Dodge Steering Service Manual

DR STEERING 19 - 1

STEERING

TABLE OF CONTENTS

page page

STEERING

DESCRIPTION ..........................1

OPERATION ............................1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - POWER

STEERING SYSTEM ....................2

DIAGNOSIS AND TESTING - POWER

STEERING FLOW AND PRESSURE ........4

SPECIAL TOOLS

STEERING ...........................5

STEERING

DESCRIPTION

CAUTION: MOPART ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.

Power steering systems consist of:

• Steering column

• Rack and pinion steering gear

• Belt driven hydraulic steering pump

• Pump pressure and return hoses

• Oil Cooler

OPERATION

The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).

Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres­sure to the steering gear.

COLUMN ...............................6

GEAR - INDEPENDENT FRONT SUSPENSION ..16

GEAR - LINK/COIL .......................19

LINKAGE - INDEPENDENT FRONT

SUSPENSION ...........................31

LINKAGE - LINK/COIL ....................33

PUMP .................................38

Fig. 1 STEERING COMPONENTS

1 - POWER STEERING PUMPASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION

19 - 2 STEERING DR

STEERING (Continued)

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM

There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing
through an orifice. There is no relationship between this noise and steering performance.

STEERING NOISE

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR
WHISTLE

RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.

CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.

1. Steering intermediate shaft to dash panel
seal.

2. Noisy valve in power steering gear. 2. Replace steering gear.

2. Loose or damaged suspension
components.

3. Internal gear noise. 3. Replace steering gear.

4. Pressure hose in contact with other
components.

5. Loose or damaged intermediate shaft or
column.

2. Pressure hose in contact with other
components.

3. Internal pump noise. 3. Replace pump.

4. Air in fluid 4. Check for lekas, Evacuate air

1. Check and repair seal at dash
panel.

2. Inspect and repair suspension.

4. Reposition hose.

5. Inspect and repair or replace.

2. Reposition hose.

from P/S system.

SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.

SCRUBBING OR
KNOCKING

2. O-ring missing or damaged on hose
fitting.

3. Low fluid level. 3. Fill to proper level.

4. Air leak between pump and reservoir. 4. Repair as necessary.

5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.

1. Wrong tire size. 1. Verify tire size.

2. Replace o-ring.

DR STEERING 19 - 3

STEERING (Continued)

BINDING AND STICKING

CONDITION POSSIBLE CAUSE CORRECTION

DIFFICULT TO TURN WHEEL

STICKS OR BINDS

INSUFFICIENT ASST. OR POOR RETURN TO CENTER

CONDITION POSSIBLE CAUSE CORRECTION

HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT

1. Low fluid level. 1. Fill to proper level.

2. Tire pressure. 2. Adjust tire pressure.

3. Steering components (ball
joints/tie rod ends).

4. Loose belt. 4. Adjust or replace.

5. Low pump pressure. 5. Pressure test and replace if

6. Column shaft coupler binding. 6. Replace coupler.

7. Steering gear worn. 7. Replace gear.

8. Pump seized / Stuck valve 8. Replace pump.

1. Tire pressure. 1. Adjust tire pressure.

2. Low fluid level. 2. Fill to proper level.

3. Loose belt. 3. Adjust or replace.

4. Low pump pressure. 4. Pressure test and repair as

5. Internal gear leak. 5. Replace gear.

3 Inspect and repair as necessary.

necessary.

necessary.

STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN STEERING
WHEEL

VEHICLE PULLS OR LEADS TO
ONE SIDE.

1. Tire pressure. 1. Adjust tire pressure.

2. Wheel alignment. 2. Align front end.

3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.

4. High friction in steering gear. 4. Replace gear.

LOOSE STEERING AND VEHICLE LEAD

1. Worn or loose suspension or

steering components.

2. Worn or loose wheel bearings. 2. Inspect and repair or adjust

3. Steering gear mounting. 3. Tighten gear mounting bolts to

4. Gear out of adjustment. 4. Replace gear.

5. Worn or loose steering coupler. 5. Inspect and replace as

1. Tire Pressure. 1. Adjust tire pressure.

2. Radial tire lead. 2. Rotate tires.

3. Brakes dragging. 3. Repair as necessary.

4. Wheel alignment. 4. Align front end.

1. Inspect and repair as necessary.

bearings.

specification.

necessary.

19 - 4 STEERING DR

STEERING (Continued)

DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE

The following procedure is used to test the opera­tion of the power steering system on the vehicle. This
test will provide the gallons per minute (GPM) or
flow rate of the power steering pump along with the
maximum relief pressure. Perform test any time a
power steering system problem is present. This test
will determine if the power steering pump or power
steering gear is not functioning properly. The follow­ing pressure and flow test is performed using Power
Steering Analyzer Tool kit 6815 and (Fig. 2) Adapter
Kit 6893.

Fig. 2 Analyzer With Tube and Adapter

1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE

FLOW AND PRESSURE TEST

(1) Check the power steering belt to ensure it is in
good condition and adjusted properly.

(2) Connect pressure gauge hose from the Power
Steering Analyzer to adapter 6826.

(3) Connect tube 6825A to Power Steering Ana­lyzer test valve end.

(4) Disconnect the high pressure hose from the
power steering pump.

(5) Connect the tube 6825A to the pump fitting.

(6) Connect the power steering hose from the
steering gear to the adapter 6826.

(7) Open the test valve completely.

(8) Start engine and let idle long enough to circu­late power steering fluid through flow/pressure test
gauge and to get air out of the fluid. Then shut off
engine.

(9) Check fluid level, add fluid as necessary. Start

engine again and let idle.

(10) Gauge should read below 862 kPa (125 psi), if
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure reading should be in
the range of 345-552 kPa (50-80 psi).

(11) Increase the engine speed to 1500 RPM and
read the flow meter. If the flow rate (GPM) is below
specification, (refer to pump specification chart for
GPM) the pump should be replaced.

CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.

(12) Close valve fully three times and record high­est pressure indicated each time. All three read-

ings must be above specifications and within
345 kPa (50 psi) of each other.

• Pressures above specifications but not within

345 kPa (50 psi) of each other, replace pump.

• Pressures within 345 kPa (50 psi) of each other

but below specifications, replace pump.

(13) Open the test valve and turn the steering
wheel to the extreme left and right positions three
times against the stops. Record the highest pressure
reading at each position. Compare readings to the
pump specifications chart. If pressures readings are
not within 50 psi of each other, the gear is leaking
internally and must be replaced.

CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.

PUMP SPECIFICATION

ENGINE

1500 series

2500 & 3500

series

RELIEF

PRESSURE ±

65

11032 kPa

(1615 ± 65 psi)

12400 kPa

(1800 ± 50 psi)

FLOW RATE

(GPM) AT 1500

RPM

3.1 - 3.5

3.5 - 4.0

DR STEERING 19 - 5

STEERING (Continued)

SPECIAL TOOLS

STEERING

ADAPTER, POWER STEERING FLOW/PRESSURE -

6825A

PULLER - 8677

ADAPTERS, POWER STEERING FLOW/PRESSURE

TESTER - 6893

ANALYZER SET, POWER STEERING FLOW/

PRESSURE 6815

19 - 6 COLUMN DR

COLUMN

TABLE OF CONTENTS

page page

COLUMN

DESCRIPTION ..........................6

DIAGNOSIS AND TESTING - STEERING

COLUMN .............................7

REMOVAL .............................7

INSTALLATION ..........................9

IGNITION SWITCH

DESCRIPTION ..........................9

OPERATION ............................9

DIAGNOSIS AND TESTING - IGNITION

SWITCH .............................9

REMOVAL .............................10

INSTALLATION .........................11

KEY-IN IGNITION SWITCH

DESCRIPTION .........................11

DIAGNOSIS AND TESTING - IGNITION

SWITCH AND KEY LOCK CYLINDER .......11

KEY CYLINDER

REMOVAL .............................12

COLUMN

DESCRIPTION

NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth­ods of locking the steering wheel for service will
have to be used.

INSTALLATION .........................12

GEAR SHIFT LEVER

REMOVAL .............................12

INSTALLATION .........................12

UPPER STEERING COUPLING

REMOVAL .............................13

INSTALLATION .........................14

LOWER STEERING COUPLING

REMOVAL

REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14

REMOVAL - 4X4 HD ...................14

INSTALLATION

INSTALLATION - ALL LD & HD EXCEPT 4X4

HD.................................15

INSTALLATION - 4X4 HD ................15

STEERING WHEEL

REMOVAL .............................15

INSTALLATION .........................15

POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT­INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.

The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov­ing the steering column from the vehicle.

To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS­CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND

CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear­ing.

CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.

CAUTION: Do not attempt to remove or modify the
park lock slider or link.

NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.

DR COLUMN 19 - 7

COLUMN (Continued)

NOTE: When servicing the coupler a new bolt must
be used when installing.

Fig. 1 STEERING COLUMN

1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER

(1) Position the front wheels straight ahead.
(2) Disconnect the negative (ground) cable from

the battery.

(3) Remove the two switches from the steering

wheel.

(4) Remove the airbag, (Refer to 8 - ELECTRICAL/

RESTRAINTS/DRIVER AIRBAG - REMOVAL).

(5) Remove the steering wheel with special tool

CJ98–1 or an appropriate steering wheel puller.

CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock­spring, before attempting to remove the wheel. Fail­ure to do so may damage the steering wheel/
clockspring.

(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER­ING COLUMN OPENING COVER - REMOVAL).

(7) Remove the tilt lever.

(8) Remove the column shrouds (Fig. 2).

DIAGNOSIS AND TESTING - STEERING
COLUMN

If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col­lapsed. Inspect the column mounting capsules visu­ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.

REMOVAL

WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS­ARMED. REFER TO ELECTRICAL RESTRAINT SYS­TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.

CAUTION: All fasteners must be torqued to specifi­cation to ensure proper operation of the steering
column.

Fig. 2 UPPER & LOWER SHROUDS

1 - UPPER SHROUD
2 - LOWER SHROUD

(9) Remove the clock spring, (Refer to 8 - ELEC­TRICAL/RESTRAINTS/CLOCKSPRING - REMOV­AL).

(10) Disconnect the wiring harness to the column.

(11) Remove the shift cable from the column shift
lever actuator (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT
CABLE - REMOVAL). (Fig. 3).

19 - 8 COLUMN DR

COLUMN (Continued)

Fig. 3 SHIFT CABLE CONNECTOR

1 - Shift lever
2 - Cable Connection
3 - Overdrive Electrical Wiring
4 - Mounting Screws

(12) Release the shift cable from the column

bracket and remove it from the bracket.

(13) Remove the SKIM module in order to discon-

nect the electrical connector.

(14) Remove the upper steering shaft coupler bolt

and slide the shaft down (Fig. 4) & (Fig. 5)

Fig. 5 UPPER STEERING COUPLER

1 - STEERING COUPLER
2 - PINCH BOLT HOLE

(15) Remove the brake light switch and discard
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING ­EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).

(16) Remove the four steering column mounting
nuts (Fig. 6).

Fig. 4 COUPLER SHAFT

1 - MOUNTING HOLES
2 - COUPLER BOLT HOLE

Fig. 6 MOUNTING HOLES

1 - MOUNTING HOLES

(17) Remove the steering column assembly from
the vehicle. (Fig. 7)

DR COLUMN 19 - 9

COLUMN (Continued)

(7) Install the shifter cable. (Refer to 21 - TRANS­MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)

(8) Connect the wiring harness to the column.

(9) Install the SKIM module.

(10) Install the clockspring(Refer to 8 - ELECTRI­CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).

(11) Install the shrouds.

(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER­ING COLUMN OPENING COVER - INSTALLA­TION).

(13) Align the spline on the wheel hub to shaft.

(14) Then install the steering wheel and install a
new bolt. Tighten the bolt to 61 N·m (45 ft. lbs.).

(15) Install the airbag (Refer to 8 - ELECTRICAL/

Fig. 7 STEERING COLUMN

1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable

INSTALLATION

RESTRAINTS/DRIVER AIRBAG - INSTALLATION).

(16) Install the two steering wheel switches.

(17) Install the tilt lever handle.

(18) Install the negative battery terminal.

(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.

WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS­ARMED. REFER TO ELECTRICAL RESTRAINT SYS­TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.

CAUTION: All fasteners must be torqued to specifi­cation to ensure proper operation of the steering
column.

(1) Position the steering column on the dash panel

support and loosely install the mounting nuts.

(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.

(3) Install the steering shaft coupler on the steer­ing shaft and loosely install a new bolt.

(4) Center steering column in dash opening and
tighten mounting nuts to 28 N·m (250 in. lbs.).

NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.

NOTE: A new bolt must be used for reinstallation.

(5) Tighten the coupler bolt to 57 N·m (42 ft. lbs.).

(6) Install a new brake light switch (Refer to 8 ­ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).

IGNITION SWITCH

DESCRIPTION

The ignition switch is located on the steering col­umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.

OPERATION

Vehicles equipped with an automatic trans­mission and a steering column mounted shifter:

an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.

DIAGNOSIS AND TESTING - IGNITION SWITCH

TEST AND REPAIR

If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS­AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE ­ADJUSTMENTS).

If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.

19 - 10 COLUMN DR

IGNITION SWITCH (Continued)

REMOVAL

SERVICE PRECAUTIONS

NOTE: The steering column on vehicles equipped
with an automatic transmission is not equipped
with an internal locking shaft with the ignition cyl­inder. Alternative methods of locking the steering
wheel for service will have to be used.

The tilt and standard column (Fig. 8) have been
designed to be serviced as an assembly; without wir­ing, switches, shrouds, steering wheel, etc. Most
steering column components can be serviced without
removing the steering column from the vehicle.

Fig. 8 STEERING COLUMN

1 - KEY CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - IGNITION SWITCH

AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.

CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear­ing.

CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism.

The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.

(1) Remove the negative (ground) cable from the
battery.

(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).

(3) Remove the lower and upper shrouds.

(4) Remove key cylinder. (Refer to 19 - STEER­ING/COLUMN/LOCK CYLINDER HOUSING ­REMOVAL).

(5) Disconnect the lower clockspring connectors.

(6) Remove the wire retainer from the tilt lever
bracket.

(7) Remove the tilt lever mounting screws to gain
access to the ignition switch mounting screws. (Fig.

9)

Safety goggles should be worn at all times when

working on steering columns.

To service the steering wheel, switches or airbag,
Refer to Electrical Restraints and follow all WARN­INGS and CAUTIONS.

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS­CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT­INGS AND ARE SPECIFICALLY DESIGNED FOR THE

Fig. 9 IGNITION SWITCH WITH TILT

1 - IGNITION SWITCH
2 - TILT LEVER MECHANISM

(8) For columns without tilt remove the bracket to
gain access to the ignition switch mounting screws.
(Fig. 10)

(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).

DR COLUMN 19 - 11

IGNITION SWITCH (Continued)

(3) Position switch to column and install the
mounting screw. Tighten screw to 3 N·m (26 in. lbs.).

(4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N·m (40 in. lbs.).

(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N·m (40 in. lbs.) (Fig. 10)

(6) Position the wire retainer into the tilt lever
bracket.

(7) Reconnect the lower clockspring connectors.

(8) Install the key cylinder.

(9) Install steering column upper and lower
shrouds.

(10) Enable the airbag system. (Refer to 8 - ELEC­TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL­LATION).

Fig. 10 IGNITION SWITCH WITHOUT TILT

1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws

Fig. 11 IGNITION SWITCH

1 - Ignition Switch
2 - Ignition Switch Mounting Screws

(10) Remove ignition switch mounting screw.
(11) Using a small screwdriver, push on locking

tab and remove switch from steering column.

KEY-IN IGNITION SWITCH

DESCRIPTION

The key-in ignition switch is integral to the igni­tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition key cylinder and the driver
door ajar switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition key cylinder.
The ground path is also opened when the driver door
ajar switch is open (driver door is closed).

The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG­NITION SWITCH - REMOVAL).

DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER

ELECTRICAL DIAGNOSIS

For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri­cal Wiring Diagrams.

INSTALLATION

The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before installing ignition switch.

(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.

(2) Connect the electrical connector to rear of the
ignition switch. Make sure that locking tabs are fully
seated into wiring connector.

MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)

(Refer to 19 - STEERING/COLUMN/IGNITION

SWITCH - DIAGNOSIS AND TESTING).

19 - 12 COLUMN DR

KEY CYLINDER

REMOVAL

The ignition key must be in the key cylinder for
cylinder removal.

(1) Disconnect negative cable from battery.

(2) Remove upper and lower covers (shrouds) from
steering column.

(3) Place shifter in PARK position.

(4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.

Fig. 12 KEY CYLINDER

1 - KEY
2 - KEY CYLINDER
3 - RETAINING PIN HOLE

INSTALLATION

The ignition key must be in the key cylinder for

cylinder installation.

(1) Install the key cylinder into the housing using
care to align the end of the key cylinder with the
ignition switch.

(2) Push the key cylinder in until it clicks.

(3) Replace the upper and lower shrouds.

(4) Reconnect the battery.

GEAR SHIFT LEVER

REMOVAL

(1) Remove the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - REMOV­AL).

(2) Remove the upper and lower column shroud.

(3) Remove and discard the brake light switch.

(4) Loosen the column bolts and lower the column
enough to allow clearance for the gear shift lever
removal.

(5) Disconnect the overdrive switch harness (if
equipped).

(6) Disconnect the shift cable from the shift lever.

(7) Remove the SKIM.

(8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)

(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).

(a) Rotate key to RUN position.
(b) Press in on retaining pin while pulling key

cylinder from ignition switch (Fig. 13).

Fig. 13 KEY CYLINDER

1 - KEY CYLINDER
2 - PUNCH

Fig. 14 GEAR SHIFT LEVER

1 - PARK INHIBIT BLOCKER SPRING
2 - GEAR SHIFT LEVER

INSTALLATION

(1) Install the lever assembly using care to install
the pin in the blocker to slider slot (Fig. 15) and
install the mounting screws and tighten to 12 N·m
(105 in. lbs.).

DR COLUMN 19 - 13

GEAR SHIFT LEVER (Continued)

(2) Lock the steering wheel with the tire in the
straight position.

(3) Remove and discard the lower pinch bolt.

(4) Lower the steering coupler shaft from the col­umn.

(5) Remove the upper steering coupling shaft seal
by pushing in the four tags securing it to the panel
(Fig. 16).

Fig. 15 GEAR SHIFT LEVER SPRING

1 - BLOCKER TO INHIBIT LINK SLOT
2 - GEAR SHIFT LEVER

(2) Cycle the key from ACC to RUN and ensure

that the blocker does not stick or bind.

(3) Turn the key to the OFF position and ensure

that the shifter will not pull from the PARK position.

(4) Connect the over drive switch harness (if

equipped).

NOTE: Route and tie off harness to original loca­tion.

(5) Connect the shift cable to the lever.

(6) Ensure the gear shift lever and transmission
are in the PARK position and snap the cable adjust
clip in place.

(7) Install a new brake light switch (Refer to 8 ­ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).

(8) Install the SKIM and halo.

(9) Install the upper and lower column shroud.

(10) Install the column back into place and
tighten.

(11) Install the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL­LATION).

1 - RELEASE TANGS (4)
2 - UPPER STEERING COUPLER SHAFT

(6) Remove and discard the lower coupler pinch

bolt from the lower steering coupling shaft (Fig. 17).

(7) Remove the upper steering coupling shaft from

the vehicle (Fig. 17).

Fig. 16 RELEASE TANGS

UPPER STEERING COUPLING

REMOVAL

(1) Disconnect the negative battery cable.

NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth­ods of locking the steering wheel for service will
have to be used.

Fig. 17 UPPER STEERING COUPLER SHAFT

1 - LOWER STEERING COUPLER
2 - RELEASE TANGS (4)
3 - UPPER STEERING COUPLER SHAFT

19 - 14 COLUMN DR

UPPER STEERING COUPLING (Continued)

INSTALLATION

(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).

(2) Install the upper steering coupling shaft seal
by pushing it in securing the four tangs to the panel
(Fig. 16).

NOTE: Note: A new steering coupling shaft pinch
bolt for the upper and lower shafts must be used.

(3) Install the steering coupler shaft to the column
(Fig. 17).

(4) Install the upper pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).

(5) Install the shaft to the lower coupler (Fig. 17).

(6) Install the lower pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).

(7) Unlock the steering wheel.

(8) Reconnect the negative battery cable.

LOWER STEERING COUPLING

NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth­ods of locking the steering wheel for service will
have to be used.

Fig. 18 LOWER STEERING COUPLER

REMOVAL

(3) Lock the steering wheel with the tire in the

REMOVAL - ALL LD & HD EXCEPT 4X4 HD

(1) Disconnect the negative battery cable.

(2) Raise and support the vehicle.

NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth­ods of locking the steering wheel for service will
have to be used.

straight position.

(4) Remove the left front tire and wheel assembly.
(5) Remove and discard the upper coupler pinch

bolt (Fig. 20).

(6) Remove and discard the lower coupler pinch

bolt (Fig. 19).

(3) Lock the steering wheel with the tire in the
straight position.

(4) Remove the left front tire and wheel assembly.

(5) Mark both coupler connections for proper
installation.

(6) Remove and discard the upper coupler pinch
bolt.

(7) Remove and discard the lower coupler pinch
bolt.

(8) Remove the lower steering shaft coupler (Fig.

18).

REMOVAL - 4X4 HD

(1) Disconnect the negative battery cable.

(2) Raise and support the vehicle.

Fig. 19 LOWER COUPLER PINCH BOLT

1 - INTERMEDIATE STEERING SHAFT
2 - LOWER COUPLING BOLT
3 - STEERING GEAR

DR COLUMN 19 - 15

LOWER STEERING COUPLING (Continued)

(7) Remove the lower steering shaft coupler (Fig.

20).

Fig. 20 INTERMEDIATE STEERING SHAFT

1 - UPPER COUPLING BOOTAND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR

INSTALLATION

(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN­DARD PROCEDURE).

(6) Lower the vehicle.

(7) Reconnect the negative battery cable.

(8) Unlock the steering wheel.

STEERING WHEEL

REMOVAL

(1) Disable and remove the driver’s side air­bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).

(2) Partially remove the steering wheel bolt and
leave the bolt in the column.

(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)

INSTALLATION - ALL LD & HD EXCEPT 4X4
HD

(1) Install the coupler to the steering rack & pin-

ion using the marks made in the removal process.

(2) Install the coupler to the intermediate shaft

using the marks made in the removal process.

NOTE: New pinch bolts must be used for reinstalla­tion.

(3) Install the lower pinch bolt and tighten to 57

N·m (42 ft. lbs.).

(4) Install the upper pinch bolt and tighten to 57

N·m (42 ft. lbs.).

(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN­DARD PROCEDURE).

(6) Lower the vehicle.

(7) Reconnect the negative battery cable.

(8) Unlock the steering wheel.

INSTALLATION - 4X4 HD

(1) Install the coupler to the steering gear.

(2) Install the coupler to the intermediate shaft.

NOTE: New pinch bolts must be used for reinstalla­tion.

(3) Install the lower pinch bolt and tighten to 28
N·m (250 in. lbs.).

(4) Install the upper pinch bolt and tighten to 57
N·m (42 ft. lbs.).

Fig. 21 STEERING WHEEL PULLER

1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1

(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.

INSTALLATION

NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)

(1) Install steering wheel to the column

NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.

(2) Install the new steering wheel bolt. Tighten the

bolt to 61 N·m (45 ft. lbs.).

(3) Install the driver’s side air bag. (Refer to 8 ­ELECTRICAL/RESTRAINTS/DRIVER AIRBAG ­INSTALLATION).

19 - 16 GEAR - INDEPENDENT FRONT SUSPENSION DR

GEAR - INDEPENDENT FRONT SUSPENSION

TABLE OF CONTENTS

page page

GEAR - INDEPENDENT FRONT SUSPENSION

DESCRIPTION .........................16

REMOVAL .............................16

INSTALLATION .........................17

SPECIFICATIONS

TORQUE CHART ......................18

GEAR - INDEPENDENT FRONT
SUSPENSION

DESCRIPTION

A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser­viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.

BUSHING

REMOVAL .............................18

INSTALLATION .........................18

(2) Drain and siphon the power steering fluid from

the reservoir.

(3) Raise the vehicle.
(4) Remove and discard the steering coupler pinch

bolt.

(5) Remove the power steering hoses from the rack

& pinion.

(6) Remove the tire and wheel assembly.

(7) Remove the tie rod end nuts and separate tie
rod ends from the knuckles with Special tool 8677
(Refer to 19 - STEERING/LINKAGE/TIE ROD END ­REMOVAL).

(8) Remove the skid plate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE - REMOV­AL).

(9) Remove the rack & pinion mounting bolts. (Fig.

2) & (Fig. 3)

(10) Remove the rack & pinion from the vehicle.

Fig. 1 STEERING GEAR

1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS

REMOVAL

NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth­ods of locking the steering wheel for service will
have to be used.

(1) Lock the steering wheel.

Fig. 2 STEERING GEAR MOUNTING BOLTS

1 - STEERING GEAR MOUNTING BOLTS 4X4

DR GEAR - INDEPENDENT FRONT SUSPENSION 19 - 17

GEAR - INDEPENDENT FRONT SUSPENSION (Continued)

an additional 90°. (Refer to 19 - STEERING/LINK­AGE/TIE ROD END - INSTALLATION).

(5) Install the pressure power steering hose to the
steering gear and tighten to 32 N·m (23 ft. lbs.).
(Refer to 19 - STEERING/PUMP/HOSES - INSTAL­LATION).

(6) Install the return power steering hose to the
steering gear and tighten to 71 N·m (52 ft. lbs.).
(Refer to 19 - STEERING/PUMP/HOSES - INSTAL­LATION).

(7) Install the front skid plate (Refer to 13 ­FRAME & BUMPERS/FRAME/FRONT SKID PLATE

- INSTALLATION).

(8) Install the tire and wheel assembly (Refer to 22

- TIRES/WHEELS/WHEELS - STANDARD PROCE­DURE).

Fig. 3 STEERING GEAR 4X2

1-SWAYBAR
2 - STEERING GEAR
3 - LEFT OUTER TIE ROD END
4 - LOWER CONTROLARMS
5 - LEFT INNER & RIGHT OUTER (TIE ROD ENDS)

(9) Remove the support and lower the vehicle.

(10) Fill the system with fluid, (Refer to 19 ­STEERING/PUMP - STANDARD PROCEDURE).

(11) Adjust the toe position. (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD PROCE­DURE).

INSTALLATION

NOTE: Before installing gear inspect bushings and
replace if worn or damaged.

NOTE: In the frame there is two holes for the
mounting of the steering gear one is slotted and
one is round, When tightening the gear to specifi­cations make sure to tighten the mounting bolt with
the hole first to avoided movement of the steering
gear.

(1) Install the gear on the front crossmember and
tighten the mounting bolts to 319 N·m (235 ft. lbs.).
(Fig. 4) & (Fig. 3).

(2) Slide the shaft coupler onto the gear. Install
new pinch bolt and tighten to 49 N·m (36 ft. lbs.).

(3) Clean and dry the tie rod end studs and the
knuckle tapers.

(4) Install the tie rod ends into the steering knuck­les and tighten the nuts to 61 N·m (45 ft. lbs.) then

Fig. 4 STEERING GEAR 4X4

1 - FRONT AXLE
2 - STEERING GEAR MOUNTING NUTS & BUSHINGS

19 - 18 GEAR - INDEPENDENT FRONT SUSPENSION DR

GEAR - INDEPENDENT FRONT SUSPENSION (Continued)

SPECIFICATIONS

TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Rack and Pinion Steering

Gear

Gear to Frame Bolts

Rack and Pinion Steering

Gear

Coupler Bolt
Tie Rod End

Knuckle Nut

Tie Rod End

Jam Nut

Power Steering Line

Pressure Line

Power Steering Line

Return Line

Power Steering Line

Pressure Line To Pump

Then tighten an additional

319 235 —

49 36 —

61

Then tighten an additional

90°

75 55 —

32 23 —

71 52 —

37 27 —

45

90°

—

BUSHING

REMOVAL

(1) Remove the steering gear (Refer to 19 ­STEERING/GEAR - REMOVAL).

CAUTION: Do not overtighten the vise on the gear
case.

(2) Mount the steering gear in a soft jawed vise.

NOTE: If the bushings are seized a brass punch can
be used to remove the bushings from the gear
using care not to strike the gear.

(3) Remove the front mounting bushings.

(4) Remove the rear mounting bushings.

(5) Remove the steering gear from the vise and
place it on the bench.

INSTALLATION

NOTE: Coat all bushings with a thin rubber lubri­cate oil prior to installation.

NOTE: A rubber mallet can be used to assist in the
installation of the bushings once lubricated.

(1) Coat the rear bushings with a thin rubber
lubricate oil then install the rear bushings using a
rubber mallet to seat the bushings in the gear.

(2) Coat the front bushings with a thin rubber
lubricate oil then install the front bushings using a
rubber mallet to seat the bushings in the gear.

(3) Install the steering gear (Refer to 19 - STEER­ING/GEAR - INSTALLATION).

(4) Adjust the toe position (if necessary) (Refer to 2

- SUSPENSION/WHEEL ALIGNMENT - STAN­DARD PROCEDURE).

DR GEAR - LINK/COIL 19 - 19

GEAR - LINK/COIL

TABLE OF CONTENTS

page page

GEAR - LINK/COIL

DESCRIPTION .........................19

OPERATION ...........................19

REMOVAL .............................19

INSTALLATION .........................20

ADJUSTMENTS

ADJUSTMENT ........................20

SPECIFICATIONS

POWER STEERING GEAR ..............21

TORQUE CHART ......................22

SPECIAL TOOLS

POWER STEERING GEAR ..............22

PITMAN SHAFT SEAL

REMOVAL

REMOVAL - GAS ENGINE ...............23

GEAR - LINK/COIL

DESCRIPTION

The power steering gear is a recirculating ball type

gear (Fig. 1). The gear ratio’s used are 12.5:1.

OPERATION

The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup­ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.

REMOVAL - DIESEL ...................24

INSTALLATION

INSTALLATION - GAS ENGINE ...........24

INSTALLATION - DIESEL ................25

STEERING GEAR INPUT SHAFT SEAL

REMOVAL .............................25

INSTALLATION .........................28

PITMAN SHAFT

REMOVAL

REMOVAL - GAS ......................29

REMOVAL - DIESEL ...................30

INSTALLATION

INSTALLATION - GAS ..................30

INSTALLATION - DIESEL ................30

REMOVAL

(1) Place the front wheels in a straight-ahead posi­tion.

NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth­ods of locking the steering wheel for service will
have to be used.

(2) Lock the steering wheel.

(3) Siphon out as much power steering fluid as
possible.

Fig. 1 STEERING GEAR

1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT

19 - 20 GEAR - LINK/COIL DR

GEAR - LINK/COIL (Continued)

(4) Disconnect and cap the fluid hoses from steer­ing gear (Refer to 19 - STEERING/PUMP/HOSES ­REMOVAL).

(5) Remove coupler pinch bolt at the steering gear
and slide shaft off gear (Fig. 2).

Fig. 4 STEERING GEAR REMOVAL/INSTALLATION

1 - STEERING GEAR
2 - MOUNTING BOLTS (3)

INSTALLATION

Fig. 2 COLUMN SHAFT

1 - STEERING COUPLER
2 - STEERING GEAR INPUT SHAFT

(6) Mark the pitman shaft and pitman arm for
installation reference. Remove the pitman arm from
the shaft with Puller C-4150A (Refer to 19 - STEER­ING/LINKAGE/PITMAN ARM - REMOVAL), (Fig. 3).

(1) Position the steering gear on the frame rail and
install the three mounting bolts (Fig. 4). Tighten the
mounting bolts to 196 N·m (145 ft. lbs.).

(2) Align steering coupler on gear shaft. Install
pinch bolt and tighten to 49 N·m (36 ft. lbs.) torque.

(3) Align and install the pitman arm (Refer to 19 ­STEERING/LINKAGE/PITMAN ARM - INSTALLA­TION).

(4) Install the washer and retaining nut on the pit­man shaft. Tighten the nut to 305 N·m (225 ft. lbs.).

(5) Connect fluid hoses to steering gear (Refer to
19 - STEERING/PUMP/HOSES - INSTALLATION),
tighten to 31 N·m (23 ft. lbs.).

(6) Add fluid, (Refer to 19 - STEERING/PUMP ­STANDARD PROCEDURE).

(7) Reset the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

Fig. 3 PITMAN ARM REMOVAL

1 - PITMAN ARM
2 - C-4150A PULLER

(7) Remove steering gear three mounting bolts

(Fig. 4). Remove the steering gear from the vehicle.

ADJUSTMENTS

ADJUSTMENT

CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.

NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.

DR GEAR - LINK/COIL 19 - 21

GEAR - LINK/COIL (Continued)

(1) Remove the steering gear from the vehicle

(Refer to 19 - STEERING/GEAR - REMOVAL).

(2) Mount the gear carefully into a soft-jawed vise.

CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment

(3) Hold the steering gear upside down over a
drain pan and rotate the input shaft back and forth
several times lock-to-lock to discharge the fluid from
the steering gear

(4) Rotate the input shaft to the left stop and then
back-off approximately 45 degrees. Using an inch­pound torque wrench on the input shaft, record the
peak torque required to slowly and evenly rotate the
input shaft clockwise
from the 45 degree position. This peak torque read­ing is the preload torque. The preload torque must be
within2-10in-lbs.

(5) Rotate the input shaft to its center of travel
(approximately 1.5 turns from either stop). Place the
torque wrench on the input shaft with the handle in
the vertical position. Rotate the torque wrench slowly
and evenly
and record the peak torque measure on or near cen­ter. This total on-center torque reading must be5-9
in-lbs higher than the previously measured preload
torque without exceeding a total of 17 in-lbs. The
value of the total on-center minus the preload torque
is defined as the meshload torque

1

⁄4turn (90 degrees) each side of center

1

⁄2turn (180 degrees) starting

(6) If required, adjust the on-center torque by loos­ening the adjuster screw lock nut and turning the
adjuster screw until the total on-center and meshload
torque readings fall within the specified values. Turn
the adjuster screw clockwise to increase and counter­clockwise to decrease the torque reading. While hold­ing the adjuster screw in place, tighten the lock nut
to 31 N·m (23 ft. lbs.).

(7) Re-check the preload and on-center torque
readings.

(8) Install pitman arm on the steering gear (Refer
to 19 - STEERING/LINKAGE/PITMAN ARM ­INSTALLATION).

(9) Reinstall steering gear to the vehicle (Refer to
19 - STEERING/GEAR - INSTALLATION).

SPECIFICATIONS

POWER STEERING GEAR

SPECIFICATIONS

DESCRIPTION SPECIFICATION

Steering Gear
Type

Gear Code & Ratio 12.5:1

Recirculating Ball

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Preload

Torque

Meshload Torque 0.56-1.02 — 5-9

0.23-1.13 — 2-10

+ Preload (17 Max)

19 - 22 GEAR - LINK/COIL DR

GEAR - LINK/COIL (Continued)

TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Steering Gear Mounting

Frame Bolts

Power Steering Line

Pressure

Power Steering Line

Return

Power Steering Line

Pressure Line To Pump

Steering Gear

Adjustment Screw Locknut

Steering Gear

Pitman Shaft Nut

Steering Gear

Pitman Shaft Cover Bolts

Steering Gear

Valve Housing to Gear

Bolts

Steering Gear

Retainer Ring Screw

Steering Gear
Retainer Ring

196 145 —

32 23 —

71 52 —

37 27 —

31 23 —

305 225 —

68 50 —

54 40 —

2.26 — 20

97 72 —

SPECIAL TOOLS

POWER STEERING GEAR

HANDLE C-4171

INPUT SHAFT SEAL INSTALLER - 8987

DR GEAR - LINK/COIL 19 - 23

GEAR - LINK/COIL (Continued)

PULLER, SLIDE HAMMER - C-3752

PITMAN SHAFT SEAL PROTECTOR - 8993

SEAL REMOVER ADAPTER - 8990

PITMAN SHAFT SEAL INSTALLER - 8989

INPUT SHAFT SEAL PROTECTOR - 8986

PITMAN SHAFT SEAL

REMOVAL

REMOVAL - GAS ENGINE

(1) Seperate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM ­REMOVAL).

(2) Clean exposed end of pitman shaft and housing
with a wire brush.

(3) Rotate the steering wheel from stop to stop and
count the number of turns.

(4) Center the steering wheel by rotating it from
the stop back 1 1/2 turns to achieve center position.

(5) Remove the pitman shaft cover bolts.

NOTE: The pitman shaft will not clear the housing if
it is not centered.

RETAINER RING WRENCH - 8988

(6) Remove the pitman shaft from the gear.

(7) Remove dust seal from the housing with a spe­cial tool (Fig. 5).

CAUTION: Use care not to score the housing bore
when prying out seals and washer.

(8) Remove retaining ring with snap ring pliers.

19 - 24 GEAR - LINK/COIL DR

PITMAN SHAFT SEAL (Continued)

Fig. 5 SLIDE HAMMER

1 - STEERING GEAR
2 - SLIDE HAMMER C-3752 USED WITH SPECIAL TOOL
ADAPTER
8990

(9) Remove washer from the housing.

NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.

(10) Remove oil seal from the housing with a spe-

cial tool 8990 with slide hammer C-3752.

REMOVAL - DIESEL

(1) Seperate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM ­REMOVAL).

(2) Remove the steering gear box (Refer to 19 ­STEERING/GEAR - REMOVAL).

(3) Install the steering gear in a soft jawed bench
vise.

(4) Clean exposed end of pitman shaft and housing
with a wire brush.

(5) Rotate the input shaft with a 12 point socket
from stop to stop and count the number of turns (Fig.

6).

(6) Center the input shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 6).

(7) Remove the pitman shaft cover bolts.

NOTE: The pitman shaft will not clear the housing if
it is not centered.

Fig. 6 CENTERING STEERING GEAR

1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT

CAUTION: Use care not to score the housing bore
when prying out seals.

(10) Remove retaining ring with snap ring pliers.
(11) Remove washer from the housing.

NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.

(12) Remove oil seal from the housing with a spe-

cial tool 8990 with slide hammer C-3752. (Fig. 5).

INSTALLATION

INSTALLATION - GAS ENGINE

NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.

(1) Coat the oil seal and washer with high temp

grease.

NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.

(8) Remove the pitman shaft from the gear.

(9) Remove dust seal from the housing with a spe­cial tool 8990 (Fig. 5).

(2) Install the oil seal with special tool 8989 driver

and C-4171 handle (Fig. 7).

(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.

DR GEAR - LINK/COIL 19 - 25

PITMAN SHAFT SEAL (Continued)

INSTALLATION - DIESEL

NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.

(1) Coat the oil seal and washer with high temp

grease.

NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.

(2) Install the oil seal with special tool 8989 driver

and C-4171 handle (Fig. 7).

Fig. 7 SEAL INSTALLATION

1 - SPECIAL TOOL
C-4171
2 - SPECIAL TOOL
8989
3 - STEERING GEAR

(5) Coat the dust seal with high temp grease.

(6) Install the dust seal with a driver and handle
(Fig. 7).

(7) Install protective seal protector 8993 over the
shaft (Fig. 8).

(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
(5) Coat the dust seal with high temp grease.
(6) Install the dust seal with special tool 8989

driver and C-4171 handle (Fig. 7).

(7) Install protective seal protector 8993 over the

shaft (Fig. 8).

(8) Install the pitman shaft into the steering gear

until it fully seats into the bearing.

(9) Install the new cover bolts and tighten to 68

N·m (50 ft. lbs.).

(10) Install the steering gear (Refer to 19 -

STEERING/GEAR - INSTALLATION).

(11) Install the pitman arm (Refer to 19 - STEER-

ING/LINKAGE/PITMAN ARM - INSTALLATION).

(12) Perform a wheel alignment (Refer to 2 - SUS­PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

Fig. 8 PITMAN SHAFT SEAL PROTECTOR

1 - STEERING GEAR
2 - SPECIAL TOOL
8993

(8) Install the pitman shaft into the steering gear

until it fully seats into the bearing.

(9) Install the new cover bolts and tighten to 68

N·m (50 ft. lbs.).

(10) Install the pitman arm (Refer to 19 - STEER-

ING/LINKAGE/PITMAN ARM - INSTALLATION).

STEERING GEAR INPUT
SHAFT SEAL

REMOVAL

(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).

CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment

(2) Mount the steering gear upside down over a
drain pan in a soft jawed vise.

(3) Place a drain pan under the gear and rotate
the input shaft back and forth several times lock-to­lock to discharge the fluid from the steering gear

(4) Drain all the remaining fluid from the gear.

(5) Rotate the input shaft from stop to stop and
count the number of turns using a 12 point socket
(Fig. 9).

19 - 26 GEAR - LINK/COIL DR

STEERING GEAR INPUT SHAFT SEAL (Continued)

NOTE: The pitman shaft will not clear the housing if
it is not centered.

(6) Center the input shaft by rotating it from the

stop back 1 1/2 turns to achieve center position (Fig.

9).

Fig. 9 CENTERING STEERING GEAR

1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT

(10) Remove the valve housing and wormshaft
assembly from the steering gear housing and place
the valve housing in a soft jawed vise (Fig. 11).

Fig. 11 VALVE HOUSING AND WORMSHAFT

1 - VALVE HOUSING
2 - SET SCREW
3 - RETAINER RING

(11) Remove the retainer ring set screw from the
valve housing (Fig. 12).

(7) Remove the pitman shaft (Refer to 19 -

STEERING/GEAR/PITMAN SHAFT - REMOVAL).

(8) Remove the four bolts securing the valve hous-

ing.

(9) Remove the valve housing from the steering

gear (Fig. 10).

Fig. 10 VALVE ASSEMBLY

1 - VALVE HOUSING
2 - WORMSHAFT BALLS
3 - STEERING GEAR HOUSING

Fig. 12 SET SCREW FOR THE RETAINER RING

1 - SET SCREW
2 - 3/32 ALLEN HEAD SOCKET
3 - RETAINER RING

DR GEAR - LINK/COIL 19 - 27

STEERING GEAR INPUT SHAFT SEAL (Continued)

(12) Using special tool reatainer ring wrench to
remove the steering gear worm thrust bearing
reatainer ring (Fig. 13).

Fig. 13 REATINER RING REMOVAL

1 - SPECIAL TOOL
8988
2 - RATCHET

(13) Separate the wormshaft assembly from the
valve housing, Then remove the wormshaft assembly
from the vise (Fig. 14).

(14) Remove the dust seal with a pick (Fig. 15).

Fig. 15 DUST SEAL REMOVAL

1 - PICK
2 - VALVE HOUSING
3 - SEAL

CAUTION: Use care not to score the housing bore
when removing seals.

(15) Remove the snap ring with snap ring pliers

(Fig. 16).

Fig. 14 WORMSHAFT AND VALVE ASSEMBLY

1 - PISTON TEFLON SEALS
2 - RETAINER RING

Fig. 16 SNAP RING REMOVAL

1 - SNAP RING PLIERS
2 - SNAP RING
3 - VALVE HOUSING

19 - 28 GEAR - LINK/COIL DR

STEERING GEAR INPUT SHAFT SEAL (Continued)

(16) Using special tool slide hammer C-3752 with
adapter 8990 remove the oil seal (Fig. 17).

Fig. 18 RETAINER RING INSTALLATION

1 - VALVE HOUSING

Fig. 17 OIL SEAL REMOVAL

1 - SPECIAL TOOL
8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSING

2 - SPECIAL TOOL
3 - TORQUE WRENCH

INSTALLATION

(1) Inspect the piston teflon seals for damage.
Replace if needed.

NOTE: To replace the teflon seals, use a pick to
remove the teflon o-ring and the rubber o-ring
underneath. Install a new rubber o-ring in the piston
seal grove and a new teflon o-ring over the top of it.

(2) Install the valve into the valve housing.

(3) Thread the retainer ring into the valve housing
(Fig. 18). Tighten to 97 N·m (72 ft. lbs.)

NOTE: It is very important to make sure to compen­sate for the added length of the torque wrench
when torquing to proper specifications.

(4) Install the retainer ring set screw. Tighten to

2.26 N·m (20 in. lbs.)

(5) Clean the steering gear housing.

CAUTION: Valve assembly must be centered to the
housing (Fig. 19).

(6) Install the valve assembly into the steering
gear (Fig. 19). Tighten the new bolts to 54 N·m (40 ft.
lbs.)

(7) Install the input shaft seal protector 8986 (Fig.

20).

(8) Coat the new seal in high temp grease and
Install the new oil seal using special tool 8987 driver
and C-4171 handle (Fig. 21).

Fig. 19 CENTERED GEAR TEETH

1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN
HOLE
2 - VALVE HOUSING

NOTE: Drive the oil seal into the housing until the
outer edge does not quite clear the snap ring
groove.

(9) Insert the snap ring into the housing. Using
special tool 8987 driver and C-4171 handle push the
snap ring and oil seal together until the snap ring
seats in the groove.

NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.

DR GEAR - LINK/COIL 19 - 29

STEERING GEAR INPUT SHAFT SEAL (Continued)

(14) Install the steering gear to the vehicle (Refer
to 19 - STEERING/GEAR - INSTALLATION).

(15) Perform a wheel alignment (Refer to 2 - SUS­PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

PITMAN SHAFT

REMOVAL

REMOVAL - GAS

(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM ­REMOVAL).

Fig. 20 INPUT SHAFT SEAL PROTECTOR

1 - INPUT SHAFT
2 - SPECIAL TOOL
8986

(2) Clean exposed end of pitman shaft and housing
with a wire brush.

(3) Rotate the steering wheel from stop to stop and
count the number of turns.

(4) Center the steering wheel by rotating it from
the stop back 1 1/2 turns to achieve center position.

(5) Remove the pitman shaft cover bolts.

Fig. 21 INPUT SHAFT SEAL INSTALLATION

1 - VALVE HOUSING
2 - SPECIAL TOOL
8987
3 - SPECIAL TOOL
C-4171

(10) Install the new dust seal using high temp

grease, special tool C-4171 (driver) and 8987 (han-

dle).

(11) Check to make sure the gear is centered in
the middle tooth before installing the pitman shaft
(Fig. 19).

(12) Install the pitman shaft into the steering gear
(Refer to 19 - STEERING/GEAR/PITMAN SHAFT ­INSTALLATION).

(13) Perform over-center meshload adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).

NOTE: The pitman shaft will not clear the housing if
it is not centered.

(6) Remove the pitman shaft from the gear (Fig.

22).

Fig. 22 PITMAN SHAFT

1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT

(7) Remove the cover if needed by loosing the
adjuster nut, Then removing the cover from the pit­man shaft.

19 - 30 GEAR - LINK/COIL DR

PITMAN SHAFT (Continued)

REMOVAL - DIESEL

(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM ­REMOVAL).

(2) Remove the steering gear box (Refer to 19 ­STEERING/GEAR - REMOVAL).

(3) Install the steering gear in a soft jawed bench
vise.

(4) Clean exposed end of pitman shaft and housing
with a wire brush.

(5) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns (Fig.

23).

(6) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 23).

Fig. 24 PITMAN SHAFT

1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT

Fig. 23 CENTERING STEERING GEAR

1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT

(7) Remove the pitman shaft cover bolts.

NOTE: The pitman shaft will not clear the housing if
it is not centered.

(8) Remove the pitman shaft from the gear (Fig.

24).

(9) Remove the cover if needed by loosing the
adjuster nut, Then removing the cover from the pit­man shaft.

INSTALLATION

INSTALLATION - GAS

(1) Coat the seal with power steering fluid.
(2) Install pitman shaft into the steering gear until

it fully seats into the bearing.

(3) Install the new cover bolts and tighten to 68

N·m (50 ft. lbs.).

(4) Perform over-center meshload adjustment,

(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).

(5) Install the pitman arm (Refer to 19 - STEER-

ING/LINKAGE/PITMAN ARM - INSTALLATION).

(6) Perform a wheel alignment (Refer to 2 - SUS­PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

INSTALLATION - DIESEL

(1) Coat the seal with power steering fluid.

(2) Install the pitman shaft into the steering gear
until it fully seats into the bearing.

(3) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).

(4) Perform over-center meshload adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).

(5) Install the steering gear (Refer to 19 - STEER­ING/GEAR - INSTALLATION).

(6) Install the pitman arm (Refer to 19 - STEER­ING/LINKAGE/PITMAN ARM - INSTALLATION).

(7) Perform a wheel alignment (Refer to 2 - SUS­PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

DR LINKAGE - INDEPENDENT FRONT SUSPENSION 19 - 31

LINKAGE - INDEPENDENT FRONT SUSPENSION

TABLE OF CONTENTS

page page

LINKAGE - INDEPENDENT FRONT

SUSPENSION

DIAGNOSIS AND TESTING - OUTER TIE ROD

END ................................31

LINKAGE - INDEPENDENT
FRONT SUSPENSION

DIAGNOSIS AND TESTING - OUTER TIE ROD
END

NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.

(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.

(2) Remove the front tires.

(3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.

(4) Position indicator plunger on the topside of the
outer tie rod end.

TIE ROD END

REMOVAL - OUTER TIE ROD END ..........31

INSTALLATION - OUTER TIE ROD END ......32

TIE ROD END

REMOVAL - OUTER TIE ROD END

NOTE: Do not twist the boot anytime during
removal or installation.

(1) Loosen the jam nut.
(2) Remove the outer tie rod end nut from the ball

stud.

(3) Separate the tie rod ball stud from the knuckle

with Remover 8677 (Fig. 1).

(4) Unthread the outer tie rod end from the inner

tie rod.

NOTE: The dial indicator plunger must be perpen­dicular to the machined surface of the outer tie rod
end.

(5) Position a pry bar in order to pry downwards
on the outer tie rod end.

(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).

(7) If the outer tie rod end is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).

Fig. 1 TIE ROD SEPARATION

1 - TIE ROD END
2 - SPECIAL TOOL 8677

19 - 32 LINKAGE - INDEPENDENT FRONT SUSPENSION DR

TIE ROD END (Continued)

INSTALLATION - OUTER TIE ROD END

NOTE: Do not twist the boot at anytime during
removal or installation.

(1) Thread the outer tie rod end onto the inner tie
rod, to it’s original position (Fig. 2).

(2) Install the outer tie rod end into the steering
knuckle (Fig. 2).

(3) Tighten the ball stud nut on the ball stud to 61
N·m (45 ft. lbs.) then an additional 90°.

(4) Set wheel toe pattern, (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD PROCE­DURE).

(5) Tighten jam nut to 75 N·m (55 ft. lbs.) (Fig. 2).

Fig. 2 TIE ROD END

1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER

DR LINKAGE - LINK/COIL 19 - 33

LINKAGE - LINK/COIL

TABLE OF CONTENTS

page page

LINKAGE - LINK/COIL

DESCRIPTION .........................33

STANDARD PROCEDURE - LUBRICATION ....34

SPECIFICATIONS

TORQUE CHART ......................34

SPECIAL TOOLS

STEERING LINKAGE ...................35

DAMPER

REMOVAL .............................35

INSTALLATION .........................35

DRAG LINK

REMOVAL .............................35

LINKAGE - LINK/COIL

DESCRIPTION

The steering linkage is comprised of a tie rod end,
tie rod, drag link, steering damper and pitman arm
(Fig. 1).

CAUTION: If any steering components are replaced
or serviced an alignment must be performed.

NOTE: To avoid damaging ball stud seals, use
Puller C-3894–A or an appropriate puller to remove
tie rod ends (Fig. 2).

INSTALLATION .........................35

PITMAN ARM

REMOVAL .............................35

INSTALLATION .........................36

TIE ROD END

REMOVAL .............................36

INSTALLATION .........................37

TRACK BAR

REMOVAL .............................37

INSTALLATION .........................37

Fig. 1 LINK/COIL FRONT SUSPENSION

1 - STABILIZER BAR
2 - PITMAN ARM
3 - STEERING GEAR
4 - STABILIZER LINK
5 - TIE ROD ENDS
6 - LOWER SUSPENSION ARMS
7 - DRAG LINK
8 - TRACK BAR
9 - DAMPER
10 - UPPER SUSPENSION ARM

19 - 34 LINKAGE - LINK/COIL DR

LINKAGE - LINK/COIL (Continued)

STANDARD PROCEDURE - LUBRICATION

Periodic lubrication of the steering system compo­nents is required. Refer to Lubrication And Mainte­nance for the recommended maintenance schedule.

The following components must be lubricated:

• Tie rod

• Tie rod end

• Drag link

Fig. 2 Ball Stud Puller

1 - CLAMP
2 - ADJUSTMENT SLEEVE
3 - PULLER TOOL C-3894–A
4 - SEAL
5 - TIE-ROD END

SPECIFICATIONS

TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Pitman Arm

Gear Shaft Nut

Drag Link

Pitman Arm

Drag Link

Tie Rod

Drag Link

Adjuster Clamp

Tie Rod End

Knuckle

Tie Rod End

Adjuster Clamp

Stabilizer Bar Link to Axle 68 50 —

Steering Damper

Axle

Steering Damper

Tie Rod

300 225 —

88 65 —

108 80 —

61 45 —

108 80 —

61 45 —

95 70 —

81 60 —

DR LINKAGE - LINK/COIL 19 - 35

LINKAGE - LINK/COIL (Continued)

SPECIAL TOOLS

STEERING LINKAGE

Remover Ball Stud MB-991113

Puller Tie Rod C-3894-A

(2) Remove the drag link nut from the knuckle
side.

(3) Remove the drag link from the right knuckle
and pitman arm with Puller C-3894A (Fig. 3).

Fig. 3 DRAGLINK REMOVAL

1 - PITMAN ARM
2 - DRAGLINK
3 - C -3894-A PULLER

Remover Ball Joint C-4150A

DAMPER

REMOVAL

(1) Remove the steering damper mounting nuts

and bolts.

(2) Slide the damper from the isolation bushing.
(3) Remove the damper.

INSTALLATION

(1) Install the steering damper on the axle and iso-

lation bushing. Tighten nut to 95 N·m (75 ft. lbs.).

(2) Install the steering damper on the tie rod.

Tighten nut to 81 N·m (60 ft. lbs.).

DRAG LINK

REMOVAL

(1) Remove the draglink nut from the pitman arm

side.

INSTALLATION

(1) Install the drag link to the pitman arm. Install
the nut and tighten to 88 N·m (65 ft. lbs.).

(2) Install the drag link to the right steering
knuckle. Install the nut and tighten to 108 N·m (80
ft. lbs.).

(3) Install tie rod to the left steering knuckle and
drag link. Install the nuts and tighten to 108 N·m
(80 ft. lbs.).

(4) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).

NOTE: Position the clamp on the sleeve so retain­ing bolt is located on the bottom side of the sleeve.

PITMAN ARM

REMOVAL

(1) Remove the drag link from the right knuckle
and pitman arm with Puller C-4150A (Fig. 4).

(2) Mark the pitman arm and shaft positions for
installation reference. Remove the nut and washer
from the pitman arm (Fig. 5). Remove the pitman
arm with Puller C-4150A.

19 - 36 LINKAGE - LINK/COIL DR

PITMAN ARM (Continued)

Fig. 4 PITMAN ARM REMOVAL

1 - PITMAN ARM
2 - C-4150A PULLER

Fig. 5 PITMAN ARM REMOVAL/INSTALLATION

1 - STEERING GEAR
2 - PITMAN ARM
3 - NUT
4 - WASHER

Fig. 6 PITMAN ARM INSTALLED

1 - DRAGLINK
2 - STEERING GEAR
3 - SWAYBAR
4 - NUT/WASHER
5 - PITMAN ARM

NOTE: Position the clamp on the sleeve so retain­ing bolt is located on the bottom side of the sleeve.

TIE ROD END

REMOVAL

(1) Remove tie rod nuts (Fig. 7).

(2) Remove tie rod from drag link and left knuckle
with Puller C-4150A.

INSTALLATION

(1) Align reference marks and install pitman arm.

(2) Install the lock washer and retaining nut on
the pitman shaft and tighten nut to 251 N·m (185 ft.
lbs.).

(3) Install the drag link to the pitman arm (Fig. 6).
Install the nut and tighten to 108 N·m (80 ft. lbs.).

(4) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).

Fig. 7 TIE ROD ENDS

1 - NUT
2 - TIE ROD ENDS

DR LINKAGE - LINK/COIL 19 - 37

TIE ROD END (Continued)

INSTALLATION

(1) Install tie rod to the left steering knuckle and
drag link. Install the nuts and tighten to 108 N·m
(80 ft. lbs.).

(2) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

(3) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).

NOTE: Position the clamp on the sleeve so retain­ing bolt is located on the bottom side of the sleeve.

TRACK BAR

REMOVAL

(1) Raise and support the axle.

(2) Remove the track bar bolts and nuts (Fig. 8).

(3) Remove the track bar (Fig. 8).

INSTALLATION

(1) Install the track bar.

(2) Install the new bolts and nuts. Tighten to 203
N·m (150 ft lbs.).

Fig. 8 TRACK BAR REMOVAL/INSTALLATION

1 - TRACK BAR
2 - BOLT
3 - NUT

(3) Remove the supports under the axle and lower

the vehicle to the ground.

19 - 38 PUMP DR

PUMP

TABLE OF CONTENTS

page page

PUMP

DESCRIPTION .........................38

OPERATION ...........................38

DIAGNOSIS AND TESTING - PUMP LEAKAGE . 39
STANDARD PROCEDURE

STANDARD PROCEDURE - POWER

STEERING PUMP - INITIAL OPERATION....39

STANDARD PROCEDURE - FLUSHING

POWER STEERING SYSTEM ............39

REMOVAL

REMOVAL - GAS ......................40

REMOVAL - DIESEL ...................40

INSTALLATION

INSTALLATION - GAS ..................41

INSTALLATION - DIESEL ................41

SPECIFICATIONS

TORQUE CHART ......................41

FLUID

DESCRIPTION .........................42

STANDARD PROCEDURE - POWER

STEERING FLUID LEVEL CHECKING ......42

FLUID COOLER

REMOVAL .............................42

INSTALLATION .........................42

HOSES - I.F.S.

REMOVAL

REMOVAL - RETURN HOSE - GEAR TO

COOLER ............................43

REMOVAL - PRESSURE HOSE ...........43

REMOVAL - RETURN HOSE - RESERVOIR

TO COOLER .........................43

INSTALLATION

INSTALLATION - RETURN HOSE - GEAR TO

COOLER ............................43

INSTALLATION - PRESSURE HOSE .......43

INSTALLATION - RETURN HOSE -

RESERVOIR TO COOLER ...............43

HOSES - LINK/COIL

REMOVAL

REMOVAL - RETURN HOSE - GEAR TO

COOLER ............................43

REMOVAL - PRESSURE HOSE ...........44

REMOVAL - RETURN HOSE - RESERVOIR

TO COOLER .........................44

INSTALLATION

INSTALLATION - RETURN HOSE - GEAR TO

COOLER ............................44

INSTALLATION - PRESSURE HOSE .......44

INSTALLATION - RETURN HOSE -

RESERVOIR TO COOLER ...............44

POWER STEERING PRESSURE SWITCH

DESCRIPTION .........................45

OPERATION ...........................45

REMOVAL - 3.7L, 4.7L & 5.7L ..............45

INSTALLATION - 3.7L, 4.7L & 5.7L ..........45

PULLEY

REMOVAL .............................45

INSTALLATION .........................46

RESERVOIR

REMOVAL .............................46

INSTALLATION .........................46

PUMP

DESCRIPTION

CAUTION: MOPART ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.

The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.

All vehicles are equipped with a power steering

fluid cooler.

NOTE: Power steering pumps are not interchange­able with pumps installed on other vehicles.

OPERATION

Hydraulic pressure is provided for the power steer-

ing gear by the belt driven power steering pump (Fig.

1). The power steering pumps are constant flow rate
and displacement, vane-type pumps.

DR PUMP 19 - 39

PUMP (Continued)

(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level

and let the fluid settle for at least two (2) minutes.

(3) Raise the front wheels off the ground.

(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.

NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.

(5) Start the engine. With the engine idling main­tain the fluid level.

(6) Lower the front wheels and let the engine idle
for two minutes.

(7) Turn the steering wheel in both direction and

Fig. 1 POWER STEERING PUMP

1 - 3.7L & 4.7L (6 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.7L,5.9L & 8.0L (7 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.9L DIESEL (8 GROOVE)
STEEL PULLEY
2 - PUMP ASSEMBLY
3 - RESERVOIR
4 - CAP

DIAGNOSIS AND TESTING - PUMP LEAKAGE

The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.

Check for leaks in the following areas:

• Pump shaft seal behind the pulley

• Pump to reservoir O-ring

• Reservoir cap

• Pressure and return lines

• Flow control valve fitting

verify power assist and quiet operation of the pump.

If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.

CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.

STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM

Flushing is required when the power steering/hy­draulic booster system fluid has become contami­nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer­ing gear/booster spool valve operation.

(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.

(2) Remove the return line from the pump.

NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.

STANDARD PROCEDURE

(3) Plug the return line port/ports at the pump.

STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION

WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.

CAUTION: MOPART ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.

Wipe filler cap clean, then check the fluid level.
The dipstick should indicate COLD when the fluid is
at normal temperature.

(4) Position the return line/lines into a large con-

tainer to catch the fluid.

(5) While an assistant is filling the pump reservoir

start the engine.

(6) With the engine running at idle turn the wheel

back and forth.

NOTE: Do not contact or hold the wheel against the
steering stops.

(7) Run a quart of fluid through the system then

stop the engine and install the return line/lines.

(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).

(9) Start the engine and run it for fifteen minutes
then stop the engine.

19 - 40 PUMP DR

PUMP (Continued)

(10) Remove the return line/lines from the pump

and plug the pump port/ports.

(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.

(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 ­STEERING/PUMP - STANDARD PROCEDURE).

REMOVAL

REMOVAL - GAS

(1) Drain and siphon the power steering fluid from
the reservoir.

(2) Remove the serpentine belt.

CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop­erly. If this occurs the pump needs to be replaced
with a new pump.

(3) Disconnect the return hose. (Fig. 2)

(4) Disconnect the pressure hose. (Fig. 2)

(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes. (Fig. 2)

REMOVAL - DIESEL

(1) Drain and siphon the power steering fluid from

the reservoir.

(2) Remove the serpentine belt.

CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop­erly. If this occurs the pump needs to be replaced
with a new pump.

(3) Disconnect the return hose.
(4) Disconnect the pressure hose.

(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes.

(6) Loosen the pump bracket to the block.

(7) Remove the 6 intake plenum bolts (Fig. 3).

(8) loosen the inner cooler tube clamp at the
intake plenum and remove the intake plenum.

(9) Loosen the inner cooler tube clamp at the radi­ator support side and remove the tube from the vehi­cle.

(10) Remove the power steering pump from the top
of the engine compartment where the intake plenum
was (Fig. 3).

Fig. 2 POWER STEERING PUMP

1 - POWER STEERING PULLEY
2 - POWER STEERING RESERVOIR
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE

Fig. 3 POWER STEERING PUMP ACCESS

1 - INTAKE PLENUM MOUNTING
2 - POWER STEERING PUMP

DR PUMP 19 - 41

PUMP (Continued)

INSTALLATION

INSTALLATION - GAS

(1) Align the pump with the mounting holes in the

left cylinder head.

(2) Install 3 pump mounting bolts through the pul­ley access holes. Tighten the bolts to 28 N·m (21 ft.
lbs.).

(3) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N·m (27 ft. lbs.).

(4) Install the serpentine drive belt, (Refer to 7 ­COOLING/ACCESSORY DRIVE/DRIVE BELTS ­INSTALLATION).

(5) Fill the power steering pump, (Refer to 19 ­STEERING/PUMP - STANDARD PROCEDURE).

SPECIFICATIONS

INSTALLATION - DIESEL

(1) Set the power steering pump in place in the

engine compartment from the top (Fig. 3).

(2) Install the inner cooler tube.
(3) Tighten the inner cooler tube clamp at the

radiator support side.

(4) Install the 6 intake plenum bolts (Fig. 3).
(5) Tighten the inner cooler tube clamp at the

intake plenum.

(6) Install 3 pump mounting bolts through the pul­ley access holes. Tighten the bolts to 28 N·m (21 ft.
lbs.).

(7) Tighten the pump bracket to the block.

(8) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N·m (27 ft. lbs.).

(9) Install the serpentine drive belt, (Refer to 7 ­COOLING/ACCESSORY DRIVE/DRIVE BELTS ­INSTALLATION).

(10) Fill the power steering pump, (Refer to 19 ­STEERING/PUMP - STANDARD PROCEDURE).

TORQUE CHART

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Power Steering Pressure

Switch

Power Steering Line

Pressure Line

Power Steering Line

Return Line

Power Steering Line

Pressure Line To Pump

Power Steering Pump

Mounting Bolts

Power Steering Pump

Reservoir Bolts

Power Steering Pump

Bracket Bolts

TORQUE SPECIFICATIONS

10 — 80

32 23 —

71 52 —

37 27 —

28 27 —

75—

75—

19 - 42 PUMP DR

FLUID

DESCRIPTION

The recommended fluid for the power steering sys-

tem is Mopart ATF +4.

Mopart ATF+4, when new is red in color. The
ATF+4 is dyed red so it can be identified from other
fluids used in the vehicle such as engine oil or anti­freeze. The red color is not permanent and is not an
indicator of fluid condition, As the vehicle is driven,
the ATF+4 will begin to look darker in color and may
eventually become brown. THIS IS NORMAL.
ATF+4 also has a unique odor that may change with
age. Consequently, odor and color cannot be used to
indicate the fluid condition or the need for a fluid
change.

STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING

WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.

(3) Remove the mounting bracket bolts securing

the fluid cooler to the brace. (Fig. 4)& (Fig. 5)

(4) Remove the fluid cooler from the vehicle.

Fig. 4 V6 & V8 P/S FLUID COOLER

1 - POWER STEERING FLUID COOLER
2 - MOUNTING BOLTS

CAUTION: MOPART ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.

The power steering fluid level can be viewed on the
dipstick attached to the filler cap. There are two
ranges listed on the dipstick, COLD and HOT. Before
opening power steering system, wipe the reservoir
filler cap free of dirt and debris. Remove the cap and
check the fluid level on its dipstick. When the fluid is
at normal ambient temperature, approximately 21°C
to 27°C (70°F to 80°F), the fluid level should read
between the minimum and maximum area of the cold
range. When the fluid is hot, fluid level is allowed to
read up to the highest end of the HOT range. Only
add fluid when the vehicle is cold.

Use only Mopart ATF+4 Do not overfill the
power steering system.

FLUID COOLER

REMOVAL

(1) Drain and siphon the power steering fluid.

(2) Disconnect the return and supply hoses con­nected to the power steering fluid cooler.

Fig. 5 V10 & DIESEL P/S FLUID COOLER

1 - RADIATOR
2 - POWER STEERING HOSES
3 - MOUNTING BOLTS
4 - P/S FLUID COOLER

INSTALLATION

(1) Install the fluid cooler to the vehicle.
(2) Install the mounting bracket bolts securing the

fluid cooler to the brace (Fig. 4)& (Fig. 5).

(3) Reclamp the return and supply hoses to the

power steering fluid cooler.

(4) Refill the power steering fluid (Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

DR PUMP 19 - 43

HOSES - I.F.S.

REMOVAL

REMOVAL - RETURN HOSE - GEAR TO
COOLER

(1) Drain and siphon the power steering system.

(2) Raise and support the vehicle.

(3) Disconnect the return hose at the cooler.

(4) Disconnect the return hose at the gear (Fig. 6).

(5) Remove the return hose from the routing clamp
at the fan shroud and then remove from the vehicle.

INSTALLATION

INSTALLATION - RETURN HOSE - GEAR TO
COOLER

(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reconnect the return hose at the gear. Tighten

the hose to 71 N·m (52 ft. lbs.) (Fig. 6).

(4) Reattach the hose to the routing clip at the fan

shroud.

(5) Remove the support and lower the vehicle.
(6) Refill the power steering system,(Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

INSTALLATION - PRESSURE HOSE

NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.

(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the gear.

Tighten the hose to 32 N·m (23 ft. lbs.) (Fig. 6).

(3) Reconnect the pressure hose at the pump.

Tighten the hose to 36 N·m (27 ft. lbs.).

(4) Remove the support and lower the vehicle.
(5) Refill the power steering system,(Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

Fig. 6 HOSE CONNECTIONS

1 - RETURN HOSE
2 - PRESSURE HOSE

REMOVAL - PRESSURE HOSE

(1) Drain and siphon the power steering system.

(2) Raise and support the vehicle.

(3) Disconnect the pressure hose at the pump.

(4) Disconnect the pressure hose at the gear (Fig.

6).

(5) Remove the pressure hose from the vehicle.

REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER

(1) Drain and siphon the power steering system.

(2) Disconnect the return hose at the reservoir.

(3) Raise and support the vehicle.

(4) Remove the return hose from the routing clamp
at the fan shroud.

(5) Disconnect the return hose at the cooler.

(6) Remove the hose from the vehicle.

INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER

(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reattach the hose to the routing clip at the fan

shroud.

(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

HOSES - LINK/COIL

REMOVAL

REMOVAL - RETURN HOSE - GEAR TO
COOLER

(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the return hose at the cooler.
(4) Disconnect the return hose at the gear (Fig. 7).
(5) Remove the return hose from the routing clamp

at the fan shroud and then remove from the vehicle.

19 - 44 PUMP DR

HOSES - LINK/COIL (Continued)

REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER

(1) Drain and siphon the power steering system.
(2) Disconnect the return hose at the reservoir.
(3) Raise and support the vehicle.
(4) Remove the return hose from the routing clamp

at the fan shroud.

(5) Disconnect the return hose at the cooler.
(6) Remove the hose from the vehicle.

INSTALLATION

INSTALLATION - RETURN HOSE - GEAR TO
COOLER

Fig. 7 POWER STEERING HOSES TO STEERING

GEAR

1 - HIGH PRESSURE HOSE
2 - RETURN HOSE
3 - STEERING GEAR

REMOVAL - PRESSURE HOSE

(1) Drain and siphon the power steering system.

(2) Raise and support the vehicle.

(3) Disconnect the pressure hose at the pump.

(4) Disconnect the pressure hose at the gear (Fig.

8).

(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reconnect the return hose at the gear. Tighten

the hose to 71 N·m (52 ft. lbs.) (Fig. 7).

(4) Reattach the hose to the routing clip at the fan

shroud.

(5) Remove the support and lower the vehicle.
(6) Refill the power steering system,(Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

INSTALLATION - PRESSURE HOSE

NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.

Fig. 8 HOSES INSTALLED

1 - LOWER COUPLING BOLT
2 - HIGH PRESSURE HOSE
3 - RETURN HOSE
4 - STEERING GEAR
5 - PITMAN ARM

(5) Remove the pressure hose from the vehicle.

(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the gear.

Tighten the hose to 32 N·m (23 ft. lbs.) (Fig. 8).

(3) Reconnect the pressure hose at the pump.

Tighten the hose to 36 N·m (27 ft. lbs.).

(4) Remove the support and lower the vehicle.
(5) Refill the power steering system,(Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER

(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reattach the hose to the routing clip at the fan

shroud.

(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).

DR PUMP 19 - 45

POWER STEERING PRESSURE
SWITCH

DESCRIPTION

A pressure sensing switch is used in the power
steering system. It is mounted on the high-pressure
steering hose (Fig. 9). This switch will be used with
both 3.7L, 4.7L and 5.7L engines. There is no pres­sure switch used for the 5.9L pump.

OPERATION

The switch is used on the 3.7L V-6, 4.7L & 5.7L
V-8 engines.

The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
input is provided during periods of high steering
pump load and low engine rpm; such as during park­ing maneuvers. The PCM increases the idle speed
through the Idle Air Control (IAC) motor. This is
done to prevent the engine from stalling under the
increased load.

When steering pump pressure exceeds 3275 kPa ±
690 kPa (475 psi ± 100 psi), the Normally Closed
(NC) switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.

When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.

REMOVAL - 3.7L, 4.7L & 5.7L

The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).

(1) Disconnect electrical connector from power
steering pressure switch.

(2) Place a small container or shop towel beneath
switch to collect any excess fluid.

(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.

1 - POWER STEERING PULLEY
2 - POWER STEERING PUMP HOUSING
3 - POWER STEERING FLUID RESERVOIR
4 - RETURN HOSE
5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH

PULLEY

REMOVAL

CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul­ley must be installed if removed.

(1) Remove the power steering pump assembly,

(Refer to 19 - STEERING/PUMP - REMOVAL).

(2) Remove the pulley from the pump with an

appropriate power steering pulley removal tool (Fig.

10).

Fig. 9 PRESSURE SWITCH

INSTALLATION - 3.7L, 4.7L & 5.7L

This switch is used only with the 3.7L V–6 and the

4.7L, 5.7L V-8 engines.

(1) Install power steering switch into power steer­ing line.

(2) Tighten to 8–11 N·m (70–100 in. lbs.) torque.

(3) Connect electrical connector to switch.

(4) Check power steering fluid and add as neces­sary.

(5) Start engine and again check power steering
fluid. Add fluid if necessary.

Fig. 10 PULLEY REMOVAL

1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PULLEY REMOVAL TOOL

19 - 46 PUMP DR

PULLEY (Continued)

INSTALLATION

CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul­ley must be installed if removed.

(1) Replace the pulley if it’s bent, cracked, or loose.

(2) Install the pulley on the pump with an appro­priate power steering pulley installation tool (Fig. 11)
making sure it is flush with the end of the shaft.
Ensure the tool and pulley remain aligned with the
pump shaft.

approximately 0.5 mm (0.020 in.). If noise increases,
press on 1.0 mm (0.040 in.). Be careful that pulley

does not contact mounting bolts.

RESERVOIR

REMOVAL

(1) Drain and siphon the power steering fluid from

the reservoir.

(2) Remove the serpentine belt.
(3) Remove the power steering pump (Refer to 19 -

STEERING/PUMP - REMOVAL).

(4) Remove the reservoir mounting bolts.
(5) Remove the reservoir.
(6) Remove the rear bracket to the pump mounting

bolts.

INSTALLATION

(1) Install the reservoir bracket to the pump hous­ing. Do not reuse the o-rings (install new
o-rings). Tighten bolts to 7 N·m (5 ft. lbs.).

NOTE: Ensure the reservoir is fully seated onto the
pump.

Fig. 11 PULLEY INSTALLATION

1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL

(3) Install the power steering pump assembly,

(Refer to 19 - STEERING/PUMP - INSTALLATION).

(4) Run engine until warm (5 min.) and note any

belt chirp. If chirp exists, move pulley outward

(2) Install the reservoir to the bracket/pump body.

(3) Install the reservoir mounting bolts. Tighten
bolts to 7 N·m (5 ft. lbs.).

(4) Install the power steering pump (Refer to 19 ­STEERING/PUMP - INSTALLATION).

(5) Install the serpentine drive belt, (Refer to 7 ­COOLING/ACCESSORY DRIVE/DRIVE BELTS ­INSTALLATION).

(6) Fill the power steering pump, (Refer to 19 -

STEERING/PUMP - STANDARD PROCEDURE).