Dodge Steering 3500 2005, Steering 2500 2005, Steering 1500 2005 Service Manual

DR/DH STEERING 19 - 1

STEERING

TABLE OF CONTENTS

page page

STEERING

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

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

DIAGNOSIS AND TESTING

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

POWER STEERING FLOW AND PRESSURE . 4

SPECIAL TOOLS

STEERING ...........................6

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

GEAR - INDEPENDENT FRONT SUSPENSION ..31

GEAR - LINK/COIL .......................35

LINKAGE - INDEPENDENT FRONT

SUSPENSION ...........................53

LINKAGE - LINK/COIL ....................55

PUMP .................................63

PUMP - SRT-10 ..........................78

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 (4) to change the direction of the front wheels.

Power assist is provided by an engine mounted hydraulic pump which supplies hydraulic fluid pressure to the steering gear (6).

19 - 2 STEERING DR/DH

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/DH STEERING 19 - 3

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.

STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION

LOOSE STEERING AND VEHICLE LEAD

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

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

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.

5. Steering gear valve bias. 5. Replace steering gear.

compnents.

1. Inspect and repair as necessary.

bearings.

specification.

necessary.

19 - 4 STEERING DR/DH

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 Adapter Kit 6893.

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 neces-

sary. 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 readings 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.

DR/DH STEERING 19 - 5

PUMP SPECIFICATION

ENGINE RELIEF PRESSURE ± 65 FLOW RATE (GPM) AT 1500 RPM

1500 series 11032 kPa (1615 ± 65 psi) 3.1 - 3.5

2500 & 3500

series

12400 kPa (1800 ± 50 psi) 3.5 - 4.0

19 - 6 STEERING DR/DH

SPECIAL TOOLS STEERING

DR/DH COLUMN 19 - 7

COLUMN

TABLE OF CONTENTS

page page

COLUMN

DESCRIPTION

DESCRIPTION .........................7

DESCRIPTION - SRT-10 .................8

DIAGNOSIS AND TESTING

STEERING COLUMN ....................8

REMOVAL ..............................8

INSTALLATION .........................10

IGNITION SWITCH

DESCRIPTION .........................13

OPERATION ...........................13

DIAGNOSIS AND TESTING

IGNITION SWITCH ....................13

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

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

IGNITION SWITCH - SRT-10

REMOVAL - SRT-10 .....................17

INSTALLATION - SRT-10 ..................19

KEY-IN IGNITION SWITCH

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

DIAGNOSIS AND TESTING

IGNITION SWITCH AND KEY LOCK

CYLINDER ...........................19

KEY CYLINDER

REMOVAL .............................20

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

STEERING WHEEL

REMOVAL .............................21

INSTALLATION .........................21

TILT LEVER KNOB RELEASE

REMOVAL .............................21

INSTALLATION .........................23

GEAR SHIFT LEVER

REMOVAL .............................24

INSTALLATION .........................24

UPPER STEERING COUPLING

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

INSTALLATION .........................26

LOWER STEERING COUPLING

REMOVAL

ALL LD & HD EXCEPT 4X4 HD ...........27

4X4HD .............................27

INSTALLATION

ALL LD & HD EXCEPT 4X4 HD ...........29

4X4HD .............................29

COLUMN

DESCRIPTION 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.

The tilt and standard column (4) 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.

19 - 8 COLUMN DR/DH

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 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. 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.

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

DESCRIPTION - SRT-10

The SRT-10 column has no START position on the key cylinder. The push starter button switch is mounted on the Instrument panel center stack. All SRT-10 columns are Tilt columns, Standard cab trucks come with manual transmissions, Quad cab trucks come equipped with automatic transmissions.

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.

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.

DR/DH COLUMN 19 - 9

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 (1&2).

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(2) from the column shift

lever actuator (1) (Refer to 21 - TRANSMISSION/ TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT CABLE - REMOVAL)..

12. Release the shift cable from the column bracket

and remove it from the bracket.

13. Remove the SKIM module in order to disconnect

the electrical connector.

14. Remove the upper steering shaft coupler bolt (2)..

19 - 10 COLUMN DR/DH

15. Seperate the shaft from the coupler (1).

16. Remove the brake light switch and discard (Refer

to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).

17. Remove the four steering column mounting nuts

(1).

18. Remove the steering column assembly (4) from

the vehicle..

INSTALLATION

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

DR/DH COLUMN 19 - 11

1. Position the steering column on the dash panel support and loosely install the mounting nuts (1).

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

3. Install the steering shaft coupler (1) on the steering shaft and loosely install a new bolt.

4. Center steering column in dash opening and tighten mounting nuts (1) 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 (2) to 57 N·m (42 ft. lbs.).

19 - 12 COLUMN DR/DH

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

7. Install the shifter cable (2). (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 (1&2).

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 (1) and install a

new bolt. Tighten the bolt to 61 N·m (45 ft. lbs.).

15. Install the airbag (Refer to 8 - ELECTRICAL/RE-

STRAINTS/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.

DR/DH COLUMN 19 - 13

IGNITION SWITCH

DESCRIPTION

The ignition switch (5) is located on the steering column (4). 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.

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 (4) 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.

Safety goggles should be worn at all times when working on steering columns.

19 - 14 COLUMN DR/DH

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

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 (1) mounting screws.

DR/DH COLUMN 19 - 15

8. For columns without tilt remove the bracket (2) to gain access to the ignition switch mounting screws (2).

9. Disconnect the electrical connector at rear of ignition switch (1).

10. Remove ignition switch mounting screw (2).

11. Using a small screwdriver, push on locking tab

and remove switch from steering column.

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.

3. Position switch (1) to column and install the mounting screw (2). Tighten screw to 3 N·m (26 in. lbs.).

19 - 16 COLUMN DR/DH

4. Install the tilt lever bracket (2) mounting screws. Tighten screws to 4.5 N·m (40 in. lbs.).

5. If the column is non-tilt install the bracket (2). Tighten screws to 4.5 N·m (40 in. lbs.)

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

7. Reconnect the lower clockspring connectors.

8. Install the key cylinder (1)

9. Install steering column upper and lower shrouds.

10. Enable the airbag system. (Refer to 8 - ELECTRI-

CAL/RESTRAINTS/DRIVER AIRBAG INSTALLATION).

DR/DH COLUMN 19 - 17

IGNITION SWITCH - SRT-10

REMOVAL - SRT-10

The ignition switch (1) attaches to the lock cylinder housing (2) on the end opposite the lock cylinder. For ignition switch terminal and circuit identification, refer to the Wiring Diagrams sections.

1. Disconnect negative cable from battery.

2. Place key cylinder in RUN position. Through the hole in the lower shroud (2), depress lock cylinder retaining tab and remove key cylinder.

3. Remove upper and lower shrouds (3) from steering column.

4. Disconnect electrical connectors from ignition switch (1).

19 - 18 COLUMN DR/DH

5. Remove the 2 screws on the top of the multi-function switch and relocate.

6. Remove ignition switch mounting screw with a #10 TorxT bit.

7. Pull ignition switch from steering column.

DR/DH COLUMN 19 - 19

INSTALLATION - SRT-10

1. Ensure the ignition switch is in the RUN position and the actuator shaft (2) in the lock housing (1) is in the RUN position.

2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw.

3. Install electrical connectors to ignition switch.

4. Install the multi-function switch and tighten the 2 screws.

5. Install upper and lower shrouds.

6. Install key cylinder (cylinder retaining tab will depress only in the RUN position).

7. Connect negative cable to battery.

8. Check for proper operation of ignition switch and key-in warning switch.

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.

MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)

(Refer to 19 - STEERING/COLUMN/IGNITION SWITCH - DIAGNOSIS AND TESTING).

19 - 20 COLUMN DR/DH

KEY CYLINDER

REMOVAL

The ignition key (1) must be in the key cylinder (2) 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 is located at side of key cylinder assembly (2).

a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cyl-

inder (1) from ignition switch.

INSTALLATION

The ignition key (1) must be in the key cylinder (2) for cylinder installation.

1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch.

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

3. Replace the upper and lower shrouds.

4. Reconnect the battery.

DR/DH COLUMN 19 - 21

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 (1) and leave the bolt in the column.

3. Install puller CJ98-1 (2) or equivalent using the top of the bolt to push on.

4. Remove and discard the steering wheel bolt.

5. Remove the steering wheel (1).

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).

TILT LEVER KNOB RELEASE

REMOVAL

1. Remove the tilt lever handle.

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

3. Remove the lower shroud.

NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring.

19 - 22 COLUMN DR/DH

4. Remove the two mounting screws (3) from the tilt lever knob release bracket (1).

5. Disconnect the electrical harness plastic mounting tab (2) from the the bracket (1).

6. Unsnap the cable (2) from the bracket (1).

7. Remove the end of the cable (2) from the tilt lever knob release bracket (1).

DR/DH COLUMN 19 - 23

INSTALLATION

1. Route the cable (2) into the tilt lever release knob bracket (1).

2. Snap the cable end (2) into the bracket (1).

NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring.

NOTE: New screws should be used when installing the tilt lever release knob bracket to the column.

3. Install the tilt lever release knob bracket (1) to the column and install the two new mounting screws (3) Tighten the two new screws to 4.5 N·m (40 in. lbs.).

4. Install the electrical harness plastic mounting tab (2) to the bracket (1).

5. Install the lower shroud.

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

7. Install the tilt lever handle.

19 - 24 COLUMN DR/DH

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 (2).

9. Remove the blocker pin from the inhibit link slot (1).

INSTALLATION

1. Install the lever assembly (2) using care to install the pin in the blocker to slider slot (1) and install the mounting screws and tighten to 12 N·m (105 in. lbs.).

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 (2).

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).

DR/DH COLUMN 19 - 25

UPPER STEERING COUPLING

REMOVAL

1. Disconnect the negative battery cable.

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 (2) seal by pushing in the four tags (1) securing it to the panel.

6. Remove and discard the lower coupler pinch bolt (1) from the lower steering coupling shaft (1).

7. Remove the upper steering coupling shaft (3) from the vehicle.

19 - 26 COLUMN DR/DH

INSTALLATION

1. Install the upper steering coupling shaft (3) to the vehicle.

2. Install the upper steering coupling shaft seal (2) by pushing it in securing the four tangs (1) to the panel.

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

3. Install the steering coupler shaft (1) to the column.

4. Install the upper pinch bolt (3) use new bolt and tighten to 57 N.m (42 ft.lbs).

5. Install the shaft to the lower coupler (1).

6. Install the lower pinch bolt (1) use new bolt and tighten to 57 N.m (42 ft.lbs).

7. Unlock the steering wheel.

8. Reconnect the negative battery cable.

DR/DH COLUMN 19 - 27

LOWER STEERING COUPLING

REMOVAL ALL LD & HD EXCEPT 4X4 HD

1. Disconnect the negative battery cable.

2. Raise and support the vehicle.

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.

4X4 HD

1. Disconnect the negative battery cable.

2. Raise and support the vehicle.

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

4. Remove the left front tire and wheel assembly.

19 - 28 COLUMN DR/DH

5. Remove and discard the upper coupler pinch bolt (1).

6. Remove and discard the lower coupler pinch bolt (2).

7. Remove the lower steering shaft coupler (3).

DR/DH COLUMN 19 - 29

INSTALLATION ALL LD & HD EXCEPT 4X4 HD

1. Install the coupler to the steering rack & pinion 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.

4X4 HD

1. Install the coupler (2) to the steering gear (3).

19 - 30 COLUMN DR/DH

2. Install the coupler (3) to the intermediate shaft (2).

NOTE: New pinch bolts must be used for reinstallation.

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

4. Install the upper pinch bolt (1) 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.

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