Installation

NOTE: If original steering gear assembly is being installed back in vehicle, be sure the tie rod attachment at steering gear is in center of steering gear travel. If a replacement steering gear assembly is being installed in the vehicle, be sure the tie rod attachment at steering gear is in center of steering gear travel. Then install steering gear shaft into steering coupler.





1. Install steering gear assembly back in vehicle through windshield wiper module opening in cowl.





2. Using roll pin installer, Special Tool 6831A, or equivalent install the roll pin in the flex joint of the intermediate shaft. Roll pin is installed in coupler using the following procedure. Remove knurled nut from small end of removal tool. Insert small end of removal tool through center of roll pin and then install and hand tighten knurled nut. Position sleeve of removal tool on flex joint as shown. Holding threaded shaft of tool from turning tighten nut pulling roll pin into flex joint. Roll pin must be equally spaced in flex joint.
3. Slide steering gear and intermediate shaft back into dash panel sealing boot. Align the steering gear mounting holes with its mounting holes in crossmember.

CAUTION: Tightening the steering gear to crossmember mounting bolts to the proper torque is very important. Be sure to observe the torque specifications in step 5.

4. Install the 4 bolts attaching the steering gear brackets and steering gear to the crossmember. If equipped, be sure brake line routing clip is installed under left steering gear mounting bracket. Tighten the 4 steering gear assembly to crossmember attaching bolts to a torque of 61 Nm (45 ft. lbs.).





5. Install the intermediate shaft onto the steering column shaft. Install steering column coupler pinch bolt and tighten to a torque of 28 Nm (21 ft. lbs.). Install the pinch bolt nut retaining pin in pinch bolt.





6. Attach power steering fluid, pressure and return lines into proper ports of the steering gear. Tighten both power steering hose tube nuts to a torque of 31 Nm (23 ft. lbs.).





7. Align center take off on steering gear with the tie rod assemblies. Install tie rod attaching bolts and washers into steering gear assembly. Be sure washers are installed between tie rods and steering gear. Tighten the tie rod to steering gear bolts to a torque of 90 Nm (66 ft. lbs.).





CAUTION: After tie rod attaching bolts are torqued, bend attaching bolt retaining tabs against heads of attaching bolts.

8. Install the master cylinder on the vacuum booster. Install the 2 nuts attaching the master cylinder to the vacuum booster. Tighten the master cylinder mounting nuts to a torque of 28 Nm (250 inch lbs.).
9. Install the vacuum hose for the vacuum booster on intake manifold vacuum port. Install hose clamp on vacuum hose.





10. Install windshield wiper module assembly into cowl of vehicle. Install and securely tighten the 5 screws attaching windshield wiper module to cowl.





11. Connect wiring harness connector from windshield wiper module into vehicle wiring harness.
12. Install cowl closure panel on cowl and windshield wipe module. Install and securely tighten the 6 screws attaching cowl closure to vehicle. Install weather strip on shock towers and the clips securing cowl closure panel to windshield wiper module.
13. Install windshield washer hoses on wiper arms first, then install both windshield wiper arms on windshield wiper arm pivots and lock arms in place.





14. Connect wiring harness connector from solenoid control valve onto solenoid control module. Be sure wiring harness connector seal are on connector is in good condition before installing connector on control module.
15. Raise vehicle





16. Install gear shift cable onto shift lever on transaxle. Install gear shift cable on cable mounting bracket of transaxle and securely tighten bolt.
17. Lower vehicle.
18. Install the wheel and tire assemblies.
19. Install and tighten wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).

CAUTION: The clockspring centering procedure MUST be done prior to turning the steering wheel or moving the vehicle if the steering wheel was rotated while the steering gear was removed from the vehicle. If clockspring is not centered it may be overextended, causing the clockspring to become inoperative.

20. Center the clock spring using the following procedure.
- Remove the steering wheel from the steering column.
- Depress the 2 plastic locking pins to disengage clockspring locking mechanism.
- Keeping locking mechanism disengaged, rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of the travel. Do not apply excessive torque.
- From the end of clockwise travel, slowly rotate the rotor in the counterclockwise direction 2 and a half turns. The horn wire should located at the top and the air bag wire and speed control switch wires at the bottom.
- Engage the 2 clockspring locking pins.
- Install the steering wheel.
21. Connect battery cable back on negative post of battery.

CAUTION: Do not use automatic transmission fluid.

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.
23. Adjust toe.