• STEERING 19-1

STEERING

CONTENTS
page page

GENERAL INFORMATION 1 STEERING COLUMN 3i

POWER STEERING PUMP 11 STEERING LINKAGE 17
POWER STEERING SYSTEM DIAGNOSIS . . . . . 2 TORQUE SPECIFICATIONS 40
RECIRCULATING BALL POWER STEERING GEAR . 20

GENERAL INFORMATION
STEERING SYSTEM COMPONENTS RECIRCULA TING-BALL POWER STEERING

Dodge T r u c k s use a p o w e r assisted recirculating-
ball t y p e s t e e r i n g g e a r (Fig. 1). T h e g e a r i s u s e d w i t h
four w h e e l d r i v e a n d t w o w h e e l drive v e h i c l e s .
Power steering systems u s e ;
• S t e e r i n g gear
• Steering linkage
• Pressure and return fluid hoses and fittings
• Belt driven hydraulic steering pump with fluid
reservoir
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GEARS
The recirculating ball system acts as a rolling
thread between t h e worm shaft and rack piston. The
worm shaft is supported by a thrust bearing a t t h e
lower end and a bearing assembly a t t h e upper end.
When t h e worm shaft is turned t h e rack piston
moves. The rack piston teeth mesh with t h e pitman
(sector) shaft. Turning the worm shaft turns t h e pit­
man shaft, which turns the steering linkage.
The steering gears can be adjusted and internally
serviced.
An identification code on the upper adjustment
cover designates t h e ratio.
• Code XS designates 13-16:1 ratio used in Dodge
Ram Truck vehicles

POWER STEERING PUMP

J9219-65
Fig. 1 Power Steering Systems
The steering linkage consists of a pitman a r m ,
idler arm, tie rods, and center link. Adjustment
sleeves are used on t h e tie rods for toe and steering
wheel alignment. For additional wheel alignment in­
formation refer to Group 2, Front Suspension.
Hydraulic pressure is provided by a belt driven
power steering pump. The power steering pump is a
constant flow rate and displacement, vane-type
pump. The internal parts t h a t are inside the housing
operate submerged in fluid. The flow control orifice is
part of the pressure line union. The pressure relief
valve inside t h e flow control valve limits t h e pump
pressure.
The power steering pump is connected to the steer­
ing gear via t h e pressure hose and t h e return hose.
The pump shaft h a s a pressed-on pulley t h a t is belt
driven by t h e crankshaft pulley.
Trailer tow option vehicles are equipped with a
power steering pump oil cooler. The oil cooler is
mounted to t h e engine block under t h e steering
pump cast aluminum mounting bracket.
The power steering pump on t h e D O D G E T U R B O
D I E S E L engine is bolted onto t h e rear of t h e vac­
u u m pump. The pump is driven by t h e accessory
drive through a common shaft.
19 - 2 STEERING
Dodge R a m T r u c k p o w e r s t e e r i n g p u m p s a r e
not interchangeable with p u m p s installed i n
o t h e r vehicles.
The Saginaw P-Series pump (Fig. 2) is used in
Dodge Ram Truck vehicles.
STEERING COLUMNS
Two general types of steering columns are installed
on Dodge Ram Truck vehicles: a fixed, non-tilt col­
umn and a tilt column.
The ignition key/lock cylinder and the ignition
switch are located in the steering column. When in
the LOCK position, the ignition switch and the steer­
ing shaft cannot be operated. The lock mechanism
also prevents operation of the automatic trans, gear
shift mechanism.
The intermediate shaft is attached to t h e gear and
column shaft with universal joints.
POWER STEERING S Y S T E M D I A G N O S I S
PUMP PRESSURE TEST
The following procedure can be used to test the op­
eration of the power steering system on t h e vehicle.
(1) Check belt tension and adjust as necessary.
(2) Disconnect high pressure hose at gear or pump.
Use a container for dripping fluid.
(3) Connect Gauge C-3309-E to both hoses using
adapter fitting (Fig. 1). Connect spare pressure hose
to gear or pump.
SPECIAL
1 Pressure Hose to Steering Gear
2 Shut-Off Valve
3 Pressure Hose From Pump
Fig. 1 Pressure Test Gauge
(4) Open t h e test valve completely.
(5) Start engine and let idle.
(6) Check fluid level, add fluid as necessary.
•
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Fig. 2 Saginaw P-Series Pump
Both types of steering columns have anti-theft pro­
visions. They are energy-absorbing (collapse from im­
pact in the event of a front-end collision).
(7) Gauge should read below 862 k P a (125 psi), if
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure should be in the
range of 345-552 k P a (50-80 psi).
C A U T I O N : The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. D o not leave valve closed
for more than five seconds a s the pump could be
damaged.
(8) Close valve fully three times and record high­
est pressure indicated each time. All three readings
must b e a b o v e specifications a n d within 345 k P a
(50 psi) of e a c h other.
9 Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
• Pressures within 345 k P a (50 psi) of each other
but below specifications, replace pump.
C A U T I O N : D o not force the pump to operate against
the stops for more than 2 to 4 seconds at a time be­
cause, pump damage will result.
(9) Open the test valve, t u r n steering wheel ex­
J9219-44 treme left and right positions against the stops.
Record the highest indicated pressure at each posi­
tion. Compare readings to specifications. If highest
output pressures are not the same against either
stop, the gear is leaking internally and must be re­
paired.
The steering p u m p relief pressure for all en­
gines is 1400 p.s.i. ± 50.
• STEERING 19 - 3

PUMP LEAKAGE DIAGNOSIS

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9119-1
19 - 4 STEERING

POWER STEERING SYSTEM DIAGNOSIS

P U M P NOISI

There is some noise in all power steering systems. One of the most common is a hissing sound evident at standstill parking. Hiss is
a high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve and results
from high velocityfluidpassing valve orifice edges. There is no relationship between this noise and performance of the steering.
Hiss may be expected when steering wheel is at end of travel or when slowly turning at standstill.

CONDITION POSSIBU CAUSI CORRICriON

OBJECTIONALHISSOR 1. Noisy valve in gear 1. Check for proper seal between steering
WHISTLE column coupling and dash seal.
Ensure steering column lower coupling
has no metal-to-metal contact
within the coupling by performing an
electrical continuity check. (Remove
coupling for check.)

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If hiss is still extremely objectionable,
replace steering gear.

RATTLE OR CLUNK 1. Gear loose on front crossmember 1. Check gear-to-crossmember mounting

2. Crossmember-to-frame bolts or studs loose
3. Tie rod looseness (outer or inner)
4. Pressure hose touching other parts of vehicle
5. Noise internal to gear
bolts. Tighten to specification.
2. Torque bolts and studs to specifications.
3. Check tie rod pivot points for wear.
Replace if necessary.
4. Adjust hose to proper position by
loosening, repositioning, and retightening
fitting. Do not bend tubing.
5. Replace gear.

CHIRP OR SQUEAL (IN 1. Loose belt 1. Adjust belt tension to specification.

THE AREA OF PUMP)
PARTICULARLY
NOTICEABLE AT FULL
WHEEL TRAVEL A N D
DURING STANDSTILL
PARKING

9119-2
• STEERING 19-5

POWER STEERING SYSTEM DIAGNOSIS

PUMP GROWL

Pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be
objectionable. Abnormal situations, such as a low oil level causing aeration or hoses touching the vehicle body, can create a noise
level that could bring complaints.

CONDITION POSSIBLE CAUSE CORRECTION

WHINE OR GROWL 1. Low fluid level 1. Fill to proper level and perform leakage
(PUMP NOISE) diagnosis. (Recheck after system is free
of aeration.)
2. Hose touching vehicle body or frame 2. Reposition hose. Replace hose if tube
ends are bent.
3. Extreme wear of pump internal parts 3. Replace pump andflushsystem.

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SUCKING AIR SOUND 1. Loose return line clamp 1. Tighten or replace clamp.
2. Inspect connection and replace o-ring as
2. Missing O-ring on hose connection required.
3. Fill to proper level and perform leakage
3. Low fluid level diagnosis.
4. Inspect and replace reservoir as required.
4. Air leak between reservoir and pump

SQUEAK OR RUB SOUND
1. Sound from steering column
2. Sound internal to steering gear
1. Check for squeak in steering column.
Inspect for contact between shroud
intermediate shaft, column, and wheel.
(Realign if necessary.)
2. Replace gear.

SCRUBBING/KNOCKING
1. Incorrect tire size 1. Verify tire size is the same as originally
supplied.
2. Check clearance between tires and other
vehicle components, through full travel 2. Correct as necessary.
3. Check for interference between steering gear
and other components 3. Correct as necessary.
4. Incorrect gear supplied
4. Replace gear.

9119-3
19 - 6 STEERING •
POWER STEERING SYSTEM DIAGNOSIS

B I N D S STICKS S E I Z E D

CONDITION POSSIBLE CAUSE CORRECTION

CATCHES, STICKS IN 1. Low fluid level 1. Fill to proper level and perform leakage
CERTAIN POSITIONS OR diagnosis.
DIFFICULT TO TURN 2. Tires not properly inflated 2. Inflate tires to proper pressure.
3. Lack of lube in ball joints 3. Lubricate where possible.
4. Lack of lube in outer tie rod ends 4. Lubricate where possible.
5. Loose pump belt 5. Tighten or replace belt.
6. Faulty pump flow control (Verify cause using 6. Replace pump.
Pump Test Procedure)
7. Excessive friction in steering column or 7. Correct condition. (See Steering Column
intermediate shaft Service Procedure.)

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8. Steering column coupling binding 8. Realign as necessary.
9. Excessive friction in gear 9. Replace gear.

SHAKE SHUDDER VIBRATION

CONDITION POSSIBLE CAUSE CORRECTION

VIBRATION OF THE 1. Air in the power steering system 1. Steering shudder can be expected in new
STEERING WHEEL A N D / vehicles and vehicles with recent steering
OR DASH DURING DRY system repairs. Shudder should improve
PARK OR LOW SPEED after the vehicle has been driven several
STEERING MANEUVERS weeks.
2. Tires not properly inflated 2. Inflate tires to proper pressure.
3. Excessive engine vibration 3. Make sure that engine is running properly.
4. Faulty accessory drive belt tensioner. 4. Check dynamic belt tensioner for
(Poly-V belt systems only) abnormal vibration. (See Drive Belt
Adjustments.)
5. Overcharged air conditioner 5. Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis.)

9119-4
• STEERING 19 - 7

POWER STEERING SYSTEM DIAGNOSIS

L O W ASSIST, N O ASSIST, O R H A R D STEERING

CONDITION POSSIBLE CAUSE CORRECTION

STIFF, HARD TO TURN, 1. Tires not properly inflated 1. Inflate tires to proper pressure.
SURGES, MOMENTARY 2. Low fluid level 2. Add power steering fluid as required and
INCREASE IN EFFORT perform leakage diagnosis.
WHEN TURNING
3. Loose belt 3. Tighten or replace belt.
4. Lack of ball joint lubrication 4. Lubricate or replace as required.
5. Low pressure pump (Verify using Pump Test 5. Verify cause using Pump Test Procedure.
Procedure) Replace pump if necessary.
6. High internal leak gear 6. Check steering system using test
procedure. If steering gear is at fault,
replace steering gear.

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P O O R RETURN T O CENTER

CONDITION POSSIBLE CAUSE CORRECTION

STEERING WHEEL DOES 1. Tires not properly inflated 1. Inflate tires to proper pressure.
NOT WANT TO RETURN 2. Improper front wheel alignment 2. Check and adjust as necessary.
TO CENTER POSITION
3. Lack of lubrication in ball joint 3. Replace as required or lubricate.
4. Steering column U-joints misaligned 4. Realign steering column U-joints.
5. Mispositioned dash cover 5. Reposition dash cover.
To evaluate items 6 and 7, disconnect the
intermediate steering shaft. Turn the steering
wheel and listen for internal rubbing in
column.
6. Steering wheel rubbing 6. Adjust covers.
7. Tight steering shaft bearings 7. Replace bearings.
8. Excessive friction coupling universal joint 8. Replace U-joints.
9. High friction in the steering gear 9. Replace steering gear.

91195
19 - 8 STEERING

POWER STEERING SYSTEM DIAGNOSIS

LOOSE STEERING

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE WHEEL 1. Air in system 1. Add fluid.

KICKBACK OR TOO 2. Gear loose on crossmember 2. Check gear to crossmember mounting
MUCH STEERING WHEEL bolts. Tighten to specification,
PLAY
3. Worn/broken intermediate shaft 3. Check for worn universal joint ond broken
isolator. Replace intermediate shaft if
worn.
4. Free play in steering column 4. Check and replace as required.
5. Loose ball joints 5. Check and replace as required.
6. Front wheel bearings loose or worn 6. Tighten hub nut or replace with new parts
as necessary.

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7. Loose outer tie rod ends 7. Check and replace as required.
8. Loose inner tie rod ends 8. Replace gear.
9. Defective steering gear rotary valve 9. Replace gear.

V E H I C L E L E A D S T O THE S I D E

CONDITION POSSIBLE CAUSE CORRECTION

WHEEL DOES NOT 1. Radial tire lead 1. Rotate tires as recommended in Tire
WANT TO RETURN TO Service.
CENTER POSITION 2. Alignfrontend as recommended in
2. Front end misaligned
Wheel Alignment Service Procedure.
3. Wheel braking 3. Check for dragging brakes as directed in
Brake Service Procedure.
4. Unbalanced steering gear valve. (If this is the 4. Checking for pull with outer tie rod end
cause, the steering efforts will be very light in disconnected. If verified, replace gear.
direction of lead and heavier in the opposite
direction)

9119-6
• STEERING 19-9

POWER STEERING SYSTEM DIAGNOSIS

FLUID LEAK

CONDITION POSSIBLE CAUSE CORRECTION

LOW FLUID LEVEL WITH: 1. Overfilled reservoir 1. Adjust fill level.

• N O VISIBLE SIGNS OF 2. Hose connections at pump or gear 2. Check for loose fittings and tighten to
LEAKS O N THE specifications. If fittings are tight, examine
STEERING GEAR, for damaged or missing O-ring and
PUMP, O N FLOOR, OR replace as required.
ANYWHERE ELSE 3. Identify location of leak and repair or
3. Pump or gear leak
LOW FLUID LEVEL WITH: replace as indicated in Power Steering
• VISIBLE LEAK O N
Pump and/or Gear sections of this
STEERING GEAR,
service manual.
PUMP, FLOOR, OR
ANYWHERE ELSE

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F O A M Y O R MILKY FLUID

CONDITION POSSIBLE CAUSE CORRECTION

AERATION A N D 1. Air leaks 1. Check for air leak as described under

OVERFLOW O F FLUID sucking air and correct.
2. Low fluid level 2. Extremely cold temperatures may cause
system aeration if the oil level is low.
Add fluid as required.
3. Cracked pump housing 3. Remove pump from vehicle and separate
reservoir from housing. Check expansion
plug and housing for cracks. Replace
pump as required.
4. Water contamination 4. Drain and refill fluid if there is evidence
of contamination.

9119-7
19 - 10 STEERING •
GEAR LEAKAGE DIAGNOSIS

1. SIDE C O V E R LEAK - T O R Q U E SIDE
C O V E R B O L T S T O 6 0 N T T I (45 FT.
LBS.). R E P L A C E T H E S I D E C O V E R
SEAL IF T H E L E A K A G E PERSISTS.
2. ADJUSTER P L U G SEAL - REPLACE
T H E ADJUSTER P L U G SEALS.
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3 . PRESSURE LINE FITTING - TOR­
QUE THE HOSE FITTING NUT TO
2 7 N.m ( 2 0 FT. LBS.). IF LEAKAGE
PERSISTS, REPLACE THE SEAL.
4. PITMAN SHAFT SEALS - REPLACE
THE SEALS.
5. T O P C O V E R SEAL - REPLACE T H E
SEAL. J9219-29
 • STEERING 19 - 11

POWER STEERING PUMP

INDEX

page page
Power Steering Hose 11 Pump Replacement—Gasoline Engine . . . . . . . . . 14
Power Steering Pump—Initial Operation 15 Pump Reservoir 15
Pump Pulley 15 Service Information . . . . . . . . . . . . . . . . . . . . . . . 11
Pump Replacement—Diesel Engine 12

SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an inter­
nal fluid leak occurs, the complete unit must be re­
placed.

POWER STEERING HOSE

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Max. cool, vehicles are equipped with a power
steering auxiliary fin oil cooler. The oil cooler is
mounted to the engine block under the steering
pump (Fig. 2).
Cap hose open ends and pump/steering gear fit­
tings to prevent entry of foreign material.

WARNING; P O W E R STEERING F L U I D ( A N D P U M P
COMPONENTS) A N D T H E E X H A U S T S Y S T E M C A N
BE EXTREMELY H O T IF T H E E N G I N E H A S B E E N
RECENTLY OPERATING. D O NOT S T A R T THE E N ­
GINE WITH A N Y L O O S E O R D I S C O N N E C T E D
H O S E S . DO N O T A L L O W T H E H O S E S T O T O U C H A
HOT EXHAUST M A N I F O L D OR T H E C A T A L Y T I C
CONVERTER.
Fig. 1 Power Steering Hose Diesel Engine
REMOWAL
SCREW
(1) Remove fasteners from hose retaining brackets
at all locations.
(2) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser­
voir (Fig. 1, 2).
(3) If applicable, remove cooler bracket fasteners
from block.
(4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2).

INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks. T h e
h o s e m u s t b e k e p t a w a y from e x h a u s t s y s t e m
c o m p o n e n t s . Do not distort hose tube ends by bend­
ing, kinking or over tightening.
(3) Tighten cooler bracket fasteners to 41 N»m (30
ft. lbs.) torque (Fig. 1, 2).
(4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
Fig. 2 Power Steering Hose V/6, V/8
19 - 12 STEERING •
(5) Tighten fittings at pump and gear to 35 Nnn
(25 ft. lbs.) torque.
(6) Install clamps on return hose on gear and
pump.
(7) After installation, inspect and test for fluid
leaks.

PUMP REPLACEMENT—DIESEL ENGINE

REMOVAL
(1) Place a drain pan under the power steering
pump.
(2) Disconnect and cap the vacuum and steering
pump hoses.
(3) Disconnect the electrical connector on the oil
pressure sender unit (Fig. 3). Remove sender unit
from engine block and plug hole in block.

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Fig. 4 Oil Feed Line Removal/Installation

PUMP ENGINE BLOCK

Fig. 3 Oil Pressure Sending Unit

(4) Disconnect and cap the oil feed line from the
bottom of the vacuum pump (Fig. 4).
(5) Remove the lower bolt t h a t attaches the vacu­
um/steering pump assembly to the engine block. Re­
move the n u t from the steering pump attaching
bracket (Fig. 4).
Fig. 5 Pump Assembly Upper Bolt
(6) Remove upper bolt from the pump assembly
(Fig. 5). Remove the assembly from the engine (Fig. (11) Remove the two pump body spacers (Fig. 8),
6). for pump installation.
(7) Remove the gasket from the mounting surfaces
on engine block and pump assembly. INSTALLATION
(8) Drain the fluid from the steering pump. (1) Install the two pump body spacers (Fig. 8).
(9) Remove the steering pump to vacuum pump (2) Rotate the drive gear until the steering pump
bracket attaching nuts (Fig. 7). and vacuum pump drive dogs align. Install the steer­
(10) Slide the steering pump from the bracket. Use ing pump onto the vacuum pump bracket. Use care
care not to damage the internal oil seal in the vac­ to avoid damaging the oil seal in the vacuum pump
u u m pump (Fig. 8). during installation. T h e s t e e r i n g p u m p h o u s i n g
 • STEERING 19 - 13

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PUMP BRACKET
SPACERS J9119-69

Fig. 8 Steering Pump Removal/Installation

Fig. 6 Pump Assembly Removal/Installation

PUMP
Jf 119-78
Fig. 9 Steering/Vacuum Pump Assembly
Fig. 7 Bracket Nut Removal/Installation
the block bracket. Tighten the pump-to-engine block
a n d spacers m u s t mate completely with the vac­
attaching bolts to 77 N*m (57 ft. lbs.) torque.
u u m p u m p b r a c k e t (Fig. 9).
(6) Install the steering pump to attaching bracket
(3) Install the three (3) vacuum pump bracket to
n u t and tighten to 24 N*m (18 ft. lbs.) torque.
steering pump nuts. Tighten to 24 N«m (18 Ft. lbs.)
(7) Remove plug and install the oil pressure send­
torque.
ing unit and electrical connector.
(4) Position a new gasket on the vacuum pump as­
(8) Install the oil feed line to the vacuum pump.
sembly, use sealer if necessary to retain the gasket.
Tighten the oil line connection to 7 N»m (60 in. lbs./
(5) Align and install the pump assembly on the en­
5 ft. lbs.) torque.
gine. Ensure the steering pump stud is inserted into
19 - 14 STEERING
(9) Install the fluid hoses to the power steering
pump, Tighten the pressure fitting at the pump to 30
N*m (22 ft. lbs.) torque.
(10) Install and clamp the hose on the vacuum
pump.
(11) Fill the reservoir with power steering fluid
only. If necessary, refer to P u m p Initial O p e r a t i o n
for detailed instructions.
(12) Start and r u n the engine. Check the operation
of the brakes, if necessary refer to Group 5, Brakes
for additional information.
PUMP REPLACEMENT—GASOLINE ENGINE
REMOVAL
WARNING: D O NOT REMOVE THE WATER PUMP
COOLANT TUBE UNLESS THE COOLANT SYSTEM
HAS B E E N DEPRESSUR1ZED A N D DRAINED*
WARNING: D O NOT ATTEMPT TO REMOVE THE
PUMP WITHOUT REMOVING T H E BELT FIRST. T H E
AUTOMATIC T E N S I O N E R I S U N D E R A HIGH
SPRING LOAD.
(1) Remove the serpentine drive belt. Rotate ten­
sioner clock-wise and hold in place, and remove belt
(Fig. 10).
Fig. 10 Serpentine Belt Removal/Installation
(2) Clamp the fluid return hose and disconnect the
hoses from t h e power steering pump. Cap the fit­
tings.
(3) Remove battery ground cable and nut at stud.
Unthread stud from cylinder head, do not remove
from bracket. Loosen upper bracket bolt. Remove the
•
lower bracket to engine block bolts. Pivot the pump
assembly past the coolant tube. Remove the upper
stud. Remove upper bolt from cylinder head. The
steering pump and mounting bracket will be re­
moved from engine as an assembly.
(4) Remove the pump pulley, refer to the procedure
below. This will allow access to the pump attaching
screws.
(5) Remove the bracket to pump attaching screws
(Fig. 11).
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Fig. 11 Pump Removal/Installation
INSTALLATION
(1) Install the bracket to pump mounting screws
(Fig. 11). Tighten to 54 N-m (40 ft. lbs.).
(2) Install the pump pulley, refer to the procedure
below.
(3) Position the steering pump (with pulley) and
mounting bracket on the engine block (Fig. 11). In­
stall the upper stud and bolt in bracket. Pivot the
pump down past the coolant tube. Install the lower
bolts in bracket (Fig. 11).
(4) Install the bracket to engine block attaching
bolts (Fig. 11). Tighten the bolts and n u t to 41 N*m
(30 ft. lbs.).
(5) Connect the fluid hoses to the pump.
(6) Install the serpentine drive belt. Rotate ten­
sioner clock-wise and hold in place, slip the belt over
the pulleys. Refer to Group 7, Cooling for belt rout­
ing.
C A U T I O N : D o not use automatic transmission fluid
to fill the reservoir.
(7) Fill the reservoir with power steering fluid
only. If necessary, refer to P u m p Initial O p e r a t i o n
for detailed instructions.
 # _ , STEERING
PUMP PULLEY
REMOVAL
(1) Remove the pulley with Puller C-4333 (Fig.
12).
Fig. 12 Pulley Removal (Typical)
D o n o t hammer o n pulley b e c a u s e t h i s will
damage it a n d the pump.
(2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install the pulley with Installer C-4063-A (Fig.
13). Do not use the tool adapters.
(2) Ensure t h a t the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.
(3) Force pulley flush with the end of the shaft.
With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise is increases, press on 1.0 mm (0.040 in.). Be
careful that pulley does not contact mounting
bolts.
PUMP RESERVOIR
REMOVAL
Discard all O-ring seals during disassembly,
they are not re-usable.
(1) Remove the filler cap and drain the fluid from
reservoir before removing parts.
(2) Remove mounting studs and pressure fitting
(Fig. 14). Rock reservoir by hand or use a soft face
mallet to remove.
19-15
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Fig. 13 Pulley Installation (Typical)
(3) Remove O-ring seals from housing and reser­
voir (Fig. 14).
(4) Remove flow control valve and spring from
housing.
INSTALLATION
Clean all parts before installation. Lubricate
n e w O-ring seals with MOPAR® P o w e r Steering
Fluid or a n equivalent product.
(1) Install flow control valve and spring (Fig. 15).
(2) Install new O-ring seals in housing (Fig. 15).
Tighten mounting studs to 48 N«m (35 ft. lbs.)
torque.
(3) Install fitting in flow control valve bore.
Tighten the fitting to 75 N-m (55 ft. lbs.) torque.
POWER STEERING PUMP-INITIAL OPERATION
C A U T I O N : The fluid level should be checked with
engine off to prevent injury from moving compo­
nents. U s e only M O P A R ® Power Steering Fluid. D o
not use automatic transmission fluid. D o not over­
fill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the
fluid is at normal temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let r u n for a few seconds.
The turn the engine off.
(3) Add fluid if necessary. Repeat the above proce­
dure until the fluid level remains constant after run­
ning the engine.
(4) Raise the front wheels off the ground.
19 - 16 STEERING •
EXPANSION PLUG - D O N O T REMOVE; RESERVOIR
IF DEFORMED OR DISLODGED,
REPLACE HOUSING CAP

HOUSING

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FITTING
75 N-m
SEAL (55 FT. LBS.) 9119-9

Fig. 14 Pump and Reservoir

(5) Start the engine. Slowly t u r n the steering VALVE A N D
wheel right and left, lightly contacting the wheel SPRING
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and t u r n the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi­
cle to stand a few minutes and repeat the above pro­
cedure.

J8919-101

Fig. 15 Flow Control Valve/Spring Installation

• STEERING 19 - 17

STEERING L I N K A G E
SERVICE INFORMATION IDLER
The tie-rod end ball stud seals should be inspected ARM
during all oil changes.
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, re­
place the tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a com­
plete replacement tie-rod end should be installed. Lu­
bricate the tie-rod end with MOPAR® Multi-Mileage
Lubricant, or equivalent.
Use Puller C-3894-A for tie rod removal. Fail­
ure to use this tool c o u l d d a m a g e the tie rod a n d
seal (Fig. 1).

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DUTY
TIE ROD J9119-66

Fig. 2 Steering Linkage—2WD Vehicles

Fig. 1 Ball Stud Removal

STEERING LINKAGE—2WD
REMOWAL
(1) Remove the cotter pin and nut from the tie-rod.
(2) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2),
Use care to avoid damaging the seals.
(2) Remove inner tie-rod ends (Fig. 1 and 2) from
center link.
(3) Remove idler arm ball stud from center link
(Fig. 2). Remove idler a r m bolts from frame side rail
(Fig. 2).
(4) Remove pitman arm ball stud from center link. Fig. 3 Pitman Arm Removal
(5) Mark the pitman arm and shaft positions for (2) Center steering gear to alignment m a r k s and
reference. Remove pitman arm with Puller C-4150 install pitman arm.
(Fig. 3). (3) Install the washer and retaining n u t on the pit­
man shaft. Tighten the n u t to 251 N-m (185 ft. lbs.)
INSTALLATION
torque.
Replace all damaged or worn steering linkage com­
(4) Install center link to ball studs (Fig. 2). Install
ponents.
(1) Position idler arm on the frame side rail. In­ and tighten retaining nuts to 88 N-m (65 ft. lbs.)
stall bolts/nuts and tighten to 88 N-m (65 ft. lbs.) torque. Install new cotter pins.
torque.
19 - 18 STEERING •
CAUTION: It i s possible to install the center link r e ­ STEERING NUT
versed position. T h i s w i l l result i n i n c o r r e c t geome­
try and interferences during vehicle jounce. Viewed
from t h e front of the vehicle, the c e n t e r l i n k ends
s h o u l d turn u p w a r d . Viewed from the s i d e of the v e ­
hicle, the ends s h o u l d t u r n toward the front of t h e
vehicle. The t i e - r o d ball s t u d s enter the center link
bores from the rear.

(5) Install tie-rod ends into center link (Fig. 2).

Tighten the nuts to 54 N»m (40 ft. lbs.) torque. In­
stall new cotter pins.
(6) Insert tie-rod ends into steering knuckle arm
(Fig. 2). Tighten the nuts to 54 N-m (40 ft. lbs.)
torque. Install new cotter pins. LINK FITTING J9119-12
(7) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to Fig. 5 Drag Link
the Alignment Specifications chart within Group 2,

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Front Suspension).
Position the clamp on the sleeve s o retaining
bolt is located o n the bottom side of the sleeve.
(8) After adjustment, tighten the tie-rod adjust­
ment sleeve clamp bolt;
• Standard Duty— 25.4 N-m (225 in. lbs.) torque
• Heavy D u t y - 34 N-m (25 ft. lbs.) torque

STEERING LINKAGE—4WD VEHICLES

U s e Puller C-4150 to remove a drag link or pit­
m a n arm. Failure to use this tool could c a u s e
d a m a g e to the seals (Fig. 4).

Fig. 6 Steering Arm Removal— Model 44 Axle

(3) Mark the pitman arm and shaft positions for
reference. Remove the nut and washer from the pit­
m a n arm. Remove the pitman arm with Puller
C-4150 (Fig. 7).
(4) Remove the cotter pin and n u t from the tie-rod.
(5) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2).
TOOL C-4150 U s e care to avoid damaging the seals.
R H 4 0 4

Fig. 4 Drag-Link Removal INSTALLATION

REMOVAL
(1) Remove drag link tie-rod end ball studs from
steering arm and pitman arm (Fig. 4 and 5).
U s e care to avoid damaging the seals.
(2) Remove the steering arm nuts and washers
(Fig. 6). Tap the steering arm to loosen it from the
knuckle. Pry the steering arm upward and remove.
Replace all damaged or worn steering linkage com­
ponents.
(1) Center steering gear to alignment marks and
install pitman arm.
(2) Install the washer and retaining nut on the pit­
m a n shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque.
(3) Position the steering arm on the knuckle. In­
stall the washers and attaching nuts. Tighten the
nuts to 122 N-m (90 ft. lbs.).
• STEERING
Fig. 7 Pitman Arm Removal
(4) Connect the drag-link ball studs to the steering
knuckle arm and pitman arm (Fig. 8). Install the re­
taining nuts and tighten to 81 N»m (60 ft. lbs.)
torque. Install new cotter pins.
19 - 19
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POINT J9102-62
Fig. 8 Correct Drag Link installation
(5) Insert tie-rod ends into steering knuckle arm
(Fig. 2). Tighten the nuts to 61 N-m (45 ft. lbs.)
torque. Install new cotter pins.
(6) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to
the Alignment Specifications chart within Group 2,
Front Suspension).
Position the clamp o n the sleeve so retaining
bolt is located on the bottom side of the sleeve.
(7) After adjustment, tighten the tie-rod adjust­
ment sleeve clamp bolt to 34-41 N-m (25-30 ft. lbs.)
torque.
19-20 STEERING •
RECIRCULATING BALL POWER S T E E R I N G GEAR

INDEX

page page
Adjuster Plug Assembly Replacement 26 Pitman Shaft Seals and Bearing Replacement . . . 31
Check Valve Replacement 32 Rack Piston and Worm Shaft Replacement . . . . . 29
Gear Disassembly Information 23 Service Information 20
Housing End Plug 25 Steering Gear Adjustments 22
Pitman Shaft and Side Cover Replacement 25 Steering Gear Replacement 32
Pitman Shaft Seals — in Car Replacement . . . . . 20 Valve Replacement 27

SERVICE INFORMATION • Stop the engine.

A recirculating-ball steering gear is used with the (5) Remove backup washer and single lip seal with
power (assisted) steering system. The power steering screwdriver.
gear can be adjusted and internally serviced. (6) Inspect t h e housing for burrs and remove if
necessary. Inspect the pitman shaft seal surface for

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PITMAN SHAFT SEALS - IN CAR REPLACEMENT roughness and pitting. If pitted replace shaft.

REMOVAL INSTALLATION
(1) Remove pitman a r m from gear. Refer to Pit­ (1) Install single lip seal with Installer or a suit­
man Arm Removal in Steering Linkage. able size deep socket (Fig. 2).
(2) Clean exposed end of pitman shaft and housing. SPECIAL TOOL
Use a wire brush to clean the shaft splines. C4171
(3) Remove retaining ring with snap ring pliers TOP OF TOOL
(Fig. 1). FLUSH WITH
HOUSING
RETAINING RING
SPECIAL TOOL
BACKUP WASHER G4328

DOUBLE-UP SEAL

BACKUP WASHER

SINGLE-LIP SEAL

NEEDLE BEARING

J8919-39
Fig. 1 Pitman Shaft Seals
C A U T I O N : U s e care not to score the housing bore
when prying out seals and washers.
(4) Remove backup washer and double lip seal
with screwdriver.
• Start t h e engine and t u r n the steering wheel fully
to the LEFT to force out t h e seals and washers.
J9119-42
Fig. 2 Pitman Shaft Seal Installation
(2) Coat the double lip seal and washer with
grease.
(3) Install the backup washer.
(4) Install the double lip seal.
(5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
(7) Center the steering gear.
(8) Install t h e pitman arm. Refer to Pitman Arm
Installation in Steering Linkage.
(9) Add power steering fluid. Refer to Power Steer­
ing Initial Operation.
cardiagn.com
19 - 22 STEERING — — — — •
STEERING GEAR ADJUSTMENTS
SERVICE INFORMATION
Adjusting the steering gear in the vehicle is NOT
recommended. Remove the gear from the vehicle
(Fig. 3) and mount in a vise. Drain the power steer­
ing fluid and make the following adjustments in this
order:
• FIRST - worm thrust bearing preload
• SECOND - over-center preload adjustment

WORM THRUST BEARING PRELOAD

ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 4).

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J8919-58

Fig. 5 Alignment Marking On Housing

Fig. 4 Loosening the Adjuster Plug Locknut

(2) Turn the adjuster in with Spanner Wrench
C-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed in housing.
(3) Place an index m a r k on the housing even with
one of the holes in adjuster plug (Fig. 5).
Fig. 6 Remarking The Housing
(4) Measure back (counterclockwise) 13 mm (0.50
in) and mark housing (Fig. 6). (3) Turn the pitman shaft adjuster screw back
(5) Rotate adjustment cap back (counterclockwise) (COUNTERCLOCKWISE) until extended, then t u r n
with spanner wrench until hole is aligned with the back in (CLOCKWISE) one full turn.
second mark (Fig. 7). (4) Place the torque wrench in the vertical position
(6) Install and tighten locknut to 109 N-m (80 ft. on the stub shaft. Rotate the wrench 45 degrees each
lbs.) torque. Be sure adjustment cap does not t u r n side of the center and record the highest rotational
while tightening the locknut. torque on center (Fig. 9).
(5) Turn the adjuster in until torque to t u r n stub
OVER-CENTER ADJUSTMENT
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more t h a n
(1) Rotate the stub shaft from stop to stop and
reading in Step 4.
count the number of turns.
(6) Prevent the adjuster screw from turning while
(2) Starting at either stop t u r n the stub shaft back
tightening adjuster lock nut. Tighten the adjuster
1/2 the total number of turns. This is the center of
the gear travel (Fig. 8). lock n u t to 49 N-m (36 ft. lbs.).
• STEERING 19 - 23

FIRST
MARK

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J9219-30

Fig. 7 Aligning To The Second Mark Fig. 8 Steering Gear Centered

GEAR DISASSEMBLY INFORMATION

C A U T I O N : Cleanliness is extremely important when
repairing a power steering gear. Keep the bench,
tools and components clean at all times. Thor­
oughly clean the exterior of the gear with cleaning
solvent before disassembly. Drain a s much of the
fluid a s possible. Use protective vise jaws at all
times when clamping components. During a s s e m ­
bly, lubricate all components with power steering
fluid except when instructed otherwise (Fig. 10).

Fig. 9 Checking Over-center Rotation Torque

 TO
4^

m
rn

z
o

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1 - HOUSING, STEERING GEAR 25 - BEARING ASSY., NEEDLE (PITMAN SHAFT)
2 - RACE, THRUST BEARING (WORM) 26 - SEAL, PITMAN SHAFT (SINGLE LIP)
3 - BEARING ASSY., ROLLER THRUST (WORM) 27 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
4 - RACE, THRUST BEARING (WORM) 28 - SEAL, PITAAAN SHAFT (DOUBLE LIP)
5 - WORM, STEERING 29 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
6 - SEAL "O" RING (STUB SHAFT) 30 - RING, RETAINING (PITMAN SHAFT SEAL)
7 - SHAFT, STUB 31 - WASHER, PITMAN SHAFT LOCK
8 - SPOOL, VALVE 32 - NUT, PITMAN SHAFT
9 - SEAL, "O" RING (SPOOL) 33 - NUT, RACK PISTON
10 - BODY, VALVE 34 - BALL
11 - RING, VALVE BODY (3) 35 - GUIDE, BALL RETURN (2)
12 - SEAL, "O" RING (VALVE BODY) (3) 36 - CLAMP, BALL RETURN GUIDE
13 - RETAINER, BEARING (ADJUSTER) 37 - SCREW ASSY., LOCKWASHER & (2)
14 - SPACER, THRUST BEARING 38 - PLUG, RACK PISTON
15 - RACE, UPPER THRUST BEARING (SMALL) 39 - SEAL, "O" RING (RACK PISTON)
16 - BEARING, UPPER THRUST 40 - RING, RACK PISTON
17 - RACE, UPPER THRUST BEARING (LARGE) 41 - SEAL, "O" RING (HOUSING END PLUG)
18 - SEAL, "O" RING (ADJUSTER) 42 - PLUG, HOUSING END
19 - PLUG, ADJUSTER 43 - RING, RETAINING (HOUSING END PLUG)
20 - BEARING, NEEDLE 44 - GEAR ASSY., PITMAN SHAFT
21 - SEAL, STUB SHAFT 45 - SEAL ASSY., GASKET
22 - SEAL, STUB SHAFT DUST 46 - COVER ASSY., HOUSING SIDE
23 - RING, RETAINING 47 - BOLT, HEX. HEAD (SIDE COVER) (4)
24 - NUT, ADJUSTER PLUG LOCK 48 - NUT, LASH ADJUSTER
J9219-64

Fig. 10 Power Steering Gear

• STEERING
PITMAN SHAFT AND SIDE COVER REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman a r m from steering gear. Refer
to Pitman Arm Removal in the Steering Linkage sec­
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
• Clean exposed end of pitman shaft and housing.
• Clean pitman shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear.
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as
an assembly.
(4) Remove pitman shaft from the side cover (Fig.
11).
Fig. 11 Side Cover and Pitman Shaft
ASSEMBLE
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(2) Install preload adjuster nut. D o not tighten
nut until after pitman shaft adjustment h a s b e e n
made.
19 - 25
(3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 N»m
(44 ft. lbs.).
(6) Adjust pitman shaft, refer to Over-Center Ad­
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this group.
HOUSING END PLUG
REMOVE
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(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman a r m from steering gear. Refer
to Steering Linkage in this group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
• Rotate stub shaft back and forth to drain fluid.
(1) Rotate retaining ring until one end is under
the hole in the housing. Unseat and force ring from
groove (Fig. 12).
Fig. 12 End Plug Retaining Ring
(2) Rotate stub shaft slowly COUNTER-CLOCK­
WISE to remove end plug out from housing (Fig. 13).
19 - 2 6 STEERING
C A U T I O N : D o not turn stub shaft a n y further than
necessary. T h e recirculating balls will drop out of
the rack piston circuit a n d fall inside the rack pis­
ton chamber.
•
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this group.
ADJUSTER PLUG ASSEMBLY REPLACEMENT

(3) Remove O-ring seal (Fig. 13). REMOWE

(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.

DISASSEMBLE
(1) Remove adjuster plug lock n u t from housing.
(2) Remove adjuster plug from housing with Span­
ner Wrench C-4381 (Fig. 15).
SPECIAL TOOL
C-4381 OR J-7624

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HOUSING END PLUG
O-RING SEAL

HOUSING END PLUG

RETAINING RING J9319-30

Fig. 13 End Plug Components

ASSEMBLE
• Lubricate O-ring seal with power steering fluid.
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 m m (1 Fig. 15 Remove/Install Adjustment Plug
inch) from access hole (Fig. 14). (3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 16).

BEARING RETAINER

Fig. 14 Installing The Retaining Ring

Fig. 16 Remove Retainer
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
 (4) Remove bearing spacer, races and thrust bear­ (1) Install needle bearing into adjuster plug with
ing (Fig. 17). an appropriate tool.
(2) Install lip seal and dust seal into adjuster plug
LARGE
RETAINING THRUST with an appropriate tool.
SNAP RING WASHER (3) Install retainer snap ring.
f
STUB SHAFT
DUST SEAL (4) Install O-ring seal to adjuster plug.
SMALL
THRUST WASHER (5) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(6) Install thrust washer bearing retainer to ad­
juster plug (Fig. 19).

PUNCH

NEEDLE
BEARING

NEEDLE
SEAL
BEARING

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RETAINING
SPACER RING
ADJUSTMENT RETAINER
CAP J8919-42 ADJUSTER PLUG

Fig. 17 Adjustment Plug (Cap) Components

(5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
J9219-10
with an appropriate tool (Fig. 18).
Fig. 19 Install Retainer
C A U T I O N : When installing adjuster plug, care
should be taken NOT to cut the seals.

(7) Install adjuster plug into housing with Spanner

Wrench C-4381.
(8) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(9) Install adjuster plug lock nut, and using a
NEEDLE punch (drift) in a notch, tighten securely (Fig. 20).
BEARING
REMOVAL Hold adjuster plug to maintain alignment of the
TOOL marks.
(10) Adjust pitman shaft. Refer to Over-Center Ad­
justment.

INSTALL
(1.) Install steering gear. Refer to Power Steering
Gear Replacement in this section.

VALVE REPLACEMENT
J8919-43
REMOVE
Fig. 18 Needle Bearing Removal (1) Remove steering gear from vehicle. Refer to
ASSEMBLE Power Steering Gear Replacement in this section.

C A U T I O N : Needle bearing must be installed with DISASSEMBLE

identification on bearing facing tool to prevent dam­ (1) Remove adjuster plug, refer to Adjuster Plug
age to bearing. Assembly Replacement.
19 - 28 STEERING
Fig. 20 Tighten Lock Nut
(2) Remove stub shaft and valve assembly (Fig.
GEAR, MAKE SURE ANGLE O F
THRUST RACES ARE AS SHOWN. J9319-32
Fig. 21 Bearing, Worm and Valve Assembly
(3) Remove stub shaft from valve assembly, if nec­
essary.
• Tap stub shaft lightly on a block of wood to loosen
shaft cap.
• Pull cap and valve body and disengage stub shaft
pin from hole in valve body (Fig. 22).
(4) Remove valve assembly if necessary.
• Remove valve spool by pulling and rotating from
valve body (Fig. 23).
• Remove valve spool O-ring seal.
• Remove valve body teflon rings and O-ring seals
(Fig. 24).
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J9319-36
Fig. 22 Remove and Install Stub Shaft
Fig. 23 Remove and Install Spool
ASSEMBLE
(1) Install valve spool O-ring seal to valve spool.
(2) Lubricate valve spool and O-ring seal with
power steering fluid.
(3) Install valve spool to valve body by pushing
and rotating. Hole in valve spool for stub pin must
be accessible from opposite end of valve body.
(4) Assemble stub shaft to valve spool, if necessary
and insert pin (Fig. 25).
• Notch in stub shaft cap MUST fully engage valve
body pin and seat against valve body shoulder.
(5) Install O-ring seals and teflon rings to valve
body.
(6) Lubricate O-ring seals and teflon rings with
power steering fluid.
• STEERING
J8919-48
Fig. 24 Remove and install Valve Seals
NOTCH IN CAP
VALVE BODY PIN
liHiiiiiim
J9319-38
Fig. 25 Stub Shaft Installation
(7) Install stub shaft and valve assembly to worm
shaft. Line up worm shaft to slot in the valve assem­
bly.
(8) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment. Refer to Steering Gear Ad­
justments in this section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
19 - 29
RACK PISTON AND WORM SHAFT REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove pitman shaft and side cover. Refer to
Side Cover and P i t m a n Shaft Replacement in this
section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 26).
EXTENSION E N D PLUG
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RACK J9219-9
PISTON
Fig. 26 Remove and Install Rack Piston End Plug
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 27). Hold tool tightly against worm shaft while
turning the stub shaft COUNTERCLOCKWISE.
The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(6) Remove the rack piston, rack balls, and tool to­
gether from housing.
(7) Remove valve. Refer to Valve Replacement in
this section.
(8) Remove worm shaft.
(9) Remove thrust bearing and races.
(10) Remove tool from rack piston.
(11) Remove rack piston balls.
(12) Remove screws, clamp and ball guide.
(13) Remove teflon ring and O-ring seal (Fig. 28).
CLEAN AND INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
11-30 STEERING w

INSTALL BALLS IN THIS HOLE

WHILE SLOWLY ROTATING
W O R M COUNTERCLOCKWISE

J9319-39

Fig. 27 Remove and install Rack Piston Fig. 29 Installing Balls in Rack Piston
rack piston balls are smaller than the silver

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balls. THE BLACK AND SILVEE BALLS MUST
B E I N S T A L L E D A L T 1 E N A T E L Y INTO T H E
RACK PISTON AND BALL GUIDE. This proce­
d u r e will maintain w o r m shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning worm shaft COUN­
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 30).
(5) Install guide onto rack piston and return with
GUIDE

J92T9-12

Fig. 28 Remove and Install Seal on Rack Piston

(2) Check for scores, nicks or burrs on the rack pis­
ton finished surface. Slight wear is normal on the
worm gear surfaces.

ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align
worm shaft spiral groove with rack piston ball guide
BALLS J9319-40
hole (Fig. 29).
Fig. 30 Balls in the Return Guide
WARNING: MAKE S U R E A L L RACK PISTON BALLS
#
A R E REINSTALLED IN THE RACK PISTON. IM­ clamp and screws. Tighten screws to 58 N m (43 in.
P R O P E R INSTALLATION MAY R E S U L T IN P E R ­ lbs.) torque.
S O N A L INJURY. (6) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly against worm shaft while turning
T h e r e a r e 24 b a l l s in t h e r a c k p i s t o n circuit, 12 the stub shaft COUNTERCLOCKWISE.
a r e M a c k a n d 12 a r e silver ( C h r o m e ) . T h e b l a c k
• STEERING 19 - 31

The rack piston will be forced onto the tool and PITMAN SHAFT SEALS AND BEARING
hold the rack piston balls in place. REPLACEMENT
(7) Install the races and t h r u s t bearing to worm
shaft (Fig. 31). REMOVE
(1) Remove steering gear from vehicle. Refer to
WORM SHAFT THRUST RACES Power Steering Gear Replacement in this section.

DISASSEMBLE
(1) Remove p i t m a n arm from gear. Refer to Pit­
m a n Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and housing.
Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 32).

RETAINING RING
BACKUP WASHER

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DOUBLE-UP SEAL

BACKUP WASHER

SINGLE-LIP SEAL

MAKE SURE ANGLE OF THRUST NEEDLE BEARING

RACES ARE AS SHOWN
J9319-41

Fig. 31 Worm Shaft and Bearing

(8) Install worm shaft to housing.
(9) Install valve. Refer to Valve Replacement in
this section.
(10) Install rack piston to worm shaft from tool,
compress seals.
Hold Arbor tightly against worm shaft and turn
J8919-39
stub shaft CLOCKWISE until rack piston is seated
on worm shaft.
Fig. 32 Pitman Shaft Seals
WARNING: M A K E S U R E A L L R A C K PISTON B A L L S C A U T I O N : U s e care not to score the housing bore
A R E R E I N S T A L L E D IN T H E R A C K P I S T O N . I M ­ when prying out seals and washers.
P R O P E R I N S T A L L A T I O N M A Y R E S U L T IN P E R ­
S O N A L INJURY. (4) Remove backup washer and double lip seal
with screwdriver.
(11) Install rack piston plug and tighten to 150 (5) Remove backup washer and single lip seal with
N»m (111 ft. lbs.) torque. screwdriver.
(12) Install housing end plug. Refer to Housing (6) Inspect the housing for burrs and remove if
End Plug Replacement in this section. necessary.
(13) Install pitman shaft and side cover. Refer to (7) Remove needle bearing from side cover area of
Side Cover and Pitman Shaft Replacement in this housing (Fig. 33).
section.
ASSEMBLE
(14) Adjust steering gear. Refer to Steering Gear
(1) Install needle bearing into housing (Fig. 34).
Adjustments in this section.
(2) Install single lip seal with Installer or a suit­
able size socket (Fig. 35).
INSTALL
(3) Coat t h e double lip seal and washer with
(1) Install steering gear. Refer to Power Steering
grease.
Gear Replacement in this section.
(4) Install the backup washer.
(5) Install the double lip seal.
(6) Install the backup washer.
19 - 32 STEERING

REMOVER SIDE COVER SPECIAL TOOL

AREA C-4171
TOP OF TOOL
FLUSH WITH
HOUSING

SPECIAL TOOL
C4328

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J9319-42 J9119-42

Fig. 33 Needle Bearing Removal Fig. 35 Pitman Shaft Seal Installation

SPECIAL TOOL CHECK VALVE REPLACEMENT
C-4171
REMOVE
DO NOT (1) Remove steering gear from vehicle. Refer to
BOTTOM BEARING
IN HOUSING Power Steering Gear Replacement in this section.
WHEN TOOL
BOTTOMS ON DISASSEMBLE
HOUSING, BEARING IS
FULLY INSTALLED C A U T I O N : Use care not to damage the threads of
the housing when prying out check valve.

(1) Remove valve by prying from housing with a

SPECIAL TOOL small screwdriver.
C-4178
ASSEMBLE
(1) Install the valve into the housing with a 3/8-
inch diameter piece of tubing 100 m m (4 inches)
long.

INSTALL
(1) Install steering gear. Refer to Power Steering
\ J9119-4 Gear Replacement in this section.

Fig. 34 Pitman Shaft Bearing Installation STEERING GEAR REPLACEMENT

(7) Install the retainer ring with snap ring pliers.
(8) Install the pitman shaft and side cover. Refer
to Side Cover and Pitman Shaft Replacement in this
section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
REMOVAL
(1) Place the front wheels in a straight-ahead posi­
tion.
(2) Disconnect and cap the fluid hoses from steer­
ing gear.
(3) Remove the coupler roll pin and disconnect a t
the steering gear (Fig. 36).
(4) Mark the pitman shaft and pitman a r m for in­
stallation reference. Remove t h e pitman a r m from
the shaft with Puller C-4150 (Fig. 37).
(6) Remove the steering gear retaining bolts and
• STEERING
Fig. 36 Column Shaft Removal
Fig. 37 Pitman Arm Removal
nuts. Remove the steering gear from the vehicle (Fig.
38, 39).
9 2WD vehicles; remove the steering gear retaining
bolts from the frame rail and remove the gear (Fig.
40).
• 4WD vehicles; remove the steering gear and rein­
forcement bracket from the frame rail. Remove the
gear from the reinforcement bracket (Fig. 39).
INSTALLATION
(1) Align the column coupler shaft to steering
gear. Install the roll pin in shaft coupling (Fig. 38).
(2) Position the steering gear on the frame rail and
install the bolts (Fig. 38, 39). Tighten the bolts to
101 N-m (75 ft. lbs.) torque.
• 2WD vehicles; position the steering gear at the
frame rail. Install and tighten the attaching bolts
11-33
SCREW REINFORCEMENT
Fig. 38 Steering Gear Removal/Installation (2WD)
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Fig. 39 Steering Gear Removal/Installation (4 WD)
finger-tight (Fig. 38). Center the steering gear and
align the steering column shaft and the stub shaft.
• 4WD vehicles; install the steering gear to the
frame reinforcement bracket (Fig. 39). Tighten the
screws to 176 N»m (130 ft. lbs.) torque. Install t h e as­
sembly as above, finger tight.
A special knurled shoulder bolt is used for the
lower bracket to frame bolt. The bolt is available for
service to eliminate bracket shift t h a t produces an off
center condition. The tight fit between the frame and
bracket will eliminate any movement between the
two parts.
(3) Re-position gear at frame to eliminate any
binding, tighten attaching bolts/nuts;
• 2WD vehicles; tighten gear to frame bolts to 136
N-m (100 ft. lbs.) torque.
19 - 34 STEERING •
• 4WD vehicles; tighten gear frame reinforcement
bracket to frame bolts/nuts to 223 N-m (165 ft. lbs.)
torque.
(4) Align and install the pitman arm.
(5) Install the washer and retaining nut on the pit­
man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)

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torque.
(6) Connect fluid hoses to steering gear, tighten to
28 N-m (21 ft. lbs.). Add fluid, refer to Power Steer­
ing Pump Initial Operation.
POWER STEERING GEAR SPECIFICATIONS

Steering Gear Type . . . . . . . . . . . . . Recirculating ball with Steering Gear Adjustments:

hydraulic assist.
Ratio Code (Top of Gear)
BH,NZ 14:1
BF, XS 13-16:1
Steering Gear Hydraulic Fluid Use Mopar Power
Steering Fluid, or equivalent.
Steering Gear Lubricants Lubricate pitman shaft
seals, bearings races, and rack
piston recirculating balls with
petroleum jelly. Lubricate all other
parts with power steering fluid.
Wormshaft Bearing Preload Torque 0.45-1.13 N m
(4 to 10 in-lbs)
Pitman Shaft Overcenter Drag Torque:
New Gear
(less than 400 miles/640 km) . . . . . . . . . 0.45-0.90 N m
(4 to 8 in-lbs) in addition to wormshaft
bearing preload but not to exceed
combined total of 2 N m (18 in-lbs).
Used Gear
(over 400 miles/640 km) 0.5-0.6 Nm (4 to 5 in-lbs)
in addition to wormshaft bearing
preload but not to exeed
combined total of 2 N-m (18 in-lbs).
C a u t i o n : Gears must be adjusted exactly as outlined in
Steering Gear Adjustments-On Bench. Failure to
adhere to the recommended procedures may result
in gear damage or improper steering response.

J9219-36
• STEERING 19 - 3 i

S T E E R I N G COLUMN
SERVICE INFORMATION
The Acustar columns ( F i g . l ) have been designed to
be serviced as an assembly; less wiring, switches,
shrouds, steering wheel, etc. Also most steering col­
umn components can be serviced without removing
the column from the vehicle. For additional informa­
tion refer to Group 8H, Electrical.
C A U T I O N : Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
C A U T I O N : Disconnect negative (ground) cable from
the battery before servicing any component on the
column.
STEERING WHEEL
REMOWAL
(1) Make sure the front wheels are in the straight
a h e a d position.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the horn pad components (Fig. 2).
(4) Remove the steering wheel retaining nut. Score
or paint alignment marks on the column shaft and
steering wheel (if none exist) for installation refer­
ence.
HORN PAD

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C A U T I O N : D o not attempt to remove the pins to dis­
semble the tilting mechanism. Damage will occur.

Safety g o g g l e s should be w o r n at all times

w h e n involved w i t h steering column service.

Fig. 2 Horn Pad Removal/installation

STEERING TILT UPPER PANEL TOE COUPLER ROLL

Fig. 1 Acustar Steering Column

19-36 STEERING •
(5) Remove the steering wheel with Puller (6) Pull clockspring assembly from column by lift­
C-3428-B (Fig. 3). D o not h a m m e r or j o l t t h e ing locking fingers as necessary. The clockspring
steering c o l u m n o r shaft during r e m o v a l of t h e cannot be repaired, and must be replaced if faulty.
wheel.
INSTALLATION
S
P E
CAIL
TOOL (1) Snap clockspring assembly onto column. If
C3
-4
28B- clockspring is not properly positioned, follow the cen­
tering procedures before installing steering wheel.
(2) Connect the wire connector to the clockspring.

WARNING: ENSURE CLOCKSPRING WIRE CON­

NECTION IS C O M P L E T E L Y S E A T E D . T H E LATCH­
ING C L I P A R M S M U S T B E P R O P E R L Y E N G A G E D
ON THE MODULE.

(3) Install upper and lower steering column

shrouds. Be sure wiring is inside of shrouds and not
pinched.

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(4) Install the steering wheel and air bag module,
refer to Steering Wheel Installation.

CENTERING PROCEDURE
If the rotating tape within the clockspring is not
positioned properly, the clockspring may fail during
S
TEE
RN
IG use. The following procedures MUST BE USED to
W H
EEL J
921
9-
56 center the clockspring.
Fig. 3 Steering Wheel Removal (1) Place the front wheels in the straight ahead po­
sition before starting the procedure.
INSTALLATION (2) Depress the 2 locking tabs to disengage the
(1) Install the steering wheel with the scored locking mechanism (Fig. 4).
marks or master splines aligned.
(2) Pull the speed control wires through the lower,
larger hole in the steering wheel. Pull the horn wire
through the smaller hole at the top. Ensure the
wires a r e N O T pinched.
(3) Install the retaining n u t and tighten to 61 N«m
(45 ft. lbs.) torque. Force the s t e e r i n g w h e e l d o w n
on the shaft w i t h the r e t a i n i n g nut only. D o not
hammer or s h o c k the c o l u m n w i t h s u d d e n im­
pact to install the wheel.
(4) Connect the wire feed to the horn buttons.
(5) Connect the wire feeds to the speed control
switch (Fig. 2).
(6) Connect the battery ground (negative) cable.

CLOCKSPRING
REMOVAL
(1) Place the front wheels in the straight ahead po­
sition before starting the repair.
(2) Disconnect battery negative cable and isolate.
(3) Remove the steering wheel, refer to Steering
Wheel Removal. Fig. 4 Clockspring (Auto-Locking)
(4) Remove upper and lower steering column (3) Keeping the mechanism disengaged, rotate the
shrouds to gain access to the clockspring wiring. clockspring rotor in the CLOCKWISE DIRECTION
(5) Release wire connector at clockspring. to the end of the travel. Do not apply excessive
torque.
• STEERING 19 • 37

(4) From the end of travel, rotate the rotor 2 1/2 D

ASH S
CR
EW S
P R N
IG
full t u r n s in the COUNTER CLOCKWISE direction. P
"A
NEL PN
I
The horn wire should end up at the top and t h e squib S
TEE
RN
IG
GE
AR
wire at the bottom (Fig. 4).
(5) Install the steering wheel, refer to Steering
Wheel Installation.

COLUMN— REMOVAL/INSTALLATION
C A U T I O N : Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
S
TEER
NIG
COL
UM N
REMOVAL R
WA
SH
ER N U T J
?N" J9119-15
(1) Make sure the front wheels are in the s t r a i g h t
a h e a d position.
Fig. 6 Coupler Screw Removal
(2) Disconnect the negative (ground) cable from

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the battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) For vehicles equipped with a column shift, dis­
connect the link rod by prying it out of the grommet
in the shift lever (Fig. 5).

STEERING
COLUMN
COVERS

J908K-33
PRYING TOOL
Fig. 7 Steering Column Cover

RN829 S
TEER
NIG
COL
UM N
Fig. 5 Link Rod Removal ASSY.

(5) Paint installation alignment marks on the col­

u m n shaft-to-coupler. This will aid in column shaft to
wheel alignment. Remove the steering column shaft-
to-coupler screws (Fig. 6).
(6) Remove the dash panel column and fuse block
cover (Fig. 7).
(7) For column shift vehicles, make sure shift lever
is in Park position and remove PRNDL driver cable.
(8) Remove tilt lever (if equipped) from column. T
URNS G
IN AL
MUL
TI SWT
IC
H AND
(9) Remove the upper and lower lock housing ^
FUNCTO
IN L
EVE
R
shroud (Fig. 1). Remove the lower fixed shroud. SWT
IC
H
(10) Remove the t u r n signal multi-function switch J918J-1 CO
NNEC
TOR
with a 7mm socket (Fig. 8).
(11) Loosen the upper Support Bracket nuts to al­ Fig. 8 Multi-function Switch Wiring
low some slack. This will aid in removal of the upper (13) Remove the wiring harness from the column
fixed shroud. by prying out the plastic retainer buttons (Fig. 8).
(12) Remove the electrical connections from Key-in (14) Remove the lower dash panel and support
light, Main Ignition Switch, Horn connection or bracket standoff fasteners (Fig. 1).
Clock Spring (Speed Control) (Fig. 9). (15) Remove the column out through the passenger
19 - 38 STEERING
KEY-IN SWITCH & MULTI F U N C T I O N
SWITCH CONTROL
Fig. 9 Steering Column Wiring
compartment. Use care to avoid damaging the paint
or trim.
INSTALLATION
C A U T I O N : Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
(1) Column shift vehicles, install a new grommet
(Fig. 10). Use MOPAR® Multipurpose Lubricant, or
equivalent, to aid installation of the grommet. A
n e w grommet should be u s e d w h e n ever the rod
is disconnected from the lever.
D I R E C T I O N O F INSTALLATION
RN830
Fig. 10 Grommet Installation
(2) Install the ground clip on the left spacer slot
(Fig. 11).
(3) Remove the shipping lock pin (Fig. 1), if neces­
sary.
(4) Install column through floor pan.
(5) Position the column bracket shear pins on the
attaching studs. Install, but loose assemble the two
upper bracket washers and nuts.
(6) With t h e front wheels in the straight-ahead po­
sition. Align the steering column shaft-to-coupler
screws (Fig. 6). Tighten the screws to 22.5 N*m (200
in. lbs.) torque.
RN832
J918J-2
Fig. 11 Ground Clip & Spacer Installation
(7) Clip the wiring harness on the steering column.
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Connect the multi-function switch wiring and tighten
with 7mm socket (Fig. 8).
(8) Install the upper fixed shroud.
(9) Be sure both breakaway capsules are fully
seated in the slots in the column support bracket.
Tighten the two upper bracket nuts to 12 N-m (105
in. lbs.) torque.
(10) Tighten the toe plate to floor pan attaching
nuts to 22.5 N-m (200 in. lbs.) torque.
(11) Install the wiring connections to the column
(Fig. 10). Install the lower fixed shroud.
(12) Column shift vehicles, install the PRNDL
driver cable.
(13) Install the lock housing shrouds. Install the
tilt lever (if equipped).
(14) Install the lower dash panel column cover
(Fig. 7).
(15) Install steering wheel on column, refer to
Steering Wheel-Installation.
(16) Column shift vehicles, connect the shift link
rod to the transmission shift lever. Use MOPAR®
Multipurpose Lubricant, or an equivalent product, to
aid the installation.
(17) Check operation of the transmission shift link­
age and adjust as necessary. Refer to Group 21,
Transmission for the shift linkage adjustment.
(18) Connect the battery ground (negative) cable.
COLUMN COMPONENT SERVICE
The Acustar tilt and standard columns (Fig.l) have
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 column from the vehicle. For additional
information, refer to Group 8H, Electrical.
(1) The gear shift lever (if equipped) can be ser­
viced. Use a drift and a suitable size socket to drive
out the pin (Fig. 12).
(2) The P R N D L driver can be removed by drilling
out the rivets. Use care from bending when install-
• STEERING 19-39

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Fig. 14 Do Not Remove Retainer
19-40 STEERING
STEERING
Description
Steering Wheel to Shaft
Retaining Nut
Coupler Bolt
Upper Column Bracket
Support Nuts
Toe Plate Attaching
Bolts/Nuts
STEERING
DESCRIPTION
Adjustment Cap Locknut
Adjustment Screw Locknut....
Gear to Frame Bolts (2WD)
Gear to Frame Bracket (4WD)
Gear Frame Bracket to Frame (4WD)...
Gear to Frame Bolts (4WD)
High Pressure Fluid Line.
Intermediate Shaft Pinch
Bolt (Upper and Lower)
Pitman Shaft Nut
Return Pressure Fluid Line
Return Guide Clamp Bolt
Rack-Piston Plug
Side Cover Bolts
•
TORQUE S P E C I F I C A T I O N S
COLUMN STEERING LINKAGE
Torque DESCRIPTION TORQUE
Center Link to Ball Stud Nuts..., 88 N®m (65 ft. lbs.)
61 N»m (45 ft. lbs.) Drag Link Ball Stud Nuts (4WD-AII) 81 N®m (60 ft. lbs.)
47 N»m (35 ft. lbs.) Idler Arm to Frame Bolts... 88 N*m (65ft.lbs.)
Pitman Shaft Nut 251 NTn(185ft. lbs.)
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12N*m(105in. lbs.) Steering Arm to Knuckle
Nuts (4WD-Model 44) 122 N*m (90ft.lbs.)
Tie-Rod Clamp Nut (Standard
23 N«m (200 in. lbs.) Duty 2WD).... 25 N^m (225 in. lbs.)
J9319-61 Tie-Rod Clamp Nut (Heavy Duty 2WD). 34 N«m (25ft.lbs.)
Tie-Rod Clamp Nut (4WD) 34-41 N«m
GEAR (25-30 ft. lbs.)
tie-Rod End to Center Link Nut. 54 N«m (40ft.lbs.)
Tie-Rod End Nut to Steering
TORQUE Knuckle Arm (2WD).. 54 N*m (40ft.lbs.)
Tie-Rod End Nut to Steering
108 N»m (80 ft. lbs.) Knuckle Arm (4WD) 61 N«m(45ft. lbs.)
27 N®m (20 ft. lbs.) J9219-91
136 N®m (100 ft. lbs.)
176 N®m (130 ft. lbs.)
223 N*m (165 ft. lbs.) STEERING PUMP
203 N*m (150 ft. lbs.)
35 N*m (25 ft. lbs.)
DESCRIPTION TORQUE
47 N»m (35 ft. lbs.) Flow Control Valve 75 N®m (55ft.lbs.)
251 N»m (185 ft. lbs.) High Pressure Fluid Line 35 N«*m (25 ft. lbs.)
35 N*m (25 ft. lbs.) Oil Cooler to Block Screws 41 N*m (30ft.lbs.)
5 N*m (4 ft. lbs.) Pump Bracket to Engine
(3.9 and 5.2 L).. 41 N*m (30ft.lbs.)
102 N®m (75 ft. lbs.) 54 N®m (40ft.lbs.)
Pump to Bracket (3.9 and 5.2 L)....
61 N*m (45 ft. lbs.) Pump to Front Bracket Bolt (5.9 L). 41 N*m (30ft.lbs.)
J9219-90 Pump to Rear Bracket Nut (5.9 L) 54 N*m (40ft.lbs.)
Pump to Vacuum Pump Nuts
(Diesel Engine) 24 N®m (18ft.lbs.)
Pump Assembly to Engine
Block (Diesel Engine) 77 N*m (57ft.lbs.)
Pump to Support Bracket Nut
(Diesel Engine) 24 N T H (18ft.lbs.)
Remote Reservoir to Acc,
Drive Bracket (5.9 L) 23 N*m (200 in. lbs.)
Reservoir to Body Bolts 48 N«m (35ft.lbs.)
J9219-92