Steering Gear Replacement
REMOVALRemote Ground Cable At Shock Tower:
Correctly Isolated Remote Ground Cable:
1. Remove remote ground cable from ground stud on shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud.
2. Siphon as much power steering fluid as possible from the remote power steering fluid reservoir.
Intermediate Shaft Coupler To Steering Gear Attachment:
3. From interior of vehicle, remove the retaining pin from the intermediate shaft coupler pinch bolt. Then remove the pinch bolt from the intermediate shaft coupler and the separate intermediate shaft coupler, from steering gear shaft.
4. Raise vehicle on jack stands or centered on a frame contact type hoist.
5. Remove both front wheel and tire assemblies from the vehicle.
Removing Tie Rod End Nut:
6. Remove nuts attaching both outer tie rod ends to the steering knuckles. Nuts are to be removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench.
Tie Rod End Removal From Steering Knuckle:
7. Remove both tie rod end studs, from the steering knuckles, using Remover, Special Tool MB-991113.
CAUTION:
- This vehicles is designed and assembled using NET BUILD front suspension alignment settings. This means that front suspension alignment settings are determined as the vehicle is designed by the location of front suspension components in relation to the vehicle body. This process is carried out when building the vehicle, by accurately locating the front suspension crossmember to master gage holes located in the underbody of the vehicle. With this method of designing and building a vehicle, it is no longer necessary or possible to adjust a vehicles front suspension alignment settings. Consequently, whenever the front suspension crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. Front suspension Toe settings though are still adjustable by the outer tie rod ends.
- Before removing the front suspension crossmember from the vehicle, locating marks for the front suspension crossmember MUST be scribed on the front suspension crossmember and body of vehicle. This must be done so front suspension crossmember can be located against body of vehicle, in the same location when it is installed back in vehicle. If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assembled, NET BUILD front suspension alignment settings will not be obtained. This may lead to handling and or tire wear problems.
NOTE: Use the following procedure to mark the side to side and front to back installed location of the front suspension crossmember to the body of the vehicle.
Front Suspension Crossmember Front To Back Locating Mark (Left Side Front):
Front Suspension Crossmember Front To Back Locating Mark (Left Side Rear):
8. Using an awl, scribe a line on the body and marking the front to back installed location where the front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at both the front and back of where the crossmember is mounted to the vehicle and on each side of the vehicle. In and the left side of the vehicle is shown.
Front Suspension Crossmember Side To Side Locating Mark:
9. Using an awl, scribe a line on the front suspension crossmember marking the side to side installed location where front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at the side of the frame rail bracket where the crossmember is mounted to the vehicle. The locating mark is to be marked the same on each side of the vehicle. In the left side of the vehicle is shown.
Stabilizer Bar Bushing Clamp Attaching Bolts:
10. Remove the stabilizer bar bushing clamp to body attaching bolts only. The sway bar bushing clamp to front suspension crossmember bolts do not need to be removed.
11. If vehicle is equipped with antilock brakes, the hydraulic control unit can not hang from the brake tubes when lowering front suspension crossmember. Using wire, tie the antilock brakes hydraulic control unit to the body and engine so the wire will support it when the crossmember is lowered.
12. If vehicle is equipped with antilock brakes, remove the 3 bolts attaching the antilock brakes hydraulic control unit to the front suspension crossmember.
Shock Clevis To Lower Control Arm Bolts:
13. Remove the bolts attaching the shock absorber clevis to the left and right lower control arms.
Engine Support Bracket To Crossmember Attaching Bolts:
14. Remove the 2 bolts attaching the under engine support bracket to the front edge of the front suspension crossmember.
Rear Support Bracket Attachment To Crossmember:
15. Remove the 2 attaching bolts from the rear support bracket at the rear of the front suspension crossmember.
Engine Support Bracket To Transaxle Bracket Bolt:
16. Remove bolt attaching engine support bracket to the transaxle mounting bracket.
17. Position a transmission jack under the center of the front suspension crossmember. Transmission jack is used to lower, support and raise front suspension crossmember when removing steering gear assembly.
Crossmember To Body Attaching Bolts:
18. From each side of the vehicle, remove the 2 bolts attaching the front and rear of the front suspension crossmember to the frame rails of vehicle.
19. Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms, weight of crossmember must be supported by the transmission jack.
Power Steering Pressure And Return Hose At Steering Gear:
20. Remove power steering fluid, pressure and return hoses from the power steering gear assembly.
21. Remove wiring harness connector,from the power steering fluid pressure switch.
Steering Gear Rear Mounting Isolator Bolt:
Steering Gear Front Mounting Bolt:
Steering Gear Saddle Bracket Mounting Bolts:
22. Remove the 2 bolts, at the isolators attaching the steering gear assembly to front suspension crossmember. Then remove the 2 bolts attaching the steering gear saddle bracket to the front suspension crossmember. Remove the steering gear assembly from the front suspension crossmember.
23. Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed.
INSTALLATION
Steering Gear Rear Mounting Isolator Bolt:
Steering Gear Front Mounting Bolt:
Steering Gear Saddle Bracket Mounting Bolts:
1. Install steering gear assembly on front suspension crossmember. Install the 2 long steering gear assembly to front crossmember mounting bolts into the mounting isolators. Then install the 2 short bolts into the saddle bracket. Tighten the 4 steering gear mounting bolts to a torque of 68 Nm (50 ft. lbs.).
Power Steering Pressure And Return Hose At Steering Gear:
2. Install the power steering fluid pressure and return lines on the ports of the power steering gear. Tighten power steering fluid pressure and return lines to steering gear tube nuts to a torque of 31 Nm (275 inch lbs.).
Crossmember To Body Attaching Bolts:
3. Using transmission jack, raise front suspension crossmember and steering gear against body of vehicle. Start the 2 rear bolts into tapping plates, attaching front suspension crossmember to body of vehicle. Then install the 2 front bolts, attaching front suspension crossmember to frame rails of vehicle. Tighten the 4 mounting bolts evenly, until front suspension crossmember is against body of vehicle at the 4 mounting points. Then torque the 4 mounting bolts to 2 Nm (20 inch lbs.) to hold front suspension crossmember in position.
CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribed into body of vehicle. This MUST be done to maintain NET BUILD front suspension alignment settings.
Front Suspension Crossmember Front To Back Locating Mark (Left Side Front):
Front Suspension Crossmember Front To Back Locating Mark (Left Side Rear):
Front Suspension Crossmember Side To Side Locating Mark:
4. Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the previously scribed positioning marks on body of vehicle. When front suspension crossmember is correctly positioned, torque the 2 rear crossmember mounting bolts to 163 Nm (120 ft. lbs.). Then torque the 2 front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.).
Engine Support Bracket To Crossmember Attaching Bolts:
5. Install the engine support bracket on the front of the front suspension crossmember. Install the 2 support bracket to suspension crossmember attaching bolts and tighten to a torque of 75 Nm (55 ft. lbs.).
Engine Support Bracket To Transaxle Bracket Bolt:
Rear Support Bracket Attachment To Crossmember:
6. Install bolt attaching engine support bracket to transaxle mounting bracket. Tighten bolt to a torque of 75 Nm (55 ft. lbs.).
7. Install the 2 bolts attaching the rear support bracket, for the under engine support bracket, to the rear of the front suspension crossmember. Tighten bolts to a torque of 75 Nm (55 ft. lbs.).
Power Steering Pressure And Return Hose At Steering Gear:
8. Install vehicle wiring harness connector onto power steering fluid pressure switch on steering gear assembly. Be sure locking tab on wiring harness connector is securely latched to pressure switch.
9. Install the antilock. brakes hydraulic control unit mounting bracket on the front suspension crossmember. Install the 3 mounting bracket to crossmember attaching bolts and tighten to a torque of 28 Nm (250 inch lbs.).
Shock Clevis To Lower Control Arm Bolts:
10. Loosely install the 2 shock absorber clevis to lower control arm attaching nuts and bolts.
Tie Rod End Removal From Steering Knuckle:
11. Install tie rod seal boot heat shield on tie rod end.
Torquing Tie Rod End Attaching Nut:
12. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. V8Thile holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 61 Nm (45 ft. lbs.).
Stabilizer Bar Bushing Clamp Attaching Bolts:
13. Install the 2 stabilizer bar bushing clamp to body attaching bolts and securely tighten.
Lower Control Arm Correctly Supported By Jack Stand:
CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown.
14. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm.
15. Tighten the shock absorber clevis to lower control arm bushing thru-bolt to a torque of 92 Nm (68 ft. lbs.).
16. Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts in proper sequence to a torque of 129 Nm (95 ft. lbs.) torque.
CAUTION: Before connecting steering column intermediate shaft coupler onto steering gear shaft, front wheels must be pointed straight ahead and steering wheel must be in center position.
Intermediate Shaft Coupler To Steering Gear Attachment:
17. From interior of vehicle, reconnect the steering column intermediate shaft coupler on the steering gear shaft. Install a new Steering gear coupler retaining pinch bolt and torque to 27 Nm (240 inch lbs.). Be sure to install the upper to lower steering coupler retaining bolt, retention pin.
CAUTION: Do not use automatic transmission fluid.
18. Fill power steering pump fluid reservoir to the (Full-Cold) proper level.
19. Start the engine and let run for a few seconds. Then turn the engine off.
20. Add fluid if necessary.
21. Raise front wheels of vehicle off the ground.
22. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Fill pump reservoir to correct level with Mopar(R), Power Steering Fluid, or equivalent. See Checking Fluid Level.
23. Lower front wheels of vehicle back on the ground.
CAUTION: During this procedure do not allow the steering gear inner tie rod boots to become twisted. (See Wheel Alignment).
24. Check front alignment and adjust the front toe setting on the vehicle to specifications.
25. Tighten tie rod jam nut to 74 Nm (55 ft. lbs.) torque.
26. Adjust steering gear to tie rod boots at tie rods.