Rack and Pinion Assembly Removal and Installation: Removal

Tools Required:

KM-507-B Ball Joint Remover

Disconnect the negative battery cable.
Raise and suitably support the vehicle.
Remove the wheels. Refer to WHEEL REMOVAL AND INSTALLATION .
Disconnect the power steering gear fluid outlet pipe. Place a drain pan under the steering gear to catch the power steering fluid.
Disconnect the power steering gear fluid inlet pipe.

Fig 1: Identifying Power Steering Gear Fluid Outlet Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Position the steering gear straight ahead by turning the steering wheel until the steering wheel spokes are vertical and pointed to the left.
Scribe a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower coupling.

Fig 2: Locating Alignment Mark Position
Courtesy of SUZUKI OF AMERICA CORP.
Remove the intermediate shaft pinch bolt.

Fig 3: Identifying Intermediate Shaft Pinch Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Remove the outer tie rod nuts and disconnect the tie rod ends from the strut assembly using the ball joint remover KM-507-B.
Remove the crossmember assembly. Refer to CROSSMEMBER ASSEMBLY REMOVAL AND INSTALLATION .
On vehicles equipped with an automatic transaxle, remove the transaxle center bracket. Refer to TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION .
On vehicles equipped with a manual transaxle, remove the bolts securing the transaxle center bracket to the transaxle and the engine. Move the transaxle center bracket out of the way.

Fig 4: Identifying Bolts Securing Transaxle Center Bracket To Transaxle And Engine
Courtesy of SUZUKI OF AMERICA CORP.
Remove the nuts and bolts from the steering gear mounting bracket.

Fig 5: Identifying Steering Gear Mounting Bracket Bolts And Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the return line from the clip on the crossmember.
Disconnect the rack and pinion assembly from the crossmember assembly.

Fig 6: Identifying Return Line Clip Bolt
Courtesy of SUZUKI OF AMERICA CORP.