Steering Gear: Service and Repair
REMOVAL - POWER STEERING GEARNOTE: The power steering gear cannot be repaired or adjusted. If a malfunction or fluid leak occurs, the complete steering gear must be replaced.
1. Position the key cylinder in the lock position.
2. Rotate steering wheel 1/2 turn to the left to engage the steering column lock.
3. Disconnect the negative (-) cable from the battery and isolate cable.
4. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.
5. Raise the vehicle.
NOTE: When removing the center cap from the wheel do not use a sharp or hard tool. Use of such a tool can mare the finish on the wheel and damage the center cap.
6. Remove the center cap from the wheel. Center cap is removed by inserting a trim stick into the notch on the center cap and prying it off the wheel.
7. Remove wheels and tires from vehicle.
8. Remove the 3 nuts mounting the front fender brackets to the steering knuckles. Remove both front fenders from the steering knuckles.
9. Remove nut and washer attaching outer tie rod to steering knuckle. Nut is removed using following procedure. Hold tie rod end stud from rotating with a 11/32 socket while loosening and removing the nut with a wrench.
10. Remove outer tie rod ends from steering knuckles using Puller, Special Tool C-3894-A.
11. Install Remover, Roll Pin, Special Tool 6831A, through center of roll pin on intermediate steering shaft coupler at steering gear.
12. Remove roll pin from intermediate steering shaft coupler using the following procedure. Using a wrench, hold threaded bolt on Remover, Roll Pin, Special Tool 6831A from rotating. Using a second wrench, tighten nut against sleeve of special tool. This will pull the roll pin out of the coupler on the intermediate steering shaft.
13. Remove intermediate steering shaft from steering gear by sliding it off input shaft.
14. Remove power steering fluid pressure hose and return hose from steering gear.
15. Remove the 2 bolts and flag nuts, mounting the steering gear to the frame brackets.
16. Remove the power steering gear from the vehicle.
INSTALLATION - POWER STEERING GEAR
1. Install the power steering gear back in vehicle using the reverse order of its removal.
CAUTION: The steering gear mounting bolts must be tightened to the specified torque when installing the steering gear. Tightening the mounting bolts to the specified torque is necessary to eliminate any movement between the steering gear and its mounting brackets. Any movement of the steering gear will adversely affect the handling of the vehicle.
2. Install bolts and flag nuts mounting steering gear to frame brackets. Tighten both steering gear mounting bolts to a torque of 163 Nm (120 ft. lbs.)
3. Inspect O-rings on ends of power steering fluid hoses for any signs of damage or deterioration and replace is necessary before installation on steering gear.
4. Install power steering fluid pressure hose and return hose in steering gear fluid ports. Torque power steering pressure hose and return hose tube nuts to a torque of 31 Nm (275 inch lbs.).
5. Install outer tie rods on steering knuckles.
CAUTION: To ensure the stud of the tie rod end is adequately pulled into the steering knuckle the washer must be installed between the nut and the steering knuckle.
6. Install washer and nut attaching tie rod ends to steering knuckles. Tie rod end attaching nut is tightened and torqued using a crow foot and a 11/32 socket as shown in the image. Tighten the tie rod end castle nuts to a torque of 51 Nm (38 ft. lbs.).
7. Install front fenders on steering knuckles. Install the 3 nuts mounting the fender bracket to the steering knuckles. Tighten the nuts to a torque of 40 Nm (30 ft. lbs.).
NOTE: If a new steering gear is being installed, turn the input shaft on the steering gear 1/2 turn to the left (counter clockwise). This is required to correctly align the master spline on the steering gear input shaft with the master spline on the intermediate steering shaft coupler.
8. Align master spline on intermediate steering shaft coupler with master spline steering gear input shaft. Install the intermediate steering shaft coupler on steering gear input shaft until fully seated.
9. Start roll pin into intermediate steering shaft coupler by lightly tapping it with a soft face hammer.
10. Install Roll Pin Installer, Special Tool 6831A through intermediate steering shaft coupler and roll pin. Using a wrench, hold threaded bolt on Roll Pin Installer, Special Tool 6831A from rotating. Using a second wrench, tighten nut against sleeve of special tool. This will pull the roll pin into the intermediate steering shaft coupler. Install roll pin until exposed end is flush with coupler.
11. Install wheels and tires. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
12. Install the center cap on the wheel.
13. Lower the vehicle.
14. Connect the battery (-) negative cable to battery negative post.
CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar(R) Power Steering Fluid or equivalent.
15. Fill the power steering pump reservoir to the correct fluid level. Perform the Power Steering Pump Initial Operation procedure.
16. Check for leaks at all hose connections.
17. Adjust the front wheel toe on vehicle as necessary.