B
60
Repair and Service Manual
FRONT SUSPENSION AND STEERING
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
699322
Rack and Pinion Unit Replacement
Tool List
Qty.
Socket, 13 mm.............................................................1
Ratchet ........................................................................ 1
Needle Nose Pliers......................................................1
Wrench, 11/16" ............................................................1
Ball Joint Separator .....................................................1
Plastic Faced Hammer ................................................1
Wrench, 5/8" ................................................................1
Socket, 5/8" .................................................................1
Ratchet ........................................................................ 1
Torque Wrench, ft. lbs..................................................1
Socket, 11/16"..............................................................1
Torque Wrench, in. lbs.................................................1
1.
To remove rack and pinion unit (12) (Ref. Fig. 11),
loosen front wheels and lift and support front of vehi-
cle per SAFETY section. Remove front wheels.
2.
Remove bolt (13) and washer (14) securing interme-
diate shaft (15) to rack and pinion unit (12).
3.
Remove cotter pin (2) and loosen castellated nut (3)
until rack ball joint (1) threads are protected. Using a
ball joint separator as a lever, apply pressure to ball
joint and tap nut with plastic faced hammer to
release ball joint from passenger side spindle arm.
Remove nut from ball joint and ball joint from spindle
arm.
4.
Remove the three lock nuts (18) securing rack and
pinion unit to front axle and discard nuts. The rack
and pinion unit can now be removed from vehicle.
Retain washers (19), spacers (20) and the two bolts
(16) for assembly.
5.
Replace rack and pinion unit in reverse order of
removal.
6.
Use new lock nuts (18) and tighten them to 35 - 50 ft.
lbs. (50 - 70 Nm) torque.
7.
Tighten castellated nut (3) to 36 ft. lbs. (50 Nm)
torque and continue to tighten as needed to insert
new cotter pin. Maximum torque is 50 ft. lbs. (70
Nm).
8.
Tighten bolt (13) securing intermediate shaft to pin-
ion to 155 - 215 in. lbs. (180 - 250 kg cm) torque.
After replacing or servicing steering
components, always verify that an
1/8" gap exists between large hex of
rack extension and rack and pinion unit when steer-
ing is turned fully to the right forcing passenger
spindle arm against front axle.
9.
Set the proper rack extension-to-rack and pinion unit
Checking/Adjusting Rack Exten-
sion-to-Rack and Pinion Unit Clearance on page 60
10. Install the front wheels per the WHEELS AND TIRES
section and lower vehicle per the SAFETY section.
11. Check front wheel alignment and adjust if necessary.
Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance
Tool List
Qty.
Wrench, 11/16".............................................................1
Wrench, 3/4" ................................................................1
Wrench, 1/2" ................................................................1
Wire Cutter...................................................................1
Washer, 1/8" thick ........................................................1
Crowfoot Socket, 3/4" ..................................................1
Torque Wrench, ft. lbs. .................................................1
Wire Tie, 10" long.........................................................1
Check for proper rack extension-to-rack and pinion unit
clearance by first turning steering wheel fully to the right.
The rear spindle arm on the passenger side
must rest
against
the front axle (Ref. Figure 18). If it does not, all
adjustment is made at the rack ball joint (6) (Ref. Figure
17). Loosen jam nut (5) at rack ball joint and use wrench
to thread shaft of rack extension (7) further into rack ball
joint. This will provide more travel for the steering wheel
to be turned to the right.
Figure 18 Spindle Contact with Front Axle
1.
With the spindle arm resting against the front axle,
cut the wire tie (14) securing the bellows (9) to the
rack and pinion unit (1). Slide the bellows away from
the rack and pinion unit to expose the large hex of
the rack extension. A 1/8" gap should exist between
the large hex and the end of the rack and pinion unit.
Passenger Side
Spindle Arm
Resting Against
Front Axle
Rack
Ball
Joint
Front
of Vehicle
