Steering Gear: Service and Repair
GEARREMOVAL
NOTE: Before preceding, review Warnings and Cautions. Refer to Service Precautions.
1. Remove remote ground cable from ground stud on left 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.
3. Place the steering wheel and front wheels in the STRAIGHT-AHEAD position. Lock the steering wheel in this position using a steering wheel holder.
4. Under the instrument panel, disconnect the intermediate shaft from the steering gear shaft. To do so, remove the pinch bolt from the intermediate shaft coupler, then slide the intermediate shaft up and off the steering gear shaft.
5. Raise vehicle.
6. Remove both front wheel and tire assemblies.
7. Remove fasteners attaching drive belt splash shield to crossmember.
8. Remove nuts attaching both outer tie rod ends to steering knuckles. Remove tie rod end nuts by holding tie rod end stud with a socket while loosening and removing nut with wrench.
9. Remove both tie rod end studs from 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. 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 to keep the alignment settings the same. Therefore, 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 as described in the following steps. If location of front suspension crossmember to body is not maintained when vehicle is assembled, vehicle handling and or tire wear problems may occur.
10. Using an awl, scribe lines on the body marking the front-to-rear and side-to-side location where the front suspension crossmember is mounted against the body of the vehicle. At all four locations where the crossmember mounts. The line should be scribed at all locations where the crossmember is mounted to the vehicle on each side of the vehicle.
11. Remove the stabilizer bar bushing clamp-to-body attaching bolts. The stabilizer bar bushing clamp-to-crossmember bolts do not need to be removed.
12. Remove the bolts attaching the shock absorber clevis to the left and right lower control arms.
13. Remove 3 bolts attaching engine torque mount to crossmember.
14. Remove screws fastening steering gear heat shield to crossmember.
15. Remove screws fastening power steering pressure hose to crossmember.
16. Remove brake tube routing bracket from left lower control arm rear mounting bolt.
17. Disconnect fuel tube bundle routing support above crossmember.
18. Position transmission jack under center of front suspension crossmember to support it.
19. On 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.
20. 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.
21. Remove power steering pressure and return hoses from the power steering gear fluid ports.
22. Remove wiring harness connector from the power steering fluid pressure switch.
23. Remove 4 bolts fastening power steering gear to front suspension crossmember. Remove power steering gear from front suspension crossmember.
24. Transfer required parts from removed gear to the replacement gear if a new gear is being installed.
DISASSEMBLY
1. Using a screwdriver, pry the sleeve out of the mounting bolt isolator.
2. Pry the mounting bolt isolator bushing from the steering gear mounting bracket.
ASSEMBLY
1. Lubricate replacement mounting bolt isolator bushing using Mopar, Silicone Spray Lube or an equivalent.
2. Install the mounting bolt isolator bushing into the steering gear mounting bracket from the bottom side of the bracket.
3. Install mounting bolt isolator bushing sleeve into isolator bushing by pressing the sleeve into the bushing by hand.
INSTALLATION
1. Install power steering gear on front suspension crossmember. Install all 4 steering gear mounting bolts. Tighten bolts to a torque of 68 Nm (50 ft. lbs.)
2. Install power steering fluid pressure and return hoses to the ports of the power steering gear. Tighten power steering fluid pressure and return hose tube nuts to a torque of 31 Nm (275 inch lbs.).
3. Using transmission jack, raise front suspension crossmember and steering gear against body of vehicle.
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.
4. Start the 2 rear mounting bolts into body 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 all 4 mounting bolts evenly until front suspension crossmember is against body of vehicle at all 4 mounting points. Tighten bolts to approximately 2 Nm (20 inch lbs.) to hold front suspension crossmember in position. Do not overtighten.
5. 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.
6. Once front suspension crossmember is correctly positioned, tighten the 2 rear crossmember mounting bolts to 163 Nm (120 ft. lbs.) torque. Then tighten the 2 front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.) torque.
7. Lower the transmission jack.
8. Connect fuel tube bundle routing support above crossmember.
9. Install brake tube routing bracket onto left lower control arm rear mounting bolt threads.
10. Install screws fastening power steering pressure hose routing clamps to crossmember. Tighten screws to 45 Nm (33 ft. lbs.) torque.
11. Install steering gear heat shield on crossmember.
12. Install 3 bolts attaching engine torque mount to crossmember. Tighten bolts to 65 Nm (48 ft. lbs.) torque.
13. Loosely install the 2 shock absorber clevis-to-lower control arm thru-bolts and nuts. Do not tighten bolts at this time.
14. Install tie rod seal boot heat shield on tie rod end.
15. Install tie rod end into steering knuckle. Start tie rod end-to-steering knuckle attaching nut onto tie rod stud. While holding stud stationary, tighten nut. To properly torque the nut, use a crowfoot and socket as shown and tighten the nut to 55 Nm (40 ft. lbs.) torque.
16. Install and tighten the 2 stabilizer bar bushing clamp-to-body attaching bolts to 61 Nm (45 ft. lbs.) torque.
17. Install fasteners attaching drive-belt splash shield to crossmember.
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 in.
18. Lower vehicle and support front end of vehicle by positioning jack stands as shown at each lower control arm as the vehicle is lowered. Continue to lower vehicle until the total front end weight is supported by the jack stands.
19. Tighten the shock absorber clevis-to-lower control arm bushing thru-bolts to a torque of 92 Nm (68 ft. lbs.).
20. Raise the vehicle and remove the jack stands.
21. Install the wheel and tire assemblies. Progressively tighten the wheel nuts in a crisscross tightening sequence to 135 Nm (100 ft. lbs.) torque.
CAUTION: Before connecting the steering column intermediate shaft coupler to the steering gear shaft, position the front wheels STRAIGHT-AHEAD. The steering wheel must also be in the centered position.
22. Under instrument panel, align splines inside intermediate shaft lower coupling with splines on steering gear shaft and slide intermediate shaft onto steering gear. Install a NEW coupling pinch bolt and tighten it to a torque of 44 Nm (32 ft. lbs.).
23. Remove steering wheel holder.
24. Fill power steering pump fluid reservoir to the proper level and perform Power Steering Pump Initial Operation standard procedure.
25. Check for leaks.
26. Lower vehicle.
27. Check front wheel alignment and adjust toe setting. Tighten tie rod jam nuts to 74 Nm (55 ft. lbs.) torque.