Steering Gearbox Removal and Installation (EPS)

Steering Gearbox Removal and Installation

Special Tools Required
Ball joint remover, 28 mm ( 07MAC-SL00200)

Removal

Note these items during removal:

Using solvent and a brush (avoid to electrical part), wash any oil and dirt off the end of the gearbox. Blow dry with compressed air.
Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.

1.	Make sure you have the anti-theft code for the radio, than write down the frequencies for the radio preset buttons. Remove the battery.

2.	Raise the front of vehicle, and support it with safety stands in the proper location.

3.	Remove the front wheels.

4.	Remove the steering wheel.

5.	Remove the steering joint cover A.

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

7.	Remove the steering joint cover B. Be careful not to damage the mating surface on the joint cover B and pinion shaft grommet. Replace the cover seal (A) if necessary.

8.	Remove the cotter pin from the tie-rod ball joint nut (B), and loosen the nut.

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

10.	Remove the P/S heat baffle plate (A).

11.	Disconnect the torque sensor 3P connector (A) from the steering gearbox.

12.	Disconnect the motor 2P connector (A) from the motor the steering gearbox, and seal the connector with vinyl tape or the like to avoid the adhesion of grease or water.

13.	Disconnect the ground terminal (B), and remove the wire harness stay (C).

14.	Remove the subframe right mid mount (A).

15.	Remove the steering gearbox mounting bolts on the right gearbox mout, and remove the steering stiffener plate (A).

16.	Remove the two flange bolts from the left side of the gearbox, then remove the gearbox mounting bracket (A) and cushion (B).

17.	Remove the rear engine mount stop (A).

18.	Remove the four flange bolts (B) that hold the rear engine mount rubber (C), and then loosen the one mounting bolt (D) that holds the rear engine mount bracket.

19.	To raise the rear portion of the engine, support the rear engine mount bracket with the stand jack (A) as shown in the figure below.

20.	Remove the loosened mounting bolt that holds the rear engine mount bracket, and remove the rear engine mount rubber. Then, pull up the rear engine mount rubber removed from its original position not to interfere with the removal of the steering gearbox.

21.	Remove the rear engine mount base (A) from the subframe.

22.	Remove the rear engine mount base (A) through the wheelwell opening after moving it to the left side of the vehicle.

23.	Move the steering gearbox towerd the front, and remove the pinion shaft grommet (A) from the top of the torque sensor.

24.	Apply vinyl tape (B) to the splines on the pinion shaft.

25.	Apply vinyl tape or equivalent material (A) to brake lines (B) to protect it from the pinion shaft.

26.	Move the steering gearbox to the left side, and rotate it so the pinion shaft points toward the front.

27.	Careful move the steering gearbox as an assembly toward the left side of the vehicle until pinion shaft clears wheelwell opening. Be careful not to damage the brake lines with the pinion shaft.

28.	Turn the gearbox to rearward (turn the pinion shaft upward), and further pull the motor 2P connector (A) in the left side direction as avoiding interference with the exhaust manifold cover (B). NOTE: The figure shows the view through the wheelwell opening on the right side.

29.

Turn the gearbox (A) toward the front, and remove it through the wheelwell oprning on the left side.
Be careful not to damage the following parts due to interference with the edge of the wheelwell opening when extracting and inserting the steering gearbox.

Torque sensor housing
Boots
Serrations of the pinion shaft
Motor 2P connector
Tie-rod end ball joint boot
Brake lines

Installation

1.	Before installing the steering gearbox, make sure that no any fluid or grease is on the mating surface of the gearbox and a subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove the any fluid or grease from the mount cushions and bolt holes.

2.	Apply a mild detergent solution to both side of the mount cushion mating surfaces (A).

3.	Pass the motor of the steering gearbox (B) through the wheelwell oprning on the left side.

4.	Turn the gearbox toward the front (turn the motor 2P connector toward the front), after the motor 2P connector (A) passes by the exhaust manifold cover (B). NOTE: The fugure shows the view through the wheelwell opening on the right side.

5.	Carefully move the steering gearbox toward the left side until the pinion shaft clears the wheelwell opening on the body.

6.	Rotate the steering gearbox so the pinion shaft (A) points upward.

7.	Continue moving the gearbox toward the left side until the steering gearbox is in position.Make sure the torque sensor 3P connector and motor 2P connector are routed above the gearbox.

8.	Remove the vinyl tape (A) from pinion shaft, and install the pinion shaft grommet (B). Align the slot in the pinion shaft gromment with the lug portion (C) on the torque sensor houshing.

9.	Bring the rear engine mount base (A) in the engine room through the wheelwell opening on the left side, and lead the rear engine mount base to its mounting position on the subframe over the steering gearbox.

10.	Install the rear engine mount base on the subframe.

11.	Install the rear engine mount rubber (A) between the rear engine mount base (B) and the mount bracket (C), and loosely tighten the mounting bolts.

12.	Lower the stand jack, and tighten the mounting bolts to specified torque.

13.	Install the rear engine mount stop (D).

14.	Loosely install the steering stiffener plate (A) and gearbox mounting bolts on the right side of the gearbox.

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

16.	Install the gearbox mounting bracket (C) over the mounting cushion.

17.	Tighten the flange bolts on both side of the gearbox to specified torque with alternately in two or more steps to the specified torque.

18.	Install the subframe right mid mount (A).

19.	Connect the motor 2P connector (A) and ground terminal (B) to the steering gearbox. Be sure to push the motor 2P connector until you hear a click so that the connector is secured. Poor connection or unestablished connection can cause ineffective assist.

20.	Install the wire harness stay (C).

21.	Connect the 3P connector (A) to the torque sensor. Be sure to push the connector until you hear a click so that the connector is secured. Poor connection or unestablished connection can cause ineffective assist.

22.	Install the P/S heat baffle plate (A).

23.	Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms.

24.	Install the tie-rod end ball joint nut and tighten it to the specified torque. Then install the new cotter pin (B) and bend it as shown (C) or (D).

25.	Install the new cover seal (A) all the way ground in the steering joint cover B. Make sure there no wrinkles in the seal.

26.	Install the steering joint cover B.

27.	Center the steering rack within its stroke.

28.	Position the steering column joint (A) so the bolt (B) is within the range shown.

29.	With the rack in the straight ahead driving position, cut the wire and slip the lower end of the steering joint on to pinion shaft (C).

30.

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 specified torque.

31.	Install the steering joint cover A.

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

33.	Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about three turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.

34.

Holding the tyres 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 with the resin from around the foot space.	Streering joint being in contact with the cover.
Grating from around the foot space, or grating feeling or resistance during steering.	Poor engagement of pinion shaft serrations.
Periodical swell of steering force.	Improper connection (forced connection) of the steering joint.
Clattering noise around the steering wheel.	Poor engagement of the SRS cable with the steering wheel (or damaged cable).

35.	Reconnect the battery, and perform these items. Do the idle learn procedure. Do the power window control unit reset procedure. Enter the anti-shaft codes for the radio, then enter the customer's radio station preset. Reset the clock. Do the memorize the torque sensor neutral position.

36.

After installation, parform 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 front toe inspection.
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.