Steering Gearbox Removal and Installation
Special Tools Required
Removal
Note these items during removal:
  • Use 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. Follow the same procedure in RHD type.
  1. Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
  1. Remove the front wheels.
  1. Remove the steering joint cover (A).
  1. Remove the center guide (A) (if equipped), and discard it. The center guide is for factory assembly only.
  1. Remove the cotter pin (A), from the 12 mm nut (B), and loosen the nut.
  1. LHD type: Disconnect the motor 1P connector (A), and motor 2P connector (B). Wrap the connectors with vinyl tape to avoid the contamination from grease or water.
  1. RHD type: Disconnect the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C) and motor 2P connector (D). Wrap the connectors with vinyl tape to avoid the contamination from grease or water.
  1. LHD type: Disconnect the torque sensor 4P connector (A), and motor-angle sensor 6P connector (B), then remove them from the harness clamp bracket (C). Wrap the connectors with vinyl tape to avoid the contamination from grease or water.
  1. Remove the two 12 mm flange bolts (A) from the lower torque rod bracket, and discard them.
  1. Remove the exhaust hanger (A) from the exhaust pipe A.
  1. Place the transmission jack at the center of the front subframe and support it securely.
  1. Remove the front subframe mounting bolts (A), and discard them.
  1. Lower the front subframe (B) and steering gearbox as an assembly by lowering the jack slowly.
  1. Remove the pinion shaft grommet (A) from the top of the torque sensor.
  1. Remove the stiffener plate (A) and mounting bracket B, then remove the steering gearbox from the front subframe.
LHD:
RHD:
Installation
  1. Center the steering rack within its stoke.
  1. Place the steering gearbox on the front subframe.
  1. Position the cutout (A) on the mounting cushion (C) as shown, and install it on the gearbox securely.
    NOTE:
    • Make sure to align the tab (D) on the mounting cushion with paint mark (E) on the steering gearbox.
    • Apply water on the mounting cushion.
  1. Align the tab on the mounting cushion with the locating hole (F) on the mounting bracket B, then install the stiffener plate (G) and new mounting bolts (H) loosely.
  1. Install the mounting bolts (I) and (J) loosely.
    NOTE: Make sure to avoid interference with the subframe and the mounting bracket B.
  1. Tighten the mounting bolts (H) to the specified torque.
  1. Tighten the mounting bolt (I) to the specified torque.
  1. Tighten the mounting bolts (J) to the specified torque.
LHD:
RHD:
  1. Install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the top of the torque sensor. Turn out the lip of the grommet to facilitate installation. Return the lip of the grommet after the operation of Step 11 .
  1. Set the front subframe (A) mounted with the steering gearbox on the transmission jack and support it.
  1. 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, or noise.
    • Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
  1. Install the front subframe with new 14 mm flange bolts and tighten to the specified torque.
  1. Install the exhaust hanger (A) to the exhaust pipe A.
  1. Install the new lower torque rod bracket bolts (A), and tighten to the specified torque.
  1. LHD type: Remove the vinyl tape, and connect the torque sensor 4P connector (A) and motor-angle sensor 6P connector (B) to the steering gearbox, then install them to the harness clamp bracket (C). Make sure to push these connectors until you hear a click so that the connectors are secured.
  1. RHD type: 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.
  1. LHD type: Remove the vinyl tape, then connect the motor 1P connector (A) and motor 2P connector (B) to the steering gearbox. Make sure to push these connectors until you hear a click so that the connectors are secured.
  1. Wipe off any grease contamination from the lower arm ball joint tapered section and the threads. Then reconnect the lower arm to the knuckle.
  1. Wipe off any grease contamination from the ball joint tapered section and the threads. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it.
  1. Install the new cotter pin (C) and bend it as shown.
  1. Center the steering rack within its stroke in the steering joint connection.
  1. 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.
  1. 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 in the groove of the pinion shaft securely. Pull on the steering joint to make sure that the steering joint is fully seated. Tighten the steering joint bolt to the specified torque.
  1. Install the steering joint cover (A).
  1. Install the front wheels, then set the wheels in the straight ahead position.
  1. 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 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.

  1. Reconnect the negative cable to the battery and do the following items:
  1. After installation, perform the following checks:
    • Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
    • 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.