B. Replace Steering Gear Assembly
IMPORTANT:Only those vehicles that had a loose pinion shaft nut as determined by the inspection in Section A require steering gear replacement. Very few vehicles are expected to require steering gear replacement.
1. Lower the vehicle until the wheels are just off of the ground.
2. Unlock the steering column and turn the steering wheel to the straight ahead position.
3. From the interior of the vehicle, disconnect the steering column coupler from the steering gear pinion shaft (Figure 5).
4. For vehicles equipped with a 6-cylinder engine, remove the accelerator pedal bracket bolts and set the pedal aside.
5. For vehicles equipped with a 6-cylinder engine, remove the lower dash/steering column cover (Figure 5).
6. To prevent clockspring damage, lock the steering wheel in position.
7. Siphon as much fluid as possible from the power steering reservoir.
8. Raise the vehicle to working level.
9. Remove the left front wheel and tire assembly.
10. Remove the cotter pin from the left tie rod castle nut and then remove the castle nut (Figure 5).
11. Using Special Tool MB991113 or MB990635, separate the left tie rod end from the steering knuckle (Figure 6).
12. For vehicles equipped with a 6-cylinder engine, remove the left tie rod end.
13. For vehicles equipped with a 4-cylinder engine, disconnect the stabilizer bar from the left stabilizer bar link (Figure 7).
14. Remove the right front wheel and tire assembly.
15. Remove the cotter pin from the right tie rod castle nut and then remove the castle nut (Figure 5).
16. Using Special Tool MB991113 or MB990635, separate the right tie rod end from the steering knuckle (Figure 6).
17. For vehicles equipped with a 4-cylinder engine, disconnect the stabilizer bar from the right stabilizer bar link (Figure 7).
18. Raise the vehicle on the hoist.
19. Remove the center member splash shield.
20. Remove the front engine mount (roll stopper) through bolt (Figure 8).
21. Remove the two front and two rear center member bolts (Figure 8).
22. Remove the center member (Figure 8).
23. For vehicles equipped with a 6-cylinder engine, disconnect the front upstream oxygen sensor electrical connector and remove the sensor wire from its retainers.
24. Disconnect the exhaust pipe from the manifold mounted catalytic converter(s) (Figure 9).
25. Disconnect the two front exhaust system hangers and then lower the front of the exhaust system (Figure 9).
26. For vehicles equipped with a 4-cylinder engine, remove the left and right stabilizer bar bushing clamps and then remove the stabilizer bar (Figure 7).
27. For vehicles equipped with a 4-cylinder engine, lower the vehicle.
28. For vehicles equipped with a 4-cylinder engine, remove the air inlet tube.
29. Disconnect the return tube from the steering gear assembly (Figure 10).
30. Disconnect the pressure tube from the steering gear assembly (Figure 10).
31. Disconnect the power steering line clamp from the crossmember.
32. For vehicles equipped with a 4-cylinder engine, raise the vehicle.
33. For vehicles equipped with a 6-cylinder engine, remove the rear transmission mount (roll stopper) through bolt and then remove the rear transmission mount.
34. Remove the four (4) steering gear mounting bolts/nuts (Figure 10).
35. Remove the steering gear assembly. Set the steering gear aside for return to the Warranty Material Return Center.
36. For vehicles equipped with a 6-cylinder engine, remove the left tie rod end from the new steering gear assembly.
37. Install the new steering gear assembly (Figure 10). Tighten the four (4) mounting bolts to 51 ft-lbs (69 Nm).
38. For vehicles equipped with a 4-cylinder engine, lower the vehicle.
39. Align the marks on the pressure tube and the steering gear housing (Figure 11) and then connect the pressure tube to the steering gear assembly. Tighten the fitting to lift-lbs (15 Nm).
40. Align the marks on the return tube and the steering gear housing (Figure 11) and then connect the return tube to the steering gear assembly. Tighten the fitting to 11 ft-lbs (15 Nm).
41. Install the power steering line clamp onto the crossmember.
42. For vehicles equipped with a 4-cylinder engine, install the air inlet tube.
43. For vehicles equipped with a 4-cylinder engine, raise the vehicle.
44. For vehicles equipped with a 6-cylinder engine, install the rear transmission mount (roll stopper). Tighten the bolts to 34 ft-lbs (45 Nm).
45. For vehicles equipped with a 6-cylinder engine, install the rear transmission mount (roll stopper) through bolt. Tighten the bolt to 34 ft-lbs (45 Nm).
46. For vehicles equipped with a 4-cylinder engine, install the stabilizer bar and then install the left and right stabilizer bar bushing clamps (Figure 7). Tighten the bolts to 33 ft-lbs (44 Nm).
47. Raise the front of the exhaust system and then connect the two front exhaust system hangers (Figure 9).
48. Connect the exhaust pipe to the manifold mounted catalytic converter(s) (Figure 9). Tighten the bolts to 37 ft-lbs (49 Nm).
49. For vehicles equipped with a 6-cylinder engine, connect the front upstream oxygen sensor electrical connector and secure the sensor wire in the retainers.
50. Install the center member (Figure 8). Tighten the two front center member bolts to 69 ft-lbs (93 Nm). Tighten the two rear center member bolts to 55 ft-lbs (74 Nm).
51. Install the front engine mount (roll stopper) through bolt (Figure 8). Tighten the bolt to 34 ft-lbs (45 Nm).
52. Install the center member splash shield.
53. On vehicles equipped with a 4-cylinder engine, install the front crossmember stay (left cradle reinforcement) (Figure 1). Tighten the bolts to 55 ft-lbs (74 Nm).
54. Lower the vehicle to working level.
55. On vehicles equipped with a 4-cylinder engine, connect the stabilizer bar to the right stabilizer bar link (Figure 7). Tighten the link bolt to 33 ft-lbs (44 Nm).
56. Connect the right tie rod end to the steering knuckle (Figure 5). Tighten the tie rod castle nut to 21 ft-lbs (29 Nm) and then install a new cotter pin.
57. Install the right front wheel and fire assembly. Tighten the lug nuts to 100 ft-lbs (135 Nm).
58. On vehicles equipped with a 4-cylinder engine, connect the stabilizer bar to the left stabilizer bar link (Figure 7). Tighten the link bolt to 33 ft-lbs (44 Nm).
59. For vehicles equipped with a 6-cylinder engine, install the left tie rod end.
60. Connect the left tie rod end to the steering knuckle (Figure 5). Tighten the tie rod castle nut to 21 ft-lbs (29 Nm) and then install a new cotter pin.
61. Install the left front wheel and tire assembly. Tighten the lug nuts to 100 ft-lbs (135 Nm).
62. Lower the vehicle until the front wheels are just off of the ground.
63. For vehicles equipped with a 6-cylinder engine, from the interior of the vehicle, install the lower dash/steering column cover (Figure 5). Tighten the bolts to 44 in-lbs (4.9 Nm).
64. For vehicles equipped with a 6-cylinder engine, install the accelerator pedal assembly. Tighten the nuts to 100 in-lbs (12 Nm).
65. Connect the steering column coupler to the steering gear pinion shaft (Figure 5). Tighten the coupler pinch bolt to 13 ft-lbs (18 Nm).
66. Fill the power steering reservoir to the lower position of the filler with Mopar ATF +3 (Type 7176) (PN 05010124AA or equivalent).
67. Remove the fuel pump relay from the power distribution center (Figure 12).
68. While using the starter motor to crank the engine intermittently (15-20 seconds), turn the steering wheel all the way to the left and then to the right five or six times.
CAUTION:
DO NOT start the engine during the air bleed procedure. Running the engine could cause air to be drawn into the fluid.
NOTE:
Refill the fluid reservoir during the bleed procedure. Do NOT allow the fluid level to fall below the lower mark on the reservoir.
69. Install the fuel pump relay.
70. Start the engine and let it idle.
71. Turn the steering wheel to the left and to the right until there are no air bubbles in the reservoir.
72. Turn the engine off and confirm that there is very little change in the fluid level (Figure 13).
NOTE:
If the fluid level changes 0.2" (5 mm) or more, the air has not been completely bled from the system. Repeat Steps 55-60.
73. Lower the vehicle and confirm that there are no power steering fluid leaks.
74. Place the vehicle on a front-end alignment rack. Install the wheel alignment equipment onto the vehicle per alignment equipment manufacturer's instructions.
75. Adjust the vehicle's front wheel total toe-in settings to 0.00 degrees +/- 0.6 degrees on all models. After setting the toe, tighten the tie rod end jam nuts to 38 ft-lbs (52 Nm).