from the right and left sides of the vehicle, and discard them.

27.	Lower the front subframe and steering gearbox as an assembly by lowering jack slowly.

28.	Remove the harness clips (A) from the harness clamp brackets, then remove the harness clamp brackets (B). NOTE: If the bracket type is different, remove the corresponding bolts and clips.

29.	Remove the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C) and motor 2P connector (D) from the right side of the gearbox mounting bracket (E).

30.	Remove the pinion shaft grommet (A) from top of the torque sensor.

31.	Remove the two 10 mm bolts from the right side of the steering gearbox, then remove the gearbox mounting bracket (A) and mounting cushion (B).

32.	Remove the four 10 mm flange bolts from the left side of the steering gearbox, then remove the stiffener plates (A).

33.	Remove the steering gearbox (B) from the front subframe.

Installation

1.	Place the steering gearbox in position on the front subframe.

2.	Loosely install the stiffener plates (A) and gearbox mounting bolts on the left side of the steering gearbox.

3.	Position the cutout (A) on the mounting cushion (B) as shown, and install it on the right side of the steering gearbox securely.

4.	Install the gearbox mounting bracket (C) over the mounting cushion, and loosely install the two 10 mm bolts.

5.	Tighten the 10 mm bolts on both sides of the steering gearbox to specified torque alternately in two or more steps.

6.	Install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the torque sensor. The grommet must not have a gap at the mating surface of the grommet and torque sensor.

7.	Install the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C), and motor 2P connector (D) on the right side of the gearbox mounting bracket (E).

8.	Install the harness clamp brackets (A) to the front subframe, then install the harness clips (B) to the harness clamp brackts.

9.	Carefully raise the front subframe with the jack until the subframe is in position. NOTE: Be sure that the pinion shaft grommet is in place securely. Check whether the pinion shaft grommet is not turning up. Incorrect installation can cause leakage of water, mud, and noise.

10.	Install the new front subframe rear mounting bolts (A), and tighten them to the specified torque.

11.	Install the new front subframe front mounting bolts (A), and tighten them to the specified torque.

12.	Vehicle with K20Z2 engine model (M/T): Install the new lower engine mount bolt (A) while holding the nut (B) with a wrench.

13.	Vehicle with K20Z2 engine model: Install the lower radiator hose (A) to the radiator hose stay (B).

14.	Vehicle with except K20Z2 engine model: Install the lower torque rod bracket bolts (A), and tighten them to the specified torque.

15.	Vehicle with K20Z2 engine model: Install the new lower torque rod bracket bolt (A) and tighten to the specified torque.

16.	Vehicle with K20Z2 engine model (A/T): Install the ATF filter mounting bolt (A), then clamp the ATF cooler hose with the clamp (B).

17.	Install the front subframe middle mount bolt (A) on the driver's side, and tighten it to the specified torque.

18.	Install the front subframe middle mount bolt (A) on the passenger's side, and tighten it to the specified torque.

19.	Vehicle with K20Z2 engine model: Install the exhaust hanger (A).

20.	Connect the lower arm (A) to the lower ball joint (B).

21.	Install a new flange bolt (C) and new flange nuts (D). After lightly tightening all three fasteners, tighten them to the specified torque beginning with the flange nuts.

22.	Remove the vinyl tape, then connect the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C), and motor 2P connector (D) to the steering gearbox. Make sure to push these connectors until you hear a click so that the connectors are secured.

23.	Install the front splash shield.

24.	Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B), and tighten it.

25.	Install the new cotter pin (C), and bend it as shown.

26.	Center the steering rack within its stroke in steering joint connection.

27.	With the rack in the straight ahead driving position, cut the wire (A) and slip the lower end of the steering joint onto pinion shaft (B) in the range shown.

28.

Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Tighten the steering joint bolt to the specified torque.

29.	Install the steering joint cover A.

30.	Install the driver's dashboard under cover.

31.	Install the front wheel, then set the wheels in the straight ahead position.

32.	Install the steering wheel.

33.

Holding the tires raised off the ground (lifted up), check for the following symptoms by turning the steering wheel fully to the right and left several times. Symptom  Probable cause  Rubbing sound coming from the lower steering column area.  Steering column joint is contacting the cover.  Grating sound from the lower steering column area, or a rough feeling during steering.  Poor engagement of the pinion shaft serrations.  Noise from around the steering wheel during steering.  Poor engagement of the SRS cable reel with the steering wheel, or a damaged cable reel.

34.

Reconnect the negative cable to the battery and do the following items: Enter the anti-theft code for the radio, then enter the audio presets. Set the clock. Verify cruise control, auto remote and turn signal switch operation. Make sure the steering wheel is centered. Do the memorizing the torque sensor neutral position.

35.

After installation, perform the following checks: Start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on. Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then adjust the front toe by turning the tie-rod ends, if necessary. Check the front toe inspection.