Steering Gear: Service and Repair
OVERVIEWNOTE: Before proceeding, review SERVICE WARNINGS AND CAUTIONS found at Steering Gear, Service Precautions.
NOTE: The steering gear on this vehicle is used to adjust front wheel dynamic toe pattern through the vehicles normal front suspension jounce and rebound travel.
Front wheel toe pattern is critical in controlling a vehicle's directional stability, as the vehicles suspension moves through normal jounce and rebound travel. Toe pattern adjustment is done by installing (0.5 1.0, 1.5, or 3.0 mm) shims between steering gear and steering gear mounting brackets. A maximum of 9.5 mm (.375 inch) shimming is allowed between the steering gear and its mounting brackets. If steering gear is removed for any reason or a replacement steering gear is installed, the same thickness of shim MUST be reinstalled between steering gear and mounting brackets. This is necessary to maintain correct front wheel toe pattern of the vehicle, which is set during the vehicle's assembly alignment procedure.
It is not necessary to do a front wheel toe pattern check or adjustment, if the steering gear is removed from vehicle for service or replacement. The only time front wheel toe pattern is require to be checked or adjusted, is if the frame of the vehicle is damaged.
REMOVAL
1. Disconnect the negative (-) cable from the battery and isolate cable.
2. Raise vehicle. See Hoisting in Maintenance for the required lifting procedure.
3. Remove the wheels and tires from the vehicle.
4. Remove the 4 bolts attaching the stabilizer bar bushing retainers to the frame rails. The stabilizer bar bushings and retainers do not have to be removed from the stabilizer bar.
5. Rotate the stabilizer bar forward and down until it is resting on the cross brace.
6. Remove outer tie rod end to steering knuckle attaching nuts and cotter pins on both sides of vehicle.
7. Remove both outer tie rod ends from the steering knuckles, using Puller Special Tool C-3894-A.
8. Lower the vehicle to level just above ground.
9. Remove the 2 fasteners that mount the air cleaner housing to the radiator support. Remove the fastener mounting the air cleaner housing to the cross car beam. Remove the wiring harness connector from the charge air temperature sensor in air cleaner housing. Remove the crank case vent hose and IAC hose from the air cleaner housing. Remove the hose clamps from the clean air hoses at the throttle bodies. Remove the complete air cleaner assembly from vehicle.
10. Remove the retaining bolt holding the intermediate steering shaft universal joint to the steering gear. Using a brass drift and hammer, tap the universal joint and intermediate shaft upward until it is off the shaft of the steering gear.
NOTE: When removing hoses from steering gear, remove the return hose fitting from the steering gear do not remove hose from fitting.
11. Remove the power steering pressure hose and the return hose from the steering gear.
CAUTION: Front wheel toe pattern on the Viper is an adjustable specification of the front wheel steering geometry. It is set at the factory when the vehicle is aligned. Toe pattern is adjusted by installing shims, between the steering gear and the steering gear mounting brackets. If the steering gear requires removal from vehicle, note the amount of shims installed between the steering gear and each mounting bracket. When an existing or a new steering gear is installed, the same amount of shims MUST be installed at each mounting bracket to maintain the required toe pattern.
12. Raise the vehicle.
13. Using Adapter, Special Tool 6632, loosen the 2 bolts mounting the steering gear to the steering gear mounting brackets. After mounting bolts are loosened using adapter, remove bolts from steering gear.
CAUTION: Retain toe pattern shims when steering gear is removed. Install above shims in original location with steering gear to maintain proper toe pattern.
14. Remove the steering gear from the vehicle by sliding it out left front fender well, forward of the steering knuckle.
INSTALLATION:
1. Install steering gear back in vehicle using reverse order of removal through the left front fender well.
CAUTION: Install the Toe Pattern shims in their original locations when the steering gear is installed in vehicle.
2. Align steering gear with steering gear mounting brackets. Install the 2 steering gear to mounting bracket attaching bolts and steering gear shims. Snug down the 2 steering gear to mounting bracket attaching bolts to hold the steering gear shims in place.
CAUTION: Achieving the required torque value on the steering gear mounting bolts, is required when installing the steering gear. Tightening the mounting bolts to the correct torque will eliminate any movement between the steering gear and steering gear mounting brackets. Any movement of the steering gear, will adversely affect front wheel toe pattern and handling of the vehicle.
3. Using Adapter, Special Tool 6632 , torque both steering gear mounting bolts to 203 Nm (150 ft. lbs.). When using Adapter, Special Tool 6632, for final torquing of steering gear mounting bolts. Torque wrench must be positioned as shown in to accurately torque the mounting bolts.
4. Install the outer tie rod ends on the steering knuckles. Install the tie rod end to steering knuckle attaching nuts. Tighten the tie rod end castle nuts to a torque of 51 Nm (38 ft. lbs.). Install cotter pins in tie rod ends.
5. Position the stabilizer bar and retainers against frame rails. Install the 4 attaching bolts for the stabilizer bar bushing retainers. Tighten the stabilizer bar bushing retainer attaching bolts to a torque of 23 Nm (200 inch lbs.).
6. Install the wheels and tires. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 122 Nm (90 ft. lbs.).
7. Lower the vehicle.
8. Install the power steering pressure hose and return hose in the steering gear fluid ports. Torque power steering pressure hose and return hose to steering gear tube nuts to 29 Nm (252 inch lbs.).
9. Align the master splines on the universal joint of the intermediate steering shaft and the steering gear shaft. Then using a soft (brass) drift and hammer install the universal joint on steering gear shaft until flat on steering gear shaft is aligned with bolt hole in universal joint.
10. Install the universal joint to steering gear shaft retaining bolt. Tighten the retaining bolt to a torque of 41 Nm (30 ft. lbs.).
11. Install the air cleaner in the vehicle using the following procedure.
- Install the air cleaner and hoses on the throttle bodies.
- Line up the 3 fastener holes in the air cleaner housing with the 2 j-nut locations on the radiator support and the 1 on the cross-car beam see.
- Install the 3 air cleaner assembly mounting screws but do not tighten.
- Be sure both clean air hoses are fully installed on inlets of throttle bodies then tighten hose clamps to 3 Nm (25 inch lbs.).
- Torque the 3 air cleaner assembly attaching screws to 3 Nm (25 inch lbs.).
- Install wiring harness connector onto charge air temperature sensor in the air cleaner housing.
- Install the crank case vent and Idle Air Control (IAC) hoses onto their fittings in the air cleaner housing.
12. Connect the battery (-) negative cable to battery negative post.
CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar Power Steering Fluid or equivalent.
13. Fill the power steering pump reservoir to the correct fluid level.
14. Perform Power Steering Pump Initial Operation procedure found under, Power Steering Pump, Service and Repair, Service Procedures.
15. Check for leaks at all hose connections.
16. Adjust the front wheel toe in on vehicle. (Refer to Wheels, Tires and Alignment, Alignment).