Rack and Pinion Assembly Removal

Tools Required: 

KM-507-B Ball Joint Remover 

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the wheels. Refer to WHEEL REMOVAL .
4. Disconnect the power steering gear fluid inlet pipe.
   Fig 1: Identifying Power Steering Gear Fluid Inlet Pipe

   Courtesy of SUZUKI OF AMERICA CORP.
5. Disconnect the hose from the power steering gear fluid outlet pipe. Place a drain pan under the steering gear to catch the power steering fluid.
   Fig 2: Identifying Hose From Power Steering Gear Fluid Outlet Pipe

   Courtesy of SUZUKI OF AMERICA CORP.
6. Position the steering gear straight ahead by turning the steering wheel until the steering wheel spokes are vertical and pointed to the left.
7. Scribe a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower coupling.
   Fig 3: Locating Mark On Stub Shaft Housing

   Courtesy of SUZUKI OF AMERICA CORP.
8. Remove the intermediate shaft pinch bolt.
   Fig 4: Identifying Intermediate Shaft Pinch Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
9. Remove the outer tie rod nuts and disconnect the tie rod ends from the strut assembly using the ball joint remover KM-507-B.
   Fig 5: Identifying Outer Tie Rod Nuts & Tie Rod Ends

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove the nuts and bolts from the steering gear mounting brackets. Remove the crossmember assembly for easy access of the rack and pinion assembly removal.
    WARNING: When removing the crossmember assembly it should be supported by Jack stands, in advance. Failure to support the crossmember properly can result in personal injury. In addition, remove the centermember bolt with caution when the exhaust pipe is hot.
    Fig 6: Identifying Nuts & Bolts Of Steering Gear Mounting Brackets

    Courtesy of SUZUKI OF AMERICA CORP.
11. Disconnect the SSPS solenoid valve connector.
12. Remove the rack and pinion assembly from the crossmember assembly.
    Fig 7: Identifying SSPS Solenoid Valve Connector

    Courtesy of SUZUKI OF AMERICA CORP.