I didn't like the FSM's directions to replace the steering rack. tjkj's were better, but I still didn't want to touch the diff. The generic multi-vehicle instructions said if the rack couldn't be lowered slide it out through the wheel well, so I tried and succeeded. Here's how I did it.

Removal
Set parking brake
Raise front, set on jack stands and remove wheels
Center steering
Disconnect tie rod ends (21 mm)
Remove drivers side tie rod end (count rotations and make note of it for installation)
Remove fans (Electric fan 10 mm, requires unbolting upper cross member 10 mm)
Remove serpentine belt (Tensioner 15 mm, clockwise to relieve tension)
Disconnect sensor in power steering line that connects below the power steering pump just behind the pulley.
Disconnect this same power steering line (16 mm / flange wrench recommended)
Slightly turn the steering wheel to position the steering shaft linkage bolt for easy access, then lock the steering wheel.
Remove the steering shaft linkage retaining bolt (13 mm)
Lift the steering linkage to remove it from the steering rack input shaft
Remove steering rack retaining bolts (24 mm for both the bolt and nuts under the cross member)
Grab the input shaft and rotate the steering rack forward
Remove the power steering supply lines (18 mm / flange wrench recommended)
Remove the hard lines from the steering rack (13 mm / flange wrench recommended)
Remove oil filter drainage tray from front diff (13 mm nut on passenger side / 10 mm bolt on drivers side)
If possible remove the bushings from the steering rack
Rotate the steering rack forward and push back so the cross member mounts drop behind the cross member
Push the drivers side tie rod all the way in
Fish the steering rack out the passenger side wheel well. The drivers side tie rod will have to be moved occasionally. When the steering rack input shaft is near the front diff mount the rack will need to swing towards the front of the vehicle and the drivers side tie rod will pass under the oil pan and trans cooler lines.
Remove passenger side tie rod end and jam nut (count rotations and make note of it for installation)

Installation
Install passenger side jam nut and tie rod end (used recorded count rotation for installation)
Remove the hard lines from the new steering rack (13 mm / flange wrench recommended)
Push the drivers side tie rod all the way in
Fish the steering rack in the passenger side wheel well so that the cross member mounts are behind the cross member. The drivers side tie rod needs to pass under the trans cooler lines and oil pan. The accordion boot will have to be pushed up to clear the front diff mount.
Lift and rotate back the steering rack so the cross member mounts are above the cross member
Install the steering rack bushings
Install oil filter drainage tray on front diff (13 mm nut on passenger side / 10 mm bolt on drivers side)
Install the hard lines on the steering rack (13 mm / flange wrench recommended)
Install the power steering supply lines (18 mm / flange wrench recommended)
Rotate the steering rack back
Install steering rack retaining bolts (24 mm for both the bolt and nuts under the cross member / 120 ft-lbs)
Install drivers side tie rod end (used recorded count rotation for installation)
Connect tie rod ends (21 mm / 80 ft-lbs)
Straighten steering knuckles
Install the steering linkage on the steering rack input shaft
Install the steering shaft linkage retaining bolt (13 mm)
Connect the power steering line that connects below the power steering pump just behind the pulley (16 mm / flange wrench recommended)
Connect sensor to this same power steering line
Install serpentine belt (Tensioner 15 mm, clockwise to relieve tension)
Install fans (Electric fan 10 mm, requires unbolting upper cross member 10 mm)
Add power steering fluid
Bleed power steering
Install wheels, remove from jack stands
Release parking brake

Mirror
https://sites.google.com/site/jeepliber ... ering-rack

_________________
Aaron

A vehicle isn't yours till you learn to wrench on it yourself.

2002 Jeep Liberty Sport (Eugene, I am the Passenger, And I ride and I ride.)
1999 Chev Astro 2WD (Green, Daily Driver)
1997 Chev Astro AWD (Grumpy "The Heep", $250 Rally Van, 335k miles, 2" lift, 31" tires)

That settles it....... Aaron has officially become my Jeep mechanic!!
That replacement would have been a 3 day ordeal at ANY dealership, & god knows what they'd charge.

If / when the time ever comes for repairs of this sort on my Liberty, I'll supply the parts, an endless supply of Arizona tea,
and the helping hands necessary to complete repairs.

Awesome...... totally awesome.

_________________
Brad
International Man of Mystery, Singer of Sentimental Ballads,
Soldier of Fortune, Guardian of the Holy Hand Grenade of Antioch,
Bass Player Extraordinaire, Keeper of the Eternal Flame
of the Immortals, Master Swordsman, The "5th" Beatle,
Expert Marksman, Stand-up Comedian, Martial Artist,
Jeep owner, and all around swell guy.