Steering Gear: Service and Repair

GEAR

REMOVAL

NOTE: Before proceeding, review WARNINGS and CAUTIONS.





1. Remove remote ground cable from ground stud on left shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud (Fig. 2).
2. Siphon as much power steering fluid as possible from remote power steering fluid reservoir.
3. Place steering wheel and front wheels in STRAIGHT-AHEAD position. Lock steering wheel in this position using a steering wheel holder.





4. Under instrument panel, disconnect intermediate shaft from steering gear shaft. To do so, remove pinch bolt from intermediate shaft coupler (Fig. 3), then slide intermediate shaft up and off 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 (Fig. 4).
9. Remove both tie rod end studs from steering knuckles using Remover, Special Tool C-3894-A.

CAUTION: This vehicle 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 vehicle body marking front-to-rear and side-to-side location where front suspension crossmember is mounted against body. This type line should be scribed at all locations where the crossmember is mounted to the vehicle on each side of the vehicle.





11. Remove stabilizer bar bushing clamp-to-body attaching bolts (Fig. 5). Stabilizer bar bushing clamp-to-crossmember bolts do not need to be removed.





12. Remove bolts attaching shock absorber clevis to left and right lower control arms (Fig. 6).





13. Remove 3 bolts attaching rear engine mount to crossmember (Fig. 7). If equipped, manual transmission bracket will come down when these bolts are removed. It may be necessary to loosen damper mounting bolt at engine structural collar to allow bracket and damper to swing down sufficiently (Fig. 7).





14. Remove fasteners securing steering gear heat shield to crossmember (Fig. 8).
15. Remove screws fastening power steering pressure hose to crossmember (Fig. 8).
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 (Fig. 9).
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 transmission jack.





21. Remove power steering pressure and return hoses from the power steering gear fluid ports (Fig. 10).
22. Remove wiring harness connector from power steering fluid pressure switch.
23. Remove 4 bolts fastening power steering gear to front suspension crossmember.
24. Remove power steering gear from front suspension crossmember.
25. Transfer required parts from removed gear to replacement gear if a new gear is being installed.

DISASSEMBLY





1. Using a screwdriver, pry the sleeve out of the mounting bolt isolator (Fig. 11).
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 (Fig. 12).





3. Install mounting bolt isolator bushing sleeve into isolator bushing by pressing the sleeve into the bushing by hand (Fig. 13).

INSTALLATION
1. Install power steering gear on front suspension crossmember. Install all four 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 ports of power steering gear (Fig. 10). 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 two rear mounting bolts into body tapping plates attaching front suspension crossmember to body of vehicle. Then install two front bolts attaching front suspension crossmember to frame rails of vehicle. Tighten all four mounting bolts evenly until front suspension crossmember is against body of vehicle at all four mounting points. Tighten bolts to approximately 2 Nm (20 inch lbs.) torque 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 previously scribed positioning marks on body of vehicle.
6. Once front suspension crossmember is correctly positioned, tighten two rear crossmember mounting bolts to 163 Nm (120 ft. lbs.) torque. Then tighten two front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.) torque.
7. Lower 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 (Fig. 8). Tighten screws to 45 Nm (33 ft. lbs.) torque.
11. Position steering gear heat shield on crossmember and install fasteners (Fig. 8).
12. Install 3 bolts attaching rear engine mount to crossmember (Fig. 7). If equipped, make sure manual transmission bracket is positioned in place before installing bolts (Fig. 7). Tighten bolts to 65 Nm (48 ft. lbs.) torque.
13. Loosely install two shock absorber clevis-to-lower control arm thru-bolts and nuts (Fig. 6). Do not tighten bolts at this time.





14. Install tie rod seal boot heat shield on tie rod end (Fig. 14).
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 nut, use a crowfoot and socket as shown and tighten nut to 55 Nm (40 ft. lbs.) torque (Fig. 14).
16. Install and tighten two 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 (Fig. 15).

18. Lower vehicle and support front end of vehicle by positioning jack stands as shown at each lower control arm as vehicle is lowered (Fig. 15). Continue to lower vehicle until total front end weight is supported by jack stands.
19. Tighten shock absorber clevis-to-lower control arm bushing thru-bolts to a torque of 92 Nm (68 ft. lbs.).
20. Raise vehicle and remove jack stands.
21. Install wheel and tire assemblies. Progressively tighten wheel nuts in a cries-cross 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 (Fig. 3) and tighten it to a torque of 44 Nm (32 ft. lbs.).
23. Remove steering wheel holder.
24. Install remote battery ground cable on ground stud located on left shock tower.
25. Fill power steering pump fluid reservoir to proper level and perform Power Steering Pump Initial Operation standard procedure.
26. Check for leaks.
27. Lower vehicle.
28. Check front wheel alignment and adjust toe setting Tighten tie rod jam nuts to 74 Nm (55 ft. lbs.) torque.