I am not a professional and was learning the entire time I was doing this. Please do not refer to this as the ONLY way to replace these. Tools:
Flat Head Screwdriver
T25 Torx Screwdriver/Ratchet Attachment
Ratchet
Ratchet Extensions
8mm, 10mm, 12mm, 13mm, 15mm, 3/4", and 24mm Sockets
10mm, 13mm, 15mm, 13/16", and 24mm Wrenches
5/8" and 18mm Line Wrenches
Small-Medium Pliers
Pulley Installer and Remover
Drip Pan
Rags
PATIENCE...
Parts:
Rack and Pinion
Power Steering Pump
At Least 2qts of ATF+4 Transmission Fluid (this is what power steering fluid uses)
5w-20 Motor Oil (I had to take off the oil filter and if you need to top off your oil after reinstall this is what it is for)
Steps:
1. Park with parking brake and run the seat belt through the steering wheel to keep wheel and shaft from spinning.
2. Open Hood
3. Remove Negative Battery Cable
4. Move Hood Release Cable out of the way to remove the Grille
5. Remove the Grille
Remove plastic fasteners and lift top over the hood bump stops, undo clips from atop headlight housing and use flat head screwdriver to the hidden clip off the side of the headlight housing, pull towards you and set aside.
Tricky Clip
6. Remove Headlight Housing
Using the T25 torx screwdriver remove the 3 screws mounting the housing, then unplug headlights/fog light via quarter-turn counter-clockwise.
7. Remove the Coolant/Wiper Fluid Tank
Using the T25 torx screwdriver remove the four screws mounting the tank, unscrew the radiator cap a quarter-turn and remove hose, unplug wiper pump connector via using the torx screwdriver to poke the hole and pulling up on the connector and remove hoses (90degree hose can be removed after tank is outside the engine bay, wiper fluid will slowly drain after removal of 90degree hose).
Top two screws
Wiper Connector
Driver's Side Bottom Screw
Passenger's Side Bottom Screw
8. Remove Fan Shroud
Using a 8mm socket remove the three screws mounting the fan shroud, after screws are removed lift shroud enough to unplug the fan's connector (use the flathead to pry the clip and pull out), then using the 10mm socket remove the bolt securing the wire harness connector and remove wire from shroud, set aside shroud.
Driver's Side Screw
Passenger's Side Screw
Bottom Screw (Transmission cooler lines are here)
Fan's Connector (put flathead's tip where red dash is)
Wire Harness Connector's Bolt
Finesse the fan shroud off and out.
9. Remove Serpentine Belt
Using a 5/8" socket (and a pipe extension) "tighten" the ribbed pulley (left pulley) on the belt tensioner (this goes against the torsion spring in the tensioner and releases pressure off the belt) and remove belt off of a pulley, work belt out of the engine bay.
10. Remove the Power Steering Pump
If there's fluid in the system try sucking as much out of the reservoir with a siphon (I didn't have any in there, hence why I needed to replace it all this haha). There are three 13mm bolts that you can reach via the holes in the pulley. Remove bottom to top. This will give you access to the send/return lines under the power steering pump. TIP: I removed the 4 10mm bolts that secured the fan so that I can have more wiggle room with moving the pump. There will be an all rubber hose with a pinch hose clamp on it. Angling the pump, use pliers to squeeze the hose clamp and slide it down the hose about 2"-3". The other metal line needs a 5/8" line wrench to loosen it, once loosened you can unthread with your fingers. Remove pump and place in a bucket or drip tray.
Power Steering Pump
Rubber Hose and Clamp
Metal Line (needs 5/8" line wrench)
13. Remove Pulley off Old Pump
Using a pulley puller, slide the bracket around pulley and using keeping the big wrench still, use the smaller wrench and tighten it to pull the pulley of the shaft. Save pulley for later.
12. Remove Fluid Reservoir from Old Pump and Re-install on New Pump
There are three 10mm bolts holding the fluid reservoir to the pump, two on the back and one on the front that is now available for access now that the pulley is off. After the bolts are out just pull the reservoir off gently. Take new pump and install the reservoir back the same way you took of the old one.
Back Two Bolts
Front Bolt (accessible after removing pulley)
Fluid Reservoir-Pump Connection Port
14. Re-install the Pulley on New Pump
Using the pulley installer, place pulley on top of new pump shaft and thread the installer into the pulley shaft and tighten until the inside of the pulley is flush with the shaft.
***If you do not need to replace the rack and pinion then move on to step 19***
15. Jack Up Front End and Remove Tires
16. Remove Outer Tire Rod Ends
With a pry bar press the ball joint further onto the knuckle and using a 13/16" wrench remove the nut and hammer the knuckle down so the ball joint pops out. Using a 24mm wrench back off the nut and then twist off the outer tie rod. COUNT THE AMOUNT OF TURNS IT TAKES AND WRITE IT DOWN FOR RE-INSTALL!
Outer Tire Removed (circled are the ball joint, knuckle mount hole, and securing nut for tie rod)
17. Remove Old Rack and Pinion
Using an 13mm sock and ratchet remove the alignment/compression bolt from the steering shaft to the rack and pinion shaft (I had to cheat and use an impact gun to zap it off because it was ON THERE) and pull up to remove the u-joint. Remove the two send/return lines with an 18mm line wrench (keep drip tray under vehicle) and out of the way. Using a 24mm wrench and 24mm socket, undo the two nuts off the underside of the cross member that mount the rack and pinion. Now for the fun part...patience...a lot of if. This could be done with one person but two people make it easier...twist the the steering shaft on the rack and pinion until it clears the engine pulley (I ended up removing the oil filter and oil filter drip tray/funnel to allow access to move the rack a little bit more). Remove the rack and pinion as gently as possible out the passenger's side wheel well. Unfortunately there is no easy way in remove this.
EDIT: After doing this again, I've managed to do it without removing the oil filter by removing the front differential mounting bracket. Best bet is to cut that bolt, or have a another 1/2" bolt, to be shorter so that you can remove it that much easier to work on.
Steering Shaft Alignment/Compression Bolt
Send/Return Lines on Rack and Pinion
18. Re-install New Rack and Pinion
Out the same way it came, re-install the new rack and pinion trying to be even more gentle than the old one. This goes in a little easier than removal but it's still a pain. Re-install the mounting bolts, send/return lines, and steering shaft alignment/compression bolt.
19. Re-install New Power Steering Pump
Re-install send/return lines and re-mount with the three bolts. (If you unbolted the fan re-bolt it now)
20. Cycle Fluid
With the belt still off, fill the fluid reservoir and turn the pulley counter-clockwise cycling the pump. This will lube up the pump so it doesn't destroy itself.
21. Re-install Serpentine Belt
Route everything but one pulley (I like to use the alternator pulley as the last one) and then tighten the belt tensioner pulley to give slack until you can properly install the belt onto the last pulley.
22. Re-install the Fan Shroud
23. Re-install the Coolant/Washer Fluid Tank
24. Re-install the Headlamps
25. Re-install the Grille
26. Power Steering Fluid Fill
With the front wheels off the ground, top of the reservoir with fluid and turn on the engine cycling the fluid throughout the system, then turn off as soon as fluid is gone. Continue to do this until it does not empty the reservoir. After this turn on the engine and rotate the steering wheel from lock to lock to center pushing out any air bubbles. If reservoir is low top off. Continue to do this until the grinding whining noise stops or is very low. Leave power steering fluid cap off for a few hours to allow any remaining air bubbles to work its way out the system. Come back after eating dinner and put the cap back on and go for a test drive to test out the system. If everything works:
27. GET AN ALIGNMENT
For those that follow this How-To I am not liable for any damages you did to your Jeep, yourself, or others.
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Thanks also for recording your process so others can benefit!
