steering - ertyu.org · 2004. 9. 24. · steering column lower bearing spring retainer slipped on...

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STEERING

TABLE OF CONTENTS

page page

OWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . 1OWER STEERING PUMP . . . . . . . . . . . . . . . . . . 16

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CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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ard equipment and it is the only steering system

STEERING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . 21STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . 29

POWER STEERING

TABLE OF CONTENTS

page

ESCRIPTION AND OPERATIONPOWER STEERING SYSTEM . . . . . . . . . . . . . . . . 1POWER STEERING FLUID HOSES . . . . . . . . . . . . 2POWER STEERING FLUID COOLER . . . . . . . . . . . 2POWER STEERING FLUID PRESSURE

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3IAGNOSIS AND TESTINGSTEERING SYSTEM DIAGNOSIS CHARTS . . . . . . 4POWER STEERING SYSTEM FLOW AND

PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . 9ERVICE PROCEDURESPOWER STEERING SYSTEM FLUID LEVEL

EMOVAL AND INSTALLATIONSERVICE WARNINGS AND CAUTIONS . . . . . . . . 11POWER STEERING FLUID PRESSURE HOSE. . . 11POWER STEERING FLUID RETURN HOSE. . . . . 12POWER STEERING FLUID COOLER . . . . . . . . . . 13POWER STEERING FLUID PRESSURE

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14PECIFICATIONSPOWER STEERING FASTENER TORQUE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 15PECIAL TOOLSPOWER STEERING . . . . . . . . . . . . . . . . . . . . . . . 15

ESCRIPTION AND OPERATION

OWER STEERING SYSTEMTurning of the steering wheel is converted into lin-

ar travel through the meshing of the helical pinioneeth with the rack teeth within the steering gear.

Power assist steering is provided by an open-cen-er, rotary-type control valve. It is used to directower steering fluid from the power steering pump toither side of the integral steering rack piston. Roadeel is controlled by the diameter of a torsion barhich initially steers the vehicle. As steering effort

ncreases as in a turn, the torsion bar twists, causingelative rotary motion between the rotary valve bodynd valve spool. This movement directs fluid behindhe integral rack piston, which in turn builds upydraulic pressure and assists in the turning effort.This vehicle comes with power steering as stan-

available. The power steering system consists ofthese major components:

• POWER STEERING PUMP• POWER STEERING GEAR• POWER STEERING FLUID RESERVOIR

(mounted on the pump)• POWER STEERING FLUID PRESSURE HOSE• POWER STEERING FLUID RETURN HOSE• POWER STEERING FLUID COOLER (on some

models)For information on the first two components, refer

to their respective sections within this service man-ual group. Information on the third component canbe found in POWER STEERING PUMP. Informationon all other components can be found in this sectionof this service manual group.

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DESCRIPTION AND OPERATION (Continued)

OWER STEERING FLUID HOSESThe power steering fluid hoses connect the compo-

ents of the power steering system. They transferluid from one component to the next.

The power steering fluid pressure hose is a highressure hose that connects the power steering pumpo the gear. At both ends of the flexible hose portionre steel fittings that are pressure crimped to thelexible hose. A standard tube nut fitting with an-ring is used at each end to connect it to either theower steering pump or the gear.The power steering fluid return hose is a special

ubber hose that connects the power steering gear orhe power steering fluid cooler on some models, backo the fluid reservoir mounted on the power steeringump. The power steering gear has a steel fittingttached to its outlet port that the return hose isushed onto. On vehicles equipped with a powerteering fluid cooler, the return hose attaches to theooler outlet tube instead of the steering gear steelitting. The hose is secured to either component using

standard adjustable clamp. The other end of theower steering fluid return hose attaches to theower steering fluid reservoir on the power steeringump using a standard adjustable clamp.

OWER STEERING FLUID COOLERSome models of this vehicle are equipped with a

ooler for the power steering system fluid (Fig. 1).he purpose of the cooler is to keep the temperaturef the power steering system fluid from rising to aevel that would affect the performance of the powerteering system.The power steering fluid cooler is located at the

ront of the front suspension crossmember. It isounted to the crossmember top surface using 2 fas-

eners.

The cooler is placed in series with the power steer-ing fluid return hose, between the steering gear fluidoutlet port and the fluid return hose leading to thepower steering fluid reservoir. The power steeringgear has a steel fitting attached to its outlet portthat a short hose leading to the cooler is pushed onto.This hose is secured to both the steering gear outletfitting and the cooler using standard adjustableclamps. The cooler is secured to the power steeringfluid return hose using a standard adjustable clamp.

The cooler used on this vehicle is referred to as afluid-to-air type cooler. This means that the air flowacross the tubes of the cooler is used to extract theheat from the cooler which it has absorbed from thepower steering fluid flowing through it. Utilizing asmall air dam mounted to its base to redirect airacross its coils, the cooler lowers the temperature ofthe power steering fluid prior to it entering thepower steering fluid reservoir where it is resuppliedto the power steering pump.

Fig. 1 Power Steering Fluid Cooler1 – POWER STEERING FLUID COOLER2 – TRANSAXLE3 – CLAMP4 – AIR DAM5 – CROSSMEMBER

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OWER STEERING FLUID PRESSURE SWITCHA power steering pressure switch is used to

mprove the vehicle’s idle quality. The pressurewitch improves vehicle idle quality by causing aeadjustment of the engine idle speed as necessaryhen increased fluid pressure is sensed in the power

teering system.The pressure switch functions by signaling the

owertrain control module that an increase in pres-ure of the power steering system is putting addi-ional load on the engine. This type of conditionxists when the front tires of the vehicle are turnedhile the vehicle is stationary and the engine is at

dle speed. When the powertrain control moduleeceives the signal from the power steering pressurewitch, it directs the engine to increase its idle speed.his increase in engine idle speed compensates forhe additional load, thus maintaining the requiredngine idle speed and idle quality.

The power steering pressure switch is mounteddirectly to the power steering gear (Fig. 2).

Fig. 2 Switch Location1 – WIRING HARNESS CONNECTOR2 – POWER STEERING GEAR3 – POWER STEERING FLUID PRESSURE SWITCH4 – REAR OF FRONT SUSPENSION CROSSMEMBER

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IAGNOSIS AND TESTING

TEERING SYSTEM DIAGNOSIS CHARTS

OWER STEERING NOISE

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONABLE HISS ORWHISTLE*

1. Damaged or mispositionedsteering column shaft/coupling dashpanel seal.

1. Reposition or replace steeringcolumn shaft/coupling dash panelseal.

2. Noisy valve in power steeringgear.

2. Replace power steering gear.

RATTLE OR CLUNK 1. Power steering gear loose onfront suspension crossmember.

1. Inspect power steering gearmounting bolts. Replace asnecessary. Tighten to the specifiedtorque.

2. Front suspension crossmembermounting fasteners loose at frame.

2. Tighten the front suspensioncrossmember mounting fasteners tothe specified torque.

3. Loose tie rod (outer or inner). 3. Check tie rod pivot points forwear. Replace worn/loose parts asrequired.

4. Loose lower control arm mountingbolts at front suspensioncrossmember.

4. Tighten control arm mountingbolts to the specified torques.

5. Loose strut assembly mountingfasteners at strut tower.

5. Tighten strut assembly fastenersto the specified torques.

6. Power steering fluid pressurehose touching the body of thevehicle.

6. Adjust hose to proper position byloosening, repositioning, andtightening fitting to specified torque.Do not bend tubing.

7. Internal power steering gearnoise.


8. Damaged front suspensioncrossmember.

8. Replace front suspensioncrossmember.

CHIRP OR SQUEAL (POWERSTEERING PUMP)

1. Loose power steering pump drivebelt.

1. Check and replace automatic belttensioner as necessary. Replace beltif worn or glazed.

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DIAGNOSIS AND TESTING (Continued)


WHINE OR GROWL (POWERSTEERING PUMP)**

1. Low fluid level. 1. Fill power steering fluid reservoirto proper level and check for leaks.

2. Power steering hose touchingvehicle body or frame.

2. Adjust hose to proper position byloosening, repositioning, andtightening fitting to specified torque.Do not bend tubing. Replace hose ifdamaged.

3. Extreme wear of power steeringpump internal components.

3. Replace power steering pump andflush system as necessary.

SUCKING AIR SOUND 1. Loose clamp on power steeringfluid return hose.

1. Tighten or replace hose clamp.

2. Missing O-Ring on power steeringhose connection.

2. Inspect connection and replaceO-Ring as required.

3. Low power steering fluid level. 3. Fill power steering fluid reservoirto proper level and check for leaks.

4. Air leak between power steeringfluid reservoir and power steeringpump.

4. Replace power steering pump(with reservoir).

SQUEAK OR RUBBING SOUND 1. Steering column shroud rubbing. 1. Realign shrouds as necessary.

2. Steering column shaft rubbing. 2. Move or realign item rubbingshaft.

3. Steering column shaft dry-rubbingseal at dash panel.

3. Lubricate contact surface.

4. Steering gear internally noisy. 4. Replace steering gear.

SCRUBBING OR KNOCKINGNOISE.

1. Incorrect tire or wheel size. 1. Replace incorrect size tire orwheel with size used as originalequipment.

2. Interference between steeringgear and other vehicle components.

2. Check for bent or misalignedcomponents and correct asnecessary.

3. Steering gear internal stops wornexcessively.

3. Replace steering gear.

OTE: * There is some noise in all power steeringystems. One of the most common is a hissingound evident when turning the steering wheelhen at a standstill or when parking and the steer-

ng wheel is at the end of its travel. Hiss is a veryigh frequency noise similar to that experiencedhile slowly closing a water tap. The noise isresent in every valve and results when high veloc-

ty fluid passes valve orifice edges. There is noelationship between this noise and the perfor-ance of the steering system.

NOTE: ** Power steering pump growl results fromthe development of high pressure fluid flow. Nor-mally this noise level should not be high enough tobe objectionable.

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TEERING WHEEL FEEL


STEERING WHEEL/COLUMN CLICKING,CLUNKING OR RATTLING.

1. Steering column preload is not setproperly.

1. Loosen steering column coupling pinchbolt to reset steering column preload.Replace pinch bolt and torque tospecifications.

2. Loose steering coupling pinchbolt.

2. Replace pinch bolt and torque tospecifications.

3. Steering column bearings. 3. Replace steering column.

STEERING WHEEL HASFORE AND AFTLOOSENESS.

1. Steering wheel retaining nut notproperly tightened and torqued.

1. Tighten the steering wheel retaining nutto its specified torque.

2. Steering column preload is not setproperly.

2. Loosen steering column coupling pinchbolt to reset steering column preload.Replace pinch bolt and torque tospecifications.

3. Steering column lower bearingspring retainer slipped on steeringcolumn shaft.

3. Replace steering column.

STEERING WHEEL ORDASH VIBRATES DURINGLOW SPEED ORSTANDSTILL STEERINGMANEUVERS.

1. Air in the fluid of the powersteering system.

1. Bleed air from system following thepower steering pump initial operationservice procedure.*

2. Tires not properly inflated. 2. Inflate tires to the specified pressure.

3. Excessive engine vibration. 3. Ensure that the engine is runningproperly.

4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nutto the specified torque.

5. Overcharged air conditioningsystem.

5. Check air conditioning pump headpressure and correct as necessary.

STEERING CATCHES,STICKS IN CERTAINPOSITIONS OR ISDIFFICULT TO TURN.

1. Low power steering fluid level. 1. Fill power steering fluid reservoir tospecified level and check for leaks.

2. Tires not inflated to specifiedpressure.

2. Inflate tires to the specified pressure.

3. Lack of lubrication in frontsuspension control arm ball joints.

3. Lubricate ball joints if ball joints are not alubricated for life type ball joint. If ball jointis a lubricated for life ball joint, replace balljoint or control arm.

4. Lack of lubrication in steering gearouter tie rod ends.

4. Lubricate tie rod ends if they are not alubricated for life type. If tie rod end is alubricated for life type, replace tie rod end.


5. Check and replace automatic belttensioner as necessary. If drive belt is wornor glazed, replace belt.

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6. Faulty power steering pump flowcontrol (Follow Power SteeringSystem Flow and Pressure Testprocedure).

6. Replace power steering pump.

7. Excessive friction in steeringcolumn or intermediate shaft.

7. Isolate and correct condition.

8. Binding upper strut bearing. 8. Disassemble strut assembly. Correctbinding condition in strut bearing or replacebearing.

9. Excessive friction in powersteering gear.


STIFF, HARD TO TURN,SURGE, MOMENTARYINCREASE IN EFFORTWHEN TURNING.

1. Tires not properly inflated. 1. Inflate tires to specified pressure.

2. Low power steering fluid level. 2. Add power steering fluid as required topower steering fluid reservoir to obtainproper level. Check for leaks.


3. Check and replace automatic belttensioner as necessary. If drive belt is wornor glazed, replace belt.

4. Lack of lubrication in control armball joints.

4. Lubricate ball joints if ball joints are not alubricated for life type ball joint. If ball jointis a lubricated for life ball joint, replace balljoint or control arm.

5. Low power steering pumppressure (Follow Power SteeringSystem Flow and Pressure Testprocedure).

5. Replace the power steering pump asnecessary.

6. High internal leak in powersteering gear (Follow Power SteeringSystem Flow and Pressure Testprocedure).


STEERING WHEEL DOESNOT RETURN TOCENTER POSITION.

1. Tires not inflated properly. 1. Inflate tires to specified pressure.

2. Improper front wheel alignment. 2. Check and adjust wheel alignment asnecessary.

3. Lack of lubrication in frontsuspension control arm ball joints.

3. Lubricate ball joints if ball joints are not alubricated for life type of ball joint. If balljoint is a lubricated for life ball joint, replaceball joint or control arm.

4. Steering column coupling jointsmisaligned.

4. Realign steering column coupling joints.

5. Steering wheel rubbing.** 5. Adjust steering column shrouds toeliminate rubbing condition.

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6. Damaged, mis-positioned orun-lubricated steering columncoupler to dash seal.**

6. Replace, reposition, or lubricate dashseal.

7. Binding upper strut bearing. 7. Disassemble strut assembly. Correctbinding condition in strut bearing or replacebearing.

8. Tight shaft bearing in steeringcolumn.

8. Replace the steering column.

9. Excessive friction in steeringcolumn coupling.

9. Replace steering column coupling.

10. Excessive friction in powersteering gear.


EXCESSIVE STEERINGWHEEL KICKBACK ORTOO MUCH STEERINGWHEEL FREE PLAY.

1. Air in the fluid of the powersteering system.

1. Bleed air from system following the thepower steering pump initial operationservice procedure.*

2. Power steering gear loose on frontsuspension crossmember.

2. Inspect power steering gear mountingbolts. Replace as necessary. Tighten to thespecified torque.

3. Steering column coupling worn,broken or loose.

3. Replace steering column coupling.

4. Free play in steering column. 4. Check all components of the steeringsystem and repair or replace as required.

5. Worn control arm ball joints. 5. Replace ball joint or control arm asrequired.

6. Loose steering knuckle to ball jointstud pinch bolt.

6. Inspect pinch bolts, replace asnecessary, and tighten to specified torque.

7. Front wheel bearings loose orworn.

7. Replace wheel bearing or knuckle asnecessary.

8. Loose outer tie rod ends. 8. Replace outer tie rod ends that haveexcessive free play.

9. Loose inner tie rod ends. 9. Replace power steering gear.

10 Defective steering gear rotaryvalve.


OTE: * Steering shudder can be expected in newehicles and vehicles with recent steering systemepairs. Shudder should dissipate after the vehicleas been driven several weeks.

OTE: ** To evaluate this condition, it may be nec-ssary to disconnect the coupling at the base of theteering column. Turn the steering wheel and feel oristen for internal rubbing in steering column. Tovoid damaging the column clockspring, note the

following. Before disconnecting coupling, placetires in the straight-ahead position and center steer-ing wheel. Once disconnected, DO NOT rotatesteering wheel more than one revolution in eitherdirection and place steering wheel in original loca-tion before reconnecting coupling. If this position islost, the steering column clockspring must berecentered following the procedure found within theprocedure for steering column installation in thesteering column section.

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OWER STEERING FLUID


LOW FLUID LEVEL WITHVISIBLE LEAK.

1. Loose power steering hosefittings.

1. Tighten the fitting to its specified torque.

2. Damaged or missing fitting seal,gasket, or O-ring.

2. Replace as necessary.

3. Power steering pump or powersteering gear leaking.

3. Repair or replace the leaking componentas required.

AERATED FLUID. 1. Low fluid level.* 1. Fill power steering fluid reservoir toproper level.

2. Air leak between power steeringfluid reservoir and pump.

2. Inspect for proper sealing. Replace thepower steering pump (with reservoir).

3. Cracked power steering pumphousing.

3. Replace the power steering pump.

RESERVOIR FLUIDOVERFLOW AND FLUIDIS MILKY IN COLOR

1. Water contamination. 1. Drain the power steering fluid from thesystem. Flush the system with fresh cleanpower steering fluid, drain, then refill to theproper level.

OTE: * Extremely cold temperatures may causeower steering fluid aeration, if the power steering

luid is low.

OWER STEERING SYSTEM FLOW ANDRESSURE TESTThe following procedure is to be used to test the

peration of the power steering system on this vehi-le. This test will provide the flow rate of the powerteering pump along with the maximum relief pres-ure. This test is to be performed any time a powerteering system problem is present to determine ifhe power steering pump or power steering gear isot functioning properly. The following flow and pres-ure test is performed using the Power Steering Ana-yzer Kit, Special Tool 6815 (Fig. 3), hoses, Specialools 6905 and 6959, and fittings from adapter kit,pecial Tool 6893.(1) Assemble hoses on Power Steering Analyzer,

pecial Tool 6815, as shown. Install Pressure Hose,pecial Tool 6905 (in 6893 kit), in the inlet fitting onower Steering Analyzer. Install Pressure Hose, Spe-ial Tool 6713 (in 6815 kit) on Pressure Hose, Specialool 6905. Install Pressure Hose, Special Tool 6959,n the outlet fitting on Power Steering Analyzer.

CAUTION: To prevent personal injury, safety gog-gles should be worn at all times when performingany test procedures on the power steering system.

Fig. 3 Power Steering Analyzer With Hoses Installed1 – OUTLET2 – SPECIAL TOOL 68153 – INLET

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(2) Install Adapter Fitting, Special Tool 6844, onressure Hose, Special Tool 6713. Install Adapter Fit-ing, Special Tool 6826, on Pressure Hose, Specialool 6959. Both Special Tool 6844 and 6826 can beound in Adapter Set, Special Tool 6893 (Fig. 4).

(3) Unscrew the tube nut and disconnect theower steering fluid pressure hose from the powerteering pump (Fig. 5).(4) Connect Adapter Fitting, Special Tool 6844,

ttached to pressure hose from inlet (gauge end) ofower Steering Analyzer to the pressure fitting onhe power steering pump. Tighten the tube nut to aorque of 34 N·m (25 ft. lbs.).

(5) Connect the vehicle’s power steering fluid pres-ure hose to Adapter Fitting, Special Tool 6826,hich should be already installed in the outlet hose

valve end) of Power Steering Analyzer. Tighten theube nut to a torque of 34 N·m (25 ft. lbs.).

EST PROCEDURE(1) Completely open the valve on the Power Steer-

ng Analyzer flow meter.(2) Start the engine and let idle long enough to cir-

ulate power steering fluid through the analyzer andoses, until the air is out of the fluid. Shut the offngine.(3) Check the power steering fluid level and add

luid as necessary. Start the engine again and letdle.

(4) The analyzer gauge should read below 862 kPa125 psi). If above, inspect the hoses for restrictionsnd repair as necessary. The initial pressure shoulde in the range of 345-552 kPa (50-80 psi). The floweter should read between 1.1 and 1.3 GPM.

Fig. 4 Power Steering Analyzer Adapters 6893

CAUTION: The following test procedure stepinvolves testing maximum pump pressure outputand flow control valve operation. Do not leave valveclosed for more than five seconds as the pumpcould be damaged.

NOTE: Power steering pump maximum relief pres-sure is 9308 to 9998 kPa (1350 to 1450 psi.).

(5) Close the flow meter valve fully three timesand record highest pressure indicated each time. Allthree readings must be above specificationsand within 345 kPa (50 psi) of each other.

• If the power steering pump pressure’s are abovespecifications, but not within 345 kPa (50 psi) of eachother, replace the power steering pump.

• If the pressure’s are within 345 kPa (50 psi) ofeach other, but below specifications, replace thepower steering pump.

If the power steering pump requires replacement,refer to the section POWER STEERING PUMPwithin this group for the removal and installationprocedure.

Fig. 5 Hose At Pump1 – HOSE ROUTING CLIP2 – RETURN HOSE CLAMP3 – POWER STEERING PUMP AND RESERVOIR4 – PRESSURE HOSE TUBE NUT

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AUTION: Do not force the pump to operategainst the stops for more than 5 seconds at a times pump damage may result.

(6) Completely open the valve on the Power Steer-ng Analyzer flow meter. Turn the steering wheel tohe extreme left until the stop in the steering gear iset, then turn the steering wheel to the right until

he right stop is met. Record the highest indicatedressure at each position. Compare the recordedeadings to the specifications. If the highest outputressure reading against one stop is within 50 psi ofhe highest reading at the other stop, the steeringear is leaking internally and must be replaced.If the power steering gear requires replacement,

efer to the section POWER STEERING GEARithin this group for the removal and installationrocedure.

ERVICE PROCEDURES

OWER STEERING SYSTEM FLUID LEVELHECK

ARNING: FLUID LEVEL SHOULD BE CHECKEDITH THE ENGINE OFF TO PREVENT PERSONAL

NJURY FROM MOVING PARTS.

Before opening power steering system, wipe theeservoir filler cap free of dirt and debris. Removehe cap and check the fluid level on its dipstick.

hen the fluid is at normal ambient temperature,pproximately 21°C to 27°C (70°F to 80°F), the dip-tick level should indicate COLD. Do not overfill theower steering system. In all power steering systems,se only Mopar Power Steering Fluid, or its equiva-

ent.

OTE: Do not use any type of automatic transmis-ion fluid in the power steering system.

EMOVAL AND INSTALLATION

ERVICE WARNINGS AND CAUTIONS

ARNING: POWER STEERING FLUID, ENGINEARTS AND EXHAUST SYSTEM MAY BEXTREMELY HOT IF ENGINE HAS BEEN RUNNING.O NOT START ENGINE WITH ANY LOOSE OR DIS-ONNECTED HOSES. DO NOT ALLOW HOSES TOOUCH HOT EXHAUST MANIFOLD OR CATALYST.

WARNING: FLUID LEVEL SHOULD BE CHECKEDWITH THE ENGINE OFF TO PREVENT PERSONALINJURY FROM MOVING PARTS.

CAUTION: When the system is open, cap all openends of the hoses, power steering pump fittings orpower steering gear ports to prevent entry of for-eign material into the components.

NOTE: Do not use any type of automatic transmis-sion fluid in the power steering system.

POWER STEERING FLUID PRESSURE HOSE

NOTE: Before proceeding with this removal andinstallation procedure, review SERVICE WARNINGSAND CAUTIONS at the beginning of REMOVAL ANDINSTALLATION in this section.

REMOVAL(1) Siphon as much fluid as possible from the

power steering fluid reservoir.(2) Raise the vehicle. Refer to HOISTING in the

LUBRICATION AND MAINTENANCE group in thisservice manual for the correct lifting procedure.

(3) Back out the tube nut securing the powersteering fluid pressure hose to the gear (Fig. 6).

Fig. 6 Power Steering Hoses At Gear1 – PRESSURE HOSE TUBE NUT2 – RETURN HOSE3 – POWER STEERING GEAR4 – FRONT SUSPENSION CROSSMEMBER

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REMOVAL AND INSTALLATION (Continued)

(4) Open the routing clips on the right side of theower steering gear and remove the power steeringluid pressure hose tube from the routing clips. Athe same time, remove the pressure hose tube fromhe gear.

(5) Lower the vehicle.(6) Remove the bolt securing the hose routing clip

n place on the right engine motor mount (Fig. 7).emove the power steering fluid pressure hose from

he routing clip.

(7) Back out the tube nut securing the powerteering fluid pressure hose to the power steeringump and remove the hose from the pump (Fig. 7).(8) Remove the power steering pressure hose from

he engine compartment.

NSTALLATION(1) Install the power steering pressure hose into

he engine compartment from the top. First, guidehe pump end of the hose under the pump, thenoute the rest of the hose along the right side of thengine. Guide the gear end of the hose down behindhe back of the engine towards the power steeringear.(2) Using a lint free towel, wipe clean the open

ower steering hose end and the power steering

Fig. 7 Power Steering Hoses At Pump1 – HOSE ROUTING CLIP2 – RETURN HOSE CLAMP3 – POWER STEERING PUMP AND RESERVOIR4 – PRESSURE HOSE TUBE NUT

pump port. Replace the used O-ring with new. Lubri-cate the O-ring with power steering fluid.

(3) Attach the power steering fluid pressure hoseto the outlet fitting on the bottom of the power steer-ing pump (Fig. 7). Tighten the pressure hose tubenut to a torque of 34 N·m (25 ft. lbs.).

(4) Install the power steering fluid pressure hosein the routing clip and attach the clip to the rightengine mount (Fig. 7). Tighten the hose routing clipbolt to a torque of 12 N·m (105 in. lbs.).

(5) Raise the vehicle.

CAUTION: The power steering fluid hoses mustremain away from the exhaust system, vehicle com-ponents, and unfriendly surfaces that can causepossible damage to the power steering hoses.

(6) Using a lint free towel, wipe clean the openpower steering hose end and the power steering gearport. Replace the used O-ring with new. Lubricatethe O-ring with power steering fluid.

(7) Attach the power steering fluid pressure hoseto the port on the power steering gear (Fig. 6). Startthe tube nut threads into the gear, but do not tightenit at this time.

(8) Open the routing clips on the right side of thepower steering gear and install the power steeringfluid pressure hose into the routing clips. Close theclips.

(9) Tighten the pressure hose tube nut at the gearto a torque of 34 N·m (25 ft. lbs.).

(10) Lower the vehicle.(11) Perform the POWER STEERING PUMP INI-

TIAL OPERATION service procedure which can befound in the POWER STEERING PUMP section ofthis group to properly fill and bleed the power steer-ing system.

(12) Check for leaks at all hose connections.

POWER STEERING FLUID RETURN HOSE





(3) If the vehicle is equipped with a power steeringfluid cooler, remove the hose clamp securing thereturn hose to the cooler. Slide the hose off the end ofthe cooler tube.

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(4) If the vehicle is not equipped with a powerteering fluid cooler:• Remove the hose clamp securing the return hose

o the steel fitting in the outlet port on the powerteering gear (Fig. 6).• Slide the hose off the end of the steel fitting.• Pull the hose loose from the C-clamps on the two

outing clips located on the front of the steering gearFig. 6).

(5) Lower the vehicle.(6) Remove the bolt securing the hose routing clip

n place on the right engine mount (Fig. 7). Removehe power steering fluid return hose from the routinglip.(7) Remove the hose clamp securing the return

ose to the power steering fluid reservoir (Fig. 7).lide the hose off the end of the reservoir fitting.(8) Remove the power steering return hose from

he engine compartment.

NSTALLATION(1) Slide a hose clamp onto the power steering

ump end of the hose far enough to clear the fittingn the power steering fluid reservoir once the hose isnstalled.

(2) Install the power steering return hose into thengine compartment from the top. First, guide theump end of the hose onto the fitting on the powerteering fluid reservoir, then route the rest of theose along the right side of the engine (Fig. 7). Guidehe gear end of the hose down behind the back of thengine towards the power steering gear.(3) Expand the hose clamp and slide it onto the

luid reservoir fitting. Secure the clamp once it isast the bead formed into the fluid reservoir fitting.(4) Install the power steering fluid return hose in

he hose routing clip and attach the clip to the rightngine mount (Fig. 7). Tighten the hose routing clipolt to a torque of 12 N·m (105 in. lbs.).(5) Raise the vehicle.

AUTION: The power steering fluid hoses mustemain away from the exhaust system, vehicle com-onents, and unfriendly surfaces that can causeossible damage to the power steering hoses.

(6) Using a lint free towel, wipe clean the openower steering hose end and the power steering gearort fitting or power steering fluid cooler port.(7) Install a hose clamp onto the end of the hose

ar enough to clear the fitting on the steering gear orooler once the hose is installed.(8) If the vehicle is equipped with a power steering

luid cooler, slide the hose onto the end of the coolerube. Install the hose clamp past the bead formednto the cooler tube and secure in place.

(9) If the vehicle is not equipped with a powersteering fluid cooler:

• Slide the hose onto the end of the steel fitting inthe steering gear outlet port (Fig. 6).

• Install the hose clamp past the bead formed intothe steel fitting and secure in place.

• Align and attach the hose to the C-clamps onthe two routing clips located on the front of the steer-ing gear (Fig. 6).

(10) Lower the vehicle.(11) Perform the POWER STEERING PUMP INI-

TIAL OPERATION service procedure which can befound in the POWER STEERING PUMP section ofthis group to properly fill and bleed the power steer-ing system.

(12) Check for leaks at all hose connections.

POWER STEERING FLUID COOLER





(3) Remove the hose clamp, attaching the powersteering fluid return hose to the power steering fluidcooler. Remove the return hose from the cooler.

(4) Remove the hose clamp attaching the powersteering cooler fluid hose to the steel fitting in thepower steering gear outlet port (Fig. 8).

(5) Remove the two screws securing the cooler tothe front suspension crossmember. They are locatedbehind the cooler. They can be accessed from above.

(6) Open the routing clip on the right front of thepower steering gear housing and remove the coolertube from it.

(7) Remove the cooler from the vehicle.

INSTALLATION(1) Slide a hose clamp onto the end of the power

steering cooler fluid hose far enough to clear the steelfitting on the power steering gear once the hose isinstalled.

(2) Slide the hose (with cooler attached) onto thefitting on the steering gear, then align the tube onback of the cooler with the open routing clip on theright front of the power steering gear housing, andsnap it into place. Close the clip.

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19 - 14 STEERING PL


(3) Install the hose clamp on the power steeringooler fluid hose past the bead formed into the steelitting and secure in place.

(4) Install the two screws attaching the cooler tohe front suspension crossmember. Tighten the coolerttaching screws to a torque of 10 N·m (90 in. lbs.).(5) Install the power steering fluid return hose on

he power steering fluid cooler tube. Install the hoselamp on the power steering return hose securing ito the power steering cooler. Be sure the hose clamps installed on the return hose past the bead on thend of the cooler tube.(6) Lower the vehicle.(7) Perform the POWER STEERING PUMP INI-

IAL OPERATION service procedure which can beound in the POWER STEERING PUMP section ofhis group to properly fill and bleed the power steer-ng system.

(8) Check for leaks at all connections.

OWER STEERING FLUID PRESSURE SWITCH

OTE: Before proceeding with this removal andnstallation procedure, review SERVICE WARNINGSND CAUTIONS at the beginning of REMOVAL AND

NSTALLATION in this section.

EMOVAL(1) Disconnect negative battery cable from the neg-

tive post of the battery. Be sure cable is isolatedrom negative post on battery.

Fig. 8 Power Steering Fluid Cooler1 – POWER STEERING FLUID COOLER2 – TRANSAXLE3 – CLAMP4 – AIR DAM5 – CROSSMEMBER

(2) Raise the vehicle. Refer to HOISTING in theLUBRICATION AND MAINTENANCE group in thisservice manual for the correct lifting procedure.

(3) Locate the power steering fluid pressure switchon the back side of the power steering gear (Fig. 9).

(4) Remove the vehicle wiring harness connectorfrom the power steering fluid pressure switch.

NOTE: When removing and installing the powersteering pressure switch, use a 7/8 inch deep wellsocket. The deep well socket will prevent damageto the plastic electrical connector area of the powersteering fluid pressure switch.

(5) Unscrew and remove the power steering fluidpressure switch from the power steering gear.

INSTALLATION(1) By hand, screw the power steering pressure

switch into the power steering gear until it is fullyseated (Fig. 9). Tighten the power steering pressureswitch to a maximum torque of 8 N·m (70 in. lbs.).Over-torquing will result in stripping the threads outof the power steering pressure switch port in thesteering gear.

(2) Install the vehicle wiring harness connector. Besure the latch on the wiring harness connector isfully engaged with the locking tab on the powersteering pressure switch.

(3) Lower the vehicle.(4) Fill the power steering fluid reservoir to the

correct fluid level. Use only Mopart Power Steeringluid, or equivalent.(5) Connect the negative cable to the negative post

f the battery.

Fig. 9 Switch Location1 – WIRING HARNESS CONNECTOR2 – POWER STEERING GEAR3 – POWER STEERING FLUID PRESSURE SWITCH4 – REAR OF FRONT SUSPENSION CROSSMEMBER

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PL STEERING 19 - 15


(6) Start the engine and turn the steering wheeleveral times stop-to-stop to bleed any air from theluid in the power steering system. Stop the engine,heck the fluid level, and inspect the system foreaks.

PECIFICATIONS

OWER STEERING FASTENER TORQUEPECIFICATIONS

DESCRIPTION TORQUEPOWER STEERING HOSE:

Tube Nuts . . . . . . . . . . . . . . . 34 N·m (25 ft. lbs.)Hose Routing Clip Bolt . . . . 12 N·m (105 in. lbs.)

POWER STEERING COOLER:Mounting Screws . . . . . . . . . . 10 N·m (90 in. lbs.)

POWER STEERING FLUID PRESSURESWITCH:Switch . . . . . . . . . . . . . . . . . . . 8 N·m (70 in. lbs.)

POWER STEERING PUMP:Pressure Hose Tube Nut . . . . 34 N·m (25 ft. lbs.)Pressure Fitting . . . . . . . . . . . 88 N·m (65 ft. lbs.)Front Mounting Bolts . . . . . 28 N·m (250 in. lbs.)Rear Mounting Bolt . . . . . . . 28 N·m (250 in. lbs.)Rear Support Bracket To Engine Bolts . . 54 N·m

(40 ft. lbs.)

SPECIAL TOOLS

POWER STEERING

Power Steering Analyzer 6815

Adapters, Power Steering Analyzer 6893

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19 - 16 STEERING PL

POWER STEERING PUMP

TABLE OF CONTENTS

page page

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ESCRIPTION AND OPERATIONPOWER STEERING PUMP . . . . . . . . . . . . . . . . . 16POWER STEERING FLUID RESERVOIR . . . . . . . 17ERVICE PROCEDURESPOWER STEERING PUMP INITIAL

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17EMOVAL AND INSTALLATIONSERVICE WARNINGS AND CAUTIONS . . . . . . . . 17
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 17
ISASSEMBLY AND ASSEMBLYPOWER STEERING PUMP (PULLEY) . . . . . . . . . 19PECIFICATIONSPOWER STEERING PUMP FLOW

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 20POWER STEERING FASTENER TORQUE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 20PECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 20

OWER STEERING PUMPThe hydraulic pressure for operation of the power

teering gear is provided by a belt driven powerteering pump (Fig. 1) manufactured by TTA. TheTA power steering pump is a constant flow rate andisplacement vane-type pump.

In the event of a power steering pump drive beltailure, manual steering control of the vehicle cantill be maintained. However, under these conditions,teering effort will be significantly increased.

Fig. 1 Power Steering Pump1 – POWER STEERING FLUID RESERVOIR2 – POWER STEERING PUMP3 – PULLEY4 – PUMP PRESSURE FITTING

No repair procedures are to be done on the internalcomponents of the power steering pump. The onlyserviceable components of the power steering pumpare the power steering pump pulley and the pumpitself. The power steering fluid reservoir is servicedwith the pump.

Because of unique shaft bearings, flow control lev-els or pump displacements, power steering pumpsmay be used only on specific vehicle applications. Besure that all power steering pumps are only replacedwith a pump that is the correct replacement for thatspecific application.

Hydraulic pressure is provided for operation of thepower steering gear by the belt driven power steeringpump (Fig. 1). It is a constant displacement, vanetype pump. The power steering pump is connected tothe steering gear by a power steering fluid pressurehose and return hose.

Rectangular pumping vanes in the shaft drivenrotor move power steering fluid from the intake tothe cam ring pressure cavities of the power steeringpump. As the rotor begins to turn, centrifugal forcethrows the vanes against the inside surface of thecam ring to pickup residual oil. This oil is then forcedinto the high pressure area. As more oil is picked upby the vanes, the additional oil is forced into the cav-ities of the thrust plate through two crossover holesin the cam ring and pressure plate. The crossoverholes empty into the high pressure area between thepressure plate and the housing end cover.

As the high pressure area is filled, oil flows underthe vanes in the rotor slots, forcing the vanes to fol-low the inside surface of the cam ring. As the vanesreach the restricted area of the cam ring, oil is forcedout from between the vanes. When excess oil flow isgenerated during high-speed operation, a regulatedamount of oil returns to the pump intake sidethrough a flow control valve. The flow control valve

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PL STEERING 19 - 17


educes the power required to drive the pump andolds down temperature build-up.When steering conditions exceed maximum pres-

ure requirements, such as when the wheels areurned against the stops, the pressure built up in theteering gear exerts pressure on the spring end of thelow control valve. The high pressure lifts the reliefalve ball from its seat and allows oil to flow through

trigger orifice located in the outlet fitting. Thiseduces pressure on the spring end of the flow con-rol valve which then opens and allows the oil toeturn to the intake side of the pump. This actionimits maximum pressure output of the pump to aafe level.Under normal power steering pump operating con-

itions, pressure requirements of the pump are belowaximum, causing the pressure relief valve to

emain closed.

OWER STEERING FLUID RESERVOIRThe power steering fluid reservoir is mounted on

he power steering pump using 3 bolts (Fig. 1). Ittores fluid for the power steering system.The power steering fluid reservoir is considered an

ntegral part of the power steering pump and is noterviced separately.

ERVICE PROCEDURES

OWER STEERING PUMP INITIAL OPERATION

AUTION: The fluid level should be checked withngine off to prevent injury from moving compo-ents. Use only Mopar T Power Steering Fluid. Doot use automatic transmission fluid. Do not over-

ill.

Wipe the filler cap clean, then check the fluid level.he dipstick should indicate COLD when the fluid ist normal temperature, approximately 21°C to 27°C70°F to 80°F).

(1) Fill the power steering fluid reservoir to theroper level and let the fluid settle for at least twoinutes.(2) Start the engine and let run for a few seconds,

hen turn the engine off.(3) Add fluid if necessary. Repeat the above proce-

ure until the fluid level remains constant after run-ing the engine.(4) Raise the front wheels off the ground.(5) Start the engine. Slowly turn the steeringheel right and left, lightly contacting the wheel

tops.(6) Add power steering fluid if necessary.(7) Lower the vehicle and turn the steering wheel

lowly from lock to lock.

(8) Stop the engine. Check the fluid level and refillas required.

(9) If the fluid is extremely foamy, allow the vehi-cle to stand a few minutes and repeat the above pro-cedure.

REMOVAL AND INSTALLATION

SERVICE WARNINGS AND CAUTIONS

WARNING: POWER STEERING FLUID, ENGINEPARTS AND EXHAUST SYSTEM MAY BEEXTREMELY HOT IF ENGINE HAS BEEN RUNNING.DO NOT START ENGINE WITH ANY LOOSE OR DIS-CONNECTED HOSES. DO NOT ALLOW HOSES TOTOUCH HOT EXHAUST MANIFOLD OR CATALYST.

WARNING: FLUID LEVEL SHOULD BE CHECKEDWITH THE ENGINE OFF TO PREVENT PERSONALINJURY FROM MOVING PARTS.

CAUTION: When the system is open, cap all openends of the hoses, power steering pump fittings orpower steering gear ports to prevent entry of for-eign material into the components.

NOTE: Do not use any type of automatic transmis-sion fluid in the power steering system.

POWER STEERING PUMP


REMOVAL(1) Remove battery cable from the negative post on

the battery.(2) Siphon as much fluid as possible from the

power steering fluid reservoir.(3) Remove the power steering pump drive belt

from the power steering pump pulley. Refer toACCESSORY DRIVE BELTS in the COOLING SYS-TEM service manual group for the required removaland installation procedure.

(4) Remove the hose clamp securing the returnhose to the power steering fluid reservoir. Slide thehose off the end of the reservoir fitting. (Fig. 2).

(5) Back out the tube nut securing the powersteering fluid pressure hose to the power steeringpump and remove the hose from the pump (Fig. 2).

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19 - 18 STEERING PL


(6) Remove the mounting bolt securing the supportracket to the rear of the power steering pump (Fig.).(7) Loosen the two mounting bolts securing the

upport bracket to the engine block (Fig. 3).(8) Remove the three mounting bolts holding the

ower steering pump to the cast bracket (Fig. 4).ccess to the mounting bolts can be achieved through

he holes in the pump pulley.(9) Remove the power steering pump with reser-

oir from the engine.(10) For removal and installation of the power

teering pump pulley, refer to DISASSEMBLY ANDSSEMBLY in this section.

NSTALLATION(1) Install the power steering pump with reservoir

nd pulley on the engine and install the threeounting bolts securing the pump to the cast bracket

Fig. 4). Tighten the three bolts to a torque of 28 N·m250 in. lbs.).

(2) Install the mounting bolt securing the supportracket to the rear of the power steering pump (Fig.). Do not completely tighten the bolt at this time.

Fig. 2 Power Steering Hoses At Pump1 – HOSE ROUTING CLIP2 – RETURN HOSE CLAMP3 – POWER STEERING PUMP AND RESERVOIR4 – PRESSURE HOSE TUBE NUT

(3) Tighten the two mounting bolts securing thesupport bracket to the engine block (Fig. 3). Tightenthe bolts to a torque of 54 N·m (40 ft. lbs.).

(4) Tighten the mounting bolt securing the supportbracket to the rear of the power steering pump to atorque of 28 N·m (250 in. lbs.).

(5) Install the power steering pump drive belt onthe power steering pump pulley. Refer to ACCES-

Fig. 3 Power Steering Pump Support Bracket1 – MOUNTING BOLTS2 – POWER STEERING PUMP3 – SUPPORT BRACKET

Fig. 4 Power Steering Pump Mounting Bolts1 – MOUNTING BOLTS2 – POWER STEERING PUMP3 – PULLEY

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PL STEERING 19 - 19


ORY DRIVE BELTS in the COOLING SYSTEMervice manual group for the required removal andnstallation procedure.

(6) Using a lint free towel, wipe clean all openower steering hose ends and power steering pumpittings.

(7) Install a new O-ring on the end of the powerteering pressure hose. Lubricate the O-ring usinglean power steering fluid.(8) Attach the power steering fluid pressure hose

o the pressure fitting on the lower end of the powerteering pump (Fig. 2). Thread the tube nut securinghe power steering fluid pressure hose into the powerteering pump pressure fitting. Tighten the tube nuto at torque of 34 N·m (25 ft. lbs.).

(9) Slide the power steering fluid return hose ontohe fluid reservoir fitting (Fig. 2). Position the hoselamp so it is installed on the hose past the beadormed into the fluid reservoir fitting.

(10) Perform the POWER STEERING PUMP INI-IAL OPERATION service procedure found in thisection of this group to properly fill and bleed theower steering system.(11) Check for leaks.

ISASSEMBLY AND ASSEMBLY

OWER STEERING PUMP (PULLEY)The only serviceable part of the power steering

ump is the pulley. The following procedure is for theemoval and installation of the pulley from theump.The power steering pump must be removed from

he vehicle for power steering pump pulley service.efer to POWER STEERING PUMP in REMOVALND INSTALLATION for the required procedure.

AUTION: Use care when removing and installinghe power steering pump pulley. It is made of plas-ic composite, except for the center shank. The spe-ial tools are to be used in the shank area only asescribed in the following procedure.

ISASSEMBLY

AUTION: Do not hammer on the power steeringump pulley or shaft to remove the power steeringump pulley. This will damage the pulley and theower steering pump.

(1) Install Puller, Special Tool C-4333, or an equiv-lent, on the steering pump pulley as shown (Fig. 5).ighten the puller screw drive and remove the pulley

rom the power steering pump shaft.

NOTE: Replace the power steering pump pulley if itis cracked or loose.

(2) Remove the puller from the power steeringpump pulley.

ASSEMBLY(1) Place the power steering pump pulley squarely

on end of the power steering pump shaft. MountInstaller, Special Tool C-4063, or an equivalent, inthe internal threads of the power steering pumpshaft and against power steering pump pulley (Fig.6).

Fig. 5 Pulley Removal1 – PULLEY2 – C-43333 – POWER STEERING PUMP

Fig. 6 Pulley Installation1 – C-40632 – PULLEY3 – POWER STEERING PUMP

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19 - 20 STEERING PL

DISASSEMBLY AND ASSEMBLY (Continued)

(2) Ensuring that the installer and the pulleyemain aligned with pump shaft, turn the installeruter nut and force the pulley onto the power steer-ng pump shaft until it is flush with the end of theump shaft. Once the pulley is flush with the end ofhe shaft, the installer outer nut will no longer beble to turn.(3) Remove the installer from the power steering

ump.(4) Install the power steering pump back on the

ngine. Refer to POWER STEERING PUMP inEMOVAL AND INSTALLATION for the requiredrocedure.

PECIFICATIONS

OWER STEERING PUMP FLOWPECIFICATIONS

Power Steering Pump Flow:At 1500 RPM And MinimumPressure . . 4.2 to 4.9 Liters/Min (1.1 to 1.3 GPM)Control Valve PressureRelief . . . . . 9308 to 9998 kPa (1350 to 1450 psi)

OWER STEERING FASTENER TORQUEPECIFICATIONS

DESCRIPTION TORQUEPOWER STEERING HOSE:

Tube Nuts . . . . . . . . . . . . . . . 34 N·m (25 ft. lbs.)Hose Routing Clip Bolt . . . . 12 N·m (105 in. lbs.)

POWER STEERING COOLER:Mounting Screws . . . . . . . . . . 10 N·m (90 in. lbs.)

POWER STEERING FLUID PRESSURESWITCH:Switch . . . . . . . . . . . . . . . . . . . 8 N·m (70 in. lbs.)

POWER STEERING PUMP:Pressure Hose Tube Nut . . . . 34 N·m (25 ft. lbs.)Pressure Fitting . . . . . . . . . . . 88 N·m (65 ft. lbs.)Front Mounting Bolts . . . . . 28 N·m (250 in. lbs.)Rear Mounting Bolt . . . . . . . 28 N·m (250 in. lbs.)Rear Support Bracket To Engine Bolts . . 54 N·m

(40 ft. lbs.)

SPECIAL TOOLS

POWER STEERING PUMP

Installer C-4063B

Puller C-4333

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PL STEERING 19 - 21

STEERING GEAR

TABLE OF CONTENTS

page page

ESCRIPTION AND OPERATIONPOWER STEERING GEAR. . . . . . . . . . . . . . . . . . 21EMOVAL AND INSTALLATIONSERVICE WARNINGS AND CAUTIONS . . . . . . . . 22POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 22
OUTER TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . 26
ither side of the integral rack piston.

SPECIFICATIONSPOWER STEERING GEAR FASTENER

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 28SPECIAL TOOLS

POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 28


OWER STEERING GEARThe power steering gear is mounted on the front

uspension crossmember (Fig. 1). The outer ends ofhe outer tie rods attach to the steering knuckles.

The power steering gear operates as follows: Turn-ng of the steering wheel is converted into linearravel through the meshing of the helical pinioneeth with the rack teeth of the gear. Power assistteering is provided by a pump supplying fluid to

Road feel is controlled by the diameter of a torsionbar which initially steers the vehicle. This movementdirects oil behind the integral rack piston, which, inturn, builds up hydraulic pressure and assists in theturning effort.

The drive tangs on the pinion of the power steeringgear mate loosely with a stub shaft. This is to permitmanual steering control to be maintained if the drivebelt on the power steering pump should break. How-ever, under these conditions, steering effort will beincreased.

Fig. 1 Power Steering Gear1 – OUTER TIE ROD2 – JAM NUT

3 – STEERING GEAR4 – FRONT SUSPENSION CROSSMEMBER

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19 - 22 STEERING PL


OTE: The power steering gear should not be ser-iced or adjusted. If a malfunction or oil leak occursith the steering gear, the complete steering geareeds to be replaced.



ARNING: POWER STEERING FLUID, ENGINEARTS AND EXHAUST SYSTEM MAY BEXTREMELY HOT IF ENGINE HAS BEEN RUNNING.O NOT START ENGINE WITH ANY LOOSE OR DIS-ONNECTED HOSES. DO NOT ALLOW HOSES TOOUCH HOT EXHAUST MANIFOLD OR CATALYST.

ARNING: FLUID LEVEL SHOULD BE CHECKEDITH THE ENGINE OFF TO PREVENT PERSONAL

NJURY FROM MOVING PARTS.

AUTION: When the system is open, cap all opennds of the hoses, power steering pump fittings orower steering gear ports to prevent entry of for-ign material into the components.

OTE: Do not use any type of automatic transmis-ion fluid in the power steering system.

OWER STEERING GEAR


NSTALLATION in this section.

EMOVAL(1) Place the steering wheel in the STRAIGHT-HEAD position. Using a steering wheel holder, lock

he steering wheel in place to keep it from rotatingFig. 2). This keeps the clockspring in the proper ori-ntation.(2) Inside the passenger compartment, remove the

teering column coupling retainer pin, back off theinch bolt nut, and remove the steering column cou-ling pinch bolt (Fig. 3) (the pinch bolt nut is cagedo the coupling and is not removable). Separate thepper and lower steering column couplings.(3) Raise the vehicle. Refer to HOISTING in the

UBRICATION AND MAINTENANCE group in thiservice manual for the correct lifting procedure.

(4) Remove both front tire and wheel assembliesfrom the vehicle.

(5) Remove nuts attaching both outer tie rods tothe steering knuckles (Fig. 4). Remove each nut byholding the tie rod stud stationary while looseningand removing the nut with a wrench.

(6) Remove the outer tie rod from the steeringknuckles using Remover, Special Tool MB991113(Fig. 5).

(7) Remove the tie rod heat shield.

Fig. 2 Steering Wheel Holder1 – STEERING WHEEL2 – STEERING WHEEL HOLDER3 – DRIVERS SEAT

Fig. 3 Steering Column Couplings1 – STEERING COLUMN UPPER COUPLING2 – PINCH BOLT3 – STEERING COLUMN LOWER COUPLING4 – BRAKE PEDAL5 – NUT6 – RETAINER PIN

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PL STEERING 19 - 23


(8) Release the locking tab on the wiring harnessonnector for the power steering fluid pressurewitch before connector removal. Remove the wiringarness connector from the power steering fluid pres-ure switch (Fig. 6).(9) Back out the tube nut securing the power

teering fluid pressure hose to the gear (Fig. 7).(10) On vehicles without a power steering fluid

ooler, loosen the clamp, then disconnect the powerteering fluid return hose from the gear. If the vehi-le is equipped with a power steering fluid cooler, dis-onnect the cooler hose from the gear in place of theower steering fluid return hose.(11) If the vehicle is not equipped with a power

teering cooler, remove the power steering return

Fig. 4 Tools On Outer Tie Rod Nut1 – OUTER TIE ROD2 – STUD3 – NUT

Fig. 5 Tie Rod Removal From Knuckle1 – OUTER TIE ROD2 – STEERING KNUCKLE

hose from the C-clamps on the outside of the tworouting clips on the front of the power steering gear.

(12) Open the routing clips on the front of thepower steering gear and remove the power steeringfluid pressure hose from the routing clips. At thesame time, if the vehicle is equipped with a powersteering cooler, remove the cooler tube from the rightrouting clip.

Fig. 6 Power Steering Fluid Pressure Switch1 – WIRING HARNESS CONNECTOR2 – POWER STEERING GEAR3 – POWER STEERING FLUID PRESSURE SWITCH4 – REAR OF FRONT SUSPENSION CROSSMEMBER

Fig. 7 Power Steering Hoses At Gear1 – PRESSURE HOSE TUBE NUT2 – RETURN HOSE3 – POWER STEERING GEAR4 – FRONT SUSPENSION CROSSMEMBER

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19 - 24 STEERING PL


(13) If the vehicle is equipped with a power steer-ng fluid cooler, remove the two screws securing theooler to the front suspension crossmember. They areocated behind the cooler and can be accessed frombove. Allow the cooler to hang out of the way.(14) Remove the bolt mounting the engine torque

trut to the right forward corner of the front suspen-ion crossmember (Fig. 8).

OTE: Before removing the front suspensionrossmember from the vehicle, the location of therossmember must be scribed on the body of theehicle (Fig. 9). Do this so that the crossmemberan be relocated upon reinstallation against theody of vehicle in the same location as beforeemoval. If the front suspension crossmember isot reinstalled in exactly the same location asefore removal, the preset front wheel alignmentettings (caster and camber) will be lost.

(15) Using an awl, scribe a line (Fig. 9) markinghe location of where the front suspension crossmem-er is mounted against the body of the vehicle.(16) Position a transmission jack under the center

f the front suspension crossmember and raise it toupport the bottom of the crossmember.(17) Loosen and completely remove the two front

olts (one right and one left) attaching the front sus-ension crossmember to the frame rails of vehicle.he right side bolt can be viewed in the mountingolt figure (Fig. 8). The left side bolt is located in theame location on the other side of the vehicle.

Fig. 8 Mounting Bolts1 – FRONT SUSPENSION CROSSMEMBER MOUNTING BOLTS2 – ENGINE TORQUE ISOLATOR STRUT MOUNTING BOLT3 – FRONT SUSPENSION CROSSMEMBER

(18) Loosen the two rear bolts (one right and oneleft) attaching the front suspension crossmember andlower control arms to the body of the vehicle untilthey release from the threaded tapping plates in thebody of the vehicle. Do not completely remove therear bolts because they are designed to disengagefrom the body threads yet stay within the lower con-trol arm rear isolator bushing. This allows the lowercontrol arm to stay in place on the crossmember. Theright side bolt can be viewed in the mounting boltfigure (Fig. 8). The left side bolt is located in thesame location on the other side of the vehicle.

(19) Lower the front suspension crossmemberusing the transmission jack enough to allow thepower steering gear to be removed from the rear ofthe crossmember (Fig. 10). When lowering front sus-pension crossmember, do not let crossmember hangfrom lower control arms. The weight should be sup-ported by the transmission jack.

(20) Remove the roll pin securing the steering col-umn lower coupling to the power steering gear pinionshaft using a roll pin punch (Fig. 11). Push the steer-ing column lower coupling up and off of the powersteering gear pinion shaft.

(21) Release the pinion shaft dash cover seal fromthe tabs cast into the power steering gear housingand remove the seal from the power steering gear(Fig. 12).

(22) Loosen and remove the four bolts attachingthe power steering gear to the front suspension cross-member (Fig. 1). Remove the power steering gearfrom the front suspension crossmember.

Fig. 9 Marking Crossmember Location1 – SCRIBED LINE2 – FRONT SUSPENSION CROSSMEMBER3 – AWL4 – BODY

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PL STEERING 19 - 25


NSTALLATION(1) Install the steering gear on the front suspen-

ion crossmember (Fig. 1). Install the four powerteering gear mounting bolts. Tighten the mountingolts to a torque of 61 N·m (45 ft. lbs.).(2) Install the pinion shaft dash cover seal over

he power steering pinion shaft and onto the powerteering gear housing. Align the holes on each side ofhe seal with the tabs cast into the power steeringear housing (Fig. 12).(3) With the steering column lower coupling

ushed partway up through its hole in the dashanel, match the flat on the inside of the steering

Fig. 10 Crossmember Lowered1 – STEERING COLUMN LOWER COUPLING2 – POWER STEERING GEAR3 – FRONT SUSPENSION CROSSMEMBER4 – TRANSMISSION JACK

Fig. 11 Coupling Roll Pin1 – STEERING COLUMN LOWER COUPLING2 – POWER STEERING GEAR PINION SHAFT3 – ROLL PIN4 – ROLL PIN PUNCH

column lower coupling to the flat on the power steer-ing gear pinion shaft and slide the coupling onto thetop of the pinion shaft. Align the roll pin hole in thecoupling with the groove in the pinion shaft andinstall the roll pin through the coupling until it iscentered (Fig. 11).

(4) Center the power steering gear rack in itstravel.

(5) Using the transmission jack, raise the frontsuspension crossmember and power steering gearuntil the crossmember contacts its mounting spotagainst the body and frame rails of the vehicle. Asthe crossmember is raised, carefully guide the steer-ing column lower coupling up through its hole in thedash panel.

(6) Start the two rear crossmember mounting boltsinto the tapping plates mounted in the body. Theright side bolt can be viewed in the mounting boltfigure (Fig. 8). The left side bolt is located in thesame location on the other side of the vehicle. Next,install the two front mounting bolts attaching frontsuspension crossmember to frame rails of vehicle.Lightly tighten all four mounting bolts to a approxi-mately 2 N·m (20 in. lbs.) to hold the front suspen-sion crossmember in position.

NOTE: When reinstalling the front suspensioncrossmember back in the vehicle, it is very impor-tant that the crossmember be attached to the bodyin exactly the same spot as when it was removed.Otherwise, the vehicle’s wheel alignment settings(caster and camber) will be lost.

Fig. 12 Pinion Shaft Dash Cover Seal1 – SEAL2 – PINION SHAFT3 – TAB4 – POWER STEERING GEAR

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(7) Using a soft face hammer, tap the front suspen-ion crossmember back-and-forth or side-to-side untilt is aligned with the previously scribed positioning

arks on the body of the vehicle (Fig. 9). Once theront suspension crossmember is correctly positioned,ighten the rear two crossmember (and rear lowerontrol arm) mounting bolts to a torque of 203 N·m150 ft. lbs.), then tighten the front two crossmemberounting bolts to a torque of 142 N·m (105 ft. lbs.).(8) Fasten the engine torque strut to the right for-ard corner of the front suspension crossmembersing its mounting bolt (Fig. 8). Follow the procedureescribed in the ENGINE service manual group toroperly align and tighten the torque strut and it’sounting bolts.(9) Using a lint free towel, wipe clean the open

ower steering hose ends and the power steeringear ports. Replace the pressure hose used O-ringith new. Lubricate the O-ring with power steering

luid.(10) Attach the power steering fluid pressure hose

o it’s port on the power steering gear (Fig. 7). Starthe tube nut threads into the gear, but do not tightenhem at this time. On vehicles equipped with a powerteering fluid cooler, reconnect the cooler line to theear in place of the power steering fluid return hose.(11) Open the routing clips on the front of the

teering gear housing and install the power steeringluid pressure hose into the routing clips.

(12) On vehicles equipped with a power steeringluid cooler, place the cooler in mounting position andnap the cooler tube going to the gear into the rightouting clip.(13) Close both routing clips.(14) Tighten the power steering fluid pressure

ose tube nut at the gear to a torque of 34 N·m (25t. lbs.).

(15) If the vehicle is equipped with a power steer-ng fluid cooler, install the two screws securing theooler to the front suspension crossmember. They areocated behind the cooler.

(16) On vehicle’s with a power steering fluid cooler,lace the hose clamp on the hose far enough from thend to clear the steel fitting on the gear. Do the sameor the fluid return hose on a vehicle that is notquipped with a cooler.(17) Push either hose listed in the above step onto

he steel fitting, then move and secure the clamp onhe hose past the bead on the steel fitting in theteering gears outlet port (Fig. 7).(18) Route the fluid return hose along the front of

he steering gear, clipping it into place in the-clamps on the outside of the routing clips on the

ront of the power steering gear housing.(19) Reconnect the wiring harness connector from

he power steering fluid pressure switch (Fig. 6). Be

sure the locking tab on the wiring harness connectoris securely latched.

(20) Perform the following to each outer tie rod:• Place the tie rod heat shield on the knuckle’s

steering arm, aligning the hole in the shield with thehole in the knuckle and the tangs on the outside ofthe shield with the outside configuration of the steer-ing arm. The shield should now be facing outboard,away from the power steering gear and tie rod (Fig.4).

• Attach the outer tie rod end to its steeringknuckle.

• Start the attaching nut onto the stud of theouter tie rod.

• While holding the stud of the tie rod stationarywith a wrench, tighten the attaching nut (Fig. 4).

• Using a crowfoot wrench attached to a torquewrench, tighten the attaching nut to 55 N·m (40 ft.lbs.).

(21) Install the tire and wheel assemblies back onvehicle. Tighten the wheel mounting nuts to 135 N·m(100 ft. lbs.) torque.

(22) Lower the vehicle to ground level.(23) Install the dash-to-lower coupling seal in

place over the lower coupling’s plastic collar.

NOTE: Verify that grease is present on the lip ofthe dash-to-coupling seal where it contacts the cou-pling’s plastic collar.

(24) Inside the passenger compartment, reconnectthe steering column lower coupling to the steeringcolumn upper coupling (Fig. 3). Install the couplingpinch bolt and tighten the pinch bolt nut to a torqueof 28 N·m (250 in. lbs.). Install the pinch boltretainer pin.

(25) Remove the steering wheel holder.(26) While looking under the instrument panel at

the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does notsqueak against the dash-to-coupling seal.

(27) Perform the POWER STEERING PUMP INI-TIAL OPERATION service procedure which can befound in the POWER STEERING PUMP section ofthis group to properly fill and bleed the power steer-ing system.

(28) Check for fluid leaks.(29) Adjust the front toe setting on the vehicle.

Refer to WHEEL ALIGNMENT in the SUSPENSIONservice manual group.

OUTER TIE ROD

REMOVAL(1) Raise the vehicle. Refer to HOISTING in the


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PL STEERING 19 - 27


(2) Remove the tire and wheel assembly from theehicle.(3) Loosen tie rod jam nut (Fig. 13). Thread the

am nut far enough up the inner tie rod to pull theollar away from the outer tie rod end. Pull the collarff the end of the outer tie rod.

(4) Remove the nut attaching the outer tie rod endo steering knuckle (Fig. 14). Remove the nut byolding the tie rod stud stationary while looseningnd removing the nut with a wrench.

Fig. 13 Outer Tie Rod1 – INNER TIE ROD2 – OUTER TIE ROD JAM NUT3 – STEERING KNUCKLE4 – OUTER TIE ROD END5 – COLLAR6 – INNER TIE ROD SERRATION

Fig. 14 Tools On Outer Tie Rod Nut1 – OUTER TIE ROD2 – STUD3 – NUT

(5) Remove the outer tie rod from the steeringknuckle using Remover, Special Tool MB991113 (Fig.15).

(6) Remove the tie rod heat shield.(7) Remove the outer tie rod from the inner tie rod

by unthreading it.

INSTALLATION(1) Install the jam nut on the inner tie rod threads

if it is not already installed (Fig. 13).

NOTE: Be sure the collar is installed on the innertie rod with the flat end of the collar against jam nutand the open end of the collar facing the outer tierod end.

(2) Install the collar on the inner tie rod (Fig. 13).(3) Thread the outer tie rod onto the inner tie rod.(4) Position the collar around the end of the outer

tie rod (Fig. 13).(5) Thread the jam nut down the inner tie rod far

enough to hold the collar in place on the outer tierod. Do not tighten the jam nut.

(6) Place the tie rod heat shield on the knuckle’ssteering arm, aligning the hole in the shield with thehole in the knuckle and the tangs on the outside ofthe shield with the outside configuration of the steer-ing arm. The shield should now be facing outboard,away from the power steering gear and tie rod (Fig.14).

(7) Attach the outer tie rod end to the steeringknuckle.

(8) Start the attaching nut onto the stud of theouter tie rod.

Fig. 15 Tie Rod Removal From Knuckle1 – OUTER TIE ROD2 – STEERING KNUCKLE

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(9) While holding the stud of the tie rod stationaryith a wrench, tighten the attaching nut (Fig. 14).(10) Using a crowfoot wrench attached to a torquerench, tighten the attaching nut to 75 N·m (55 ft.

bs.).(11) Install the tire and wheel assembly.(12) Lower the vehicle.(13) Adjust the front toe setting on the vehicle.efer to WHEEL ALIGNMENT in the SUSPENSIONervice manual group.

PECIFICATIONS

OWER STEERING GEAR FASTENER TORQUEPECIFICATIONS

DESCRIPTION TORQUEFRONT SUSPENSION CROSSMEMBER:

Front Mounting Bolts . . . . . 142 N·m (105 ft. lbs.)Rear Mounting Bolts . . . . . 203 N·m (150 ft. lbs.)

STEERING GEAR:Mounting Bolts . . . . . . . . . . . 61 N·m (45 ft. lbs.)

OUTER TIE ROD:Steering Knuckle Nut . . . . . . 55 N·m (40 ft. lbs.)Tie Rod Jam Nut . . . . . . . . . . 75 N·m (55 ft. lbs.)

POWER STEERING HOSE:Tube Nuts . . . . . . . . . . . . . . . 34 N·m (25 ft. lbs.)

SPECIAL TOOLS

POWER STEERING GEAR

Remover MB991113

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PL STEERING 19 - 29

STEERING COLUMN

TABLE OF CONTENTS

page page

S

ESCRIPTION AND OPERATIONSTEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 29STEERING COLUMN LOWER COUPLING . . . . . . 29IAGNOSIS AND TESTINGSTEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 30STEERING COLUMN LOWER COUPLING . . . . . . 30EMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS . . . . . . . . 31
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 31STEERING COLUMN LOWER COUPLING . . . . . . 38PECIFICATIONSSTEERING COLUMN FASTENER TORQUE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 41


TEERING COLUMNThis vehicle is equipped with both tilt and non-tilt

teering columns. Both steering columns have beenesigned to be serviced only as complete assembliesf an internal component is found to be defective (Fig.). The shaft, bearings and upper coupling are allerviced with the column.

The replaceable components on the steering col-mn assembly are:• the key cylinder• the ignition switch• the multi-function switch• the clockspring

Fig. 1 Steering Column1 – UPPER MOUNTING NUTS2 – STEERING COLUMN3 – LOWER MOUNTING NUTS

• the trim shrouds• the steering wheel• the driver airbag moduleThese components can be serviced without removal

of the steering column from the vehicle. Refer to theappropriate group and section of this service manualfor servicing these components separately.

STEERING COLUMN LOWER COUPLINGThis vehicle uses a corrugated design lower cou-

pling to connect the steering column to the steeringgear (Fig. 2).

This coupling has a hollow corrugated tube thatallows the coupling to bend rather than collapsewhen a vehicle is involved in a collision.

Fig. 2 Steering Column Lower Coupling1 – FLEX JOINT2 – SEAL COLLAR SEALING SURFACE3 – TO STEERING COLUMN4 – CORRUGATED TUBE SECTION5 – TO STEERING GEAR

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19 - 30 STEERING PL

IAGNOSIS AND TESTING

TEERING COLUMNFor diagnosis of conditions relating to the steering

olumn, refer to the STEERING SYSTEM DIAGNO-IS CHARTS in DIAGNOSIS AND TESTING in theOWER STEERING section of this service manualroup.

TEERING COLUMN LOWER COUPLINGThe steering column coupling must be inspectedhenever a vehicle is involved in an impact or when-ver any of the following conditions exist:• whenever a vehicle is involved in a collisionhich deploys the air bag, regardless of the extent ofamage done to the vehicle.• if a vehicle is involved in an impact of the vehi-

les front suspension or under carriage, which resultsn any type of damage to the front suspension cross-

ember.• under any conditions which result in the steer-

ng column assembly or steering column shaft receiv-ng a force great enough to move the steering columnr shaft forward or rearward in a vehicle.

TEERING COLUMN COUPLING INSPECTIONROCEDURE(1) Place the steering wheel in the STRAIGHT-HEAD position. Using a steering wheel holdinglamp, lock the steering wheel in place to keep itrom rotating. This keeps the clockspring in theroper orientation.(2) Inside the passenger compartment, remove the

teering column coupling retainer pin, back off theinch bolt nut, and remove the steering column cou-ling pinch bolt (Fig. 3) (the pinch bolt nut is cagedo the coupling and is not removable). Separate thepper and lower steering column couplings.(3) Remove the silencer seal enclosing the steering

olumn coupling (Fig. 4).(4) Inspect steering column lower coupling in the

ollowing areas for signs of damage:• Inspect the sealing collar on the lower coupling

Fig. 5) to ensure the it is not cracked, broken, ortherwise damaged requiring coupling replacement.• Inspect the corrugated section (Fig. 5) of the

ower coupling for the following conditions or anyther visible signs of damage.• Uneven spacing between the corrugations on the

oupling.• Dings or dents in the corrugations of the cou-

ling or anywhere else on the coupling wall.• A bend in the corrugated section of the coupling.• Inspect the lower coupling flex joint for binding.If any of the preceding conditions exist, the steer-

ng column lower coupling must be replaced.

Inspect the steering column upper coupling fordamage or binding. If the upper coupling needs to bereplaced, the steering column must be replaced.

NOTE: Verify that grease is present on the lip ofthe dash-to-coupling seal where it contacts thelower coupling’s plastic collar.

(5) If the lower coupling does not require replace-ment, install the dash panel-to-steering column cou-pling silencer seal (Fig. 4) back on the vehicle.


Fig. 4 Steering Column Coupling Seal1 – LOWER STEERING COLUMN COUPLER2 – UPPER STEERING COLUMN SHAFT COUPLER3 – SILENCER SEAL4 – BRAKE PEDAL

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OTE: Do not tighten the coupling pinch bolt any-ime the vehicle is not at curb riding height. It mayause unwanted conditions within the steering col-mn if the vehicle is suspended in any mannerhen the pinch bolt is tightened.

(6) Ensure front wheels of vehicle are positionedTRAIGHT-AHEAD, then align and attach the steer-

ng column upper coupling to the lower coupling.nstall the coupling pinch bolt (Fig. 3). Tighten theinch bolt nut to a torque of 28 N·m (250 in. lbs.).(7) Install the coupling pinch bolt retainer pin.(8) Remove the steering wheel holding clamp.



ARNING: BEFORE BEGINNING ANY SERVICEROCEDURES THAT INVOLVES REMOVING THEIR BAG. REMOVE AND ISOLATE THE NEGATIVE

-) BATTERY CABLE (GROUND) FROM THE VEHI-LE BATTERY. THIS IS THE ONLY SURE WAY TOISABLE THE AIR BAG SYSTEM. FAILURE TO DOHIS COULD RESULT IN ACCIDENTAL AIR BAGEPLOYMENT AND POSSIBLE PERSONAL INJURY.

ARNING: THE AIR BAG SYSTEM IS A SENSITIVE,OMPLEX ELECTRO-MECHANICAL UNIT. BEFORETTEMPTING TO DIAGNOSE, REMOVE OR INSTALLHE AIR BAG SYSTEM COMPONENTS YOU MUSTIRST DISCONNECT AND ISOLATE THE BATTERYEGATIVE (GROUND) CABLE. FAILURE TO DO SO

Fig. 5 Lower Coupling Inspection1 – FLEX JOINT2 – SEAL COLLAR SEALING SURFACE3 – TO STEERING COLUMN4 – CORRUGAGATED TUBE SECTION5 – TO STEERING GEAR

COULD RESULT IN ACCIDENTAL DEPLOYMENT OFTHE AIR BAG AND POSSIBLE PERSONAL INJURY.THE FASTENERS, SCREWS, AND BOLTS, ORIGI-NALLY USED FOR THE AIR BAG COMPONENTS,HAVE SPECIAL COATINGS AND ARE SPECIFI-CALLY DESIGNED FOR THE AIR BAG SYSTEM.THEY MUST NEVER BE REPLACED WITH ANY SUB-STITUTES. ANYTIME A NEW FASTENER ISNEEDED, REPLACE WITH THE CORRECT FASTEN-ERS PROVIDED IN THE SERVICE PACKAGE ORFASTENERS LISTED IN THE PARTS BOOKS.BEFORE SERVICING A STEERING COLUMNEQUIPPED WITH AN AIR BAG, REFER TO GROUP8M, ELECTRICAL FOR PROPER AND SAFE SER-VICE PROCEDURES.

WARNING: WHEN HANDLING AN UNDEPLOYEDAIR BAG MODULE DURING SERVICING OF THESTEERING COLUMN, THE FOLLOWING PRECAU-TIONS SHOULD BE OBSERVED:

• AT NO TIME SHOULD ANY SOURCE OF ELEC-TRICITY BE PERMITTED NEAR THE INFLATOR ONTHE BACK OF THE AIR BAG MODULE.

• WHEN CARRYING A LIVE MODULE, THE TRIMCOVER SHOULD BE POINTED AWAY FROM THEBODY TO MINIMIZE INJURY IF THE MODULESHOULD ACCIDENTLY DEPLOY.

• IF THE AIR BAG MODULE IS PLACED ON ABENCH OR OTHER SURFACE, THE PLASTICCOVER SHOULD BE FACE-UP TO MINIMIZE MOVE-MENT, IN CASE OF ACCIDENTAL DEPLOYMENT.

CAUTION: Safety goggles should be worn at alltimes when working on steering columns.

CAUTION: Disconnect negative (ground) cable fromthe battery, before servicing any column compo-nent.

CAUTION: Do not attempt to remove the pivot pinsto disassemble the tilting mechanism. Damage willoccur.

STEERING COLUMN


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19 - 32 STEERING PL


EMOVAL(1) Disconnect the negative (-) cable from the bat-

ery and isolate the cable.(2) Before beginning removal of the steering col-

mn, be sure the front wheels of vehicle are in theTRAIGHT-AHEAD position.(3) Remove the screw securing the left end of the

op cover to the instrument panel. It is located justbove the left instrument panel end cap.(4) Starting on the driver’s end, push upward on

he instrument panel top cover, disengaging itsetainer clips along the face of the instrument panel.isengage just enough clips to allow access to thepper ends of the instrument cluster bezel.(5) Disengage the clips along the outer edge of the

nstrument cluster bezel and remove the bezel fromhe vehicle.

(6) Remove the two screws along the bottom of theteering column cover that mounts below the steeringolumn on the instrument panel. Disengage the clipsn the upper end of the steering column cover andemove the cover by pulling it straight away from thenstrument panel.

(7) If the vehicle is equipped with speed control,emove the speed control switches from the steeringheel (Fig. 6).

Fig. 6 Steering Wheel Components1 – ELECTRICAL CONNECTOR2 – AIRBAG MOUNTING SCREWS3 – ELECTRICAL CONNECTOR4 – SPEED CONTROL SWITCH5 – AIRBAG MODULE ELECTRICAL CONNECTOR6 – AIRBAG MODULE7 – HORN SWITCH ELECTRICAL CONNECTOR8 – SPEED CONTROL SWITCH

WARNING: WHEN AN UNDEPLOYED AIRBAG MOD-ULE IS TO BE REMOVED FROM THE STEERINGWHEEL, FIRST DISCONNECT THE BATTERYGROUND CABLE AND ISOLATE IT. ALLOW THESYSTEM CAPACITOR TO DISCHARGE FOR A MINI-MUM OF TWO MINUTES, THEN BEGIN THE AIRBAGREMOVAL.

(8) If the vehicle is not equipped with speed con-trol, remove the airbag mounting screw trim capsfrom the steering wheel rear cover (Fig. 7). There isone on each side of the steering wheel.

(9) Remove the two mounting screws, one on eachside of steering wheel, attaching the airbag moduleto the steering wheel (Fig. 6).

(10) Lay the airbag module back away from thecenter of the steering wheel (Fig. 6). Disconnect theclockspring and horn switch electrical connectorsfrom the back of the airbag module. Remove the air-bag module from the steering wheel.

(11) Holding the steering wheel firmly in place,remove the steering wheel retaining nut from thesteering column shaft in the center of the steeringwheel. If equipped, remove the damper weight fromthe steering wheel.

Fig. 7 Trim Caps1 – MULTIFUNCTION SWITCH LEVER2 – STEERING WHEEL3 – TRIM CAP

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PL STEERING 19 - 33


AUTION: When installing a wheel puller on theteering wheel, be sure the puller bolts are fullyeated in the threaded holes on the steering wheel.f the bolts are not fully seated in the threadedoles, the threads may be stripped out of the steer-

ng wheel when attempting to remove the steeringheel. Also, thread the retaining nut back on thend of the shaft until it is flush with the shaft end tovoid damage to the shaft threads by the wheeluller.

(12) Install a steering wheel puller on the steeringheel (Fig. 8).

AUTION: Do not bump or hammer on steeringheel or steering column shaft when removingteering wheel from steering column.

(13) Holding the steering wheel firmly in thetaight-ahead position, remove steering wheel fromhe steering column shaft using the puller.

(14) Remove the ignition key from the ignition keyylinder.(15) Remove the two screws attaching the lower

hroud to the steering column and upper shroud (Fig.). After removing the screws, unclip the shouds fromach other by applying hand pressure along theeams where the shrouds connect on the sides, thenemove the lower shroud from the upper shroud andolumn. Remove the upper shroud from the steeringolumn.(16) At the base of the column, remove the steer-

ng column coupling retainer pin, back off the pincholt nut, and remove the steering column couplinginch bolt (Fig. 10) (the pinch bolt nut is caged to theoupling and is not removable). Separate the uppernd lower steering column couplings.

Fig. 8 Steering Wheel Puller Installed1 – STEERING WHEEL2 – STEERING WHEEL PULLER

(17) If the vehicle is equipped with a automatictransaxle, disconnect the automatic transaxle igni-tion interlock cable from the steering column.Depress the tab on top of the cable connector andremove the cable from the back side of the steeringcolumn ignition cylinder housing (Fig. 11).

(18) Remove the two lower mounting nuts attach-ing the steering column to the instrument panel (Fig.12).

(19) Remove the two upper mounting nuts attach-ing the steering column to the instrument panel (Fig.12).

Fig. 9 Steering Column Shrouds1 – UPPER SHROUD2 – LOWER SHROUD3 – MOUNTING SCREWS


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(20) Lower the steering column away from thenstrument panel.

(21) Disconnect the wiring harness electrical con-ector from the clockspring (Fig. 13).(22) Disconnect the wiring harness electrical con-

ectors from the multi-function switch, windshieldiper switch, and ignition switch (Fig. 14).

Fig. 11 Interlock Cable1 – IGNITION SWITCH2 – CLIP3 – INTERLOCK CABLE4 – BTSI SOLENOID

Fig. 12 Steering Column Mounting Nuts1 – UPPER MOUNTING NUTS2 – STEERING COLUMN3 – LOWER MOUNTING NUTS

(23) If the vehicle is equipped with a Sentry KeyImmobilizer Module (SKIM), disconnect its electricalconnector (Fig. 15).

(24) Remove the steering column from the vehicle.(25) If the steering column is being replaced, per-

form the following:(a) Remove the ignition key cylinder from the

steering column. To do this, insert the key andturn the ignition key cylinder to the ON position.Next, depress the retaining tab and remove theIgnition key cylinder by pulling the key and cylin-der straight out of the column together (Fig. 16).

Fig. 13 Clockspring Electrical Connector1 – STEERING COLUMN2 – CLOCKSPRING3 – CLOCKSPRING ELECTRICAL CONNECTOR4 – IGNITION SWITCH ELECTRICAL CONNECTOR

Fig. 14 Electrical Connectors1 – MULTI-FUNCTION SWITCH ELECTRICAL CONNECTOR2 – WINDSHIELD WIPER SWITCH ELECTRICAL CONNECTOR3 – IGNITION SWITCH ELECTRICAL CONNECTOR

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PL STEERING 19 - 35


(b) Disengage the latch hooks on the back of theclockspring by lifting the clockspring slightly toclear the column housing with the top latch hook.Next, lower the clockspring slightly to do the samefor the lower latch hook (Fig. 17). Remove theclockspring from the column.

(c) Remove the two screws securing the multi-function/windshield wiper switch to the steeringcolumn (Fig. 18). Pull the switch straight awayfrom the column to remove it.

(d) If the column is equipped with a SKIM,remove the module from the column by removingthe two mounting screws and sliding the SKIM offthe non-halo trim ring (Fig. 19).

(e) Remove the non-halo trim ring from the col-umn by unclipping it from the ignition cylinderhousing (Fig. 19).

(f) Remove the ignition switch from the steeringcolumn by first removing the mounting screw (Fig.20). Once the screw is removed, pull the switchstraight out away from the column ignition cylin-der housing.

NSTALLATION(1) If the steering column is being replaced, per-

orm the following on the column before installing itn the vehicle:

(a) Ensure the ignition switch is positioned inthe ON position.

(b) Install the ignition switch on the steeringcolumn by pushing the tapered end onto the shaftand steering column ignition cylinder housing.Install the screw securing the switch to the column(Fig. 20).

Fig. 15 SKIM Electrical Connector1 – STEERING COLUMN2 – SKIM ELECTRICAL CONNECTOR3 – SKIM

(c) Install the non-halo trim ring on the columnuntil its tabs snap into place on the ignition cylin-der housing (Fig. 19).

(d) If the column is equipped with a Sentry KeyImmobilizer Module (SKIM), install the module onthe column by sliding the module onto the non halotrim ring and installing the two mounting screws(Fig. 19). Tighten the mounting screws to a torqueof 3 N·m (25 in. lbs.).

(e) Position the multi-function/windshield wiperswitch in onto the top of the column and install thetwo screws securing the switch in place (Fig. 18).

(f) Place the clockspring onto the end of the col-umn engaging the clockspring latch hooks into thecolumn (Fig. 17).

Fig. 16 Ignition Key Cylinder Retaining Tab1 – IGNITION KEY2 – RETAINING TAB3 – STEERING COLUMN

Fig. 17 Clockspring Latch Hooks1 – CLOCKSPRING2 – LATCH HOOKS3 – STEERING COLUMN

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19 - 36 STEERING PL


(g) Install the ignition key cylinder in the steer-ing column. To do this, first position the key cylin-der in the ON position (with the key in it) so theretaining tab can be depressed. Push key cylinderinto the column ignition cylinder housing until theretaining tab locks into place (Fig. 16).

OTE: When installing a tilt column, do not releasehe tilt lever from the locked position until after theolumn is installed on the instrument panel.

(2) Install the steering column into steering col-mn access opening in the lower instrument panel.(3) If the vehicle is equipped with a SKIM, Con-

ect its wiring harness electrical connector (Fig. 15).

Fig. 18 Multi-function/Wiper Switch Mounting1 – MOUNTING SCREWS2 – MULTI-FUNCTION/WINDSHIELD WIPER SWITCH ASSEMBLY

Fig. 19 SKIM Mounting1 – HALO TRIM RING2 – MOUNTING SCREWS3 – SKIM

(4) Connect the wiring harness electrical connec-tors to the multi-function switch, windshield wiperswitch, and ignition switch (Fig. 14).

(5) Connect the wiring harness electrical connectorto the clockspring (Fig. 13).

(6) Align the slots in the mounting brackets on thesteering column with the studs in the instrumentpanel (Fig. 12) Attach the column to the instrumentpanel by first installing the two upper mounting nuts(Do not completely tighten the two upper mountingnuts at this time). Next, install the two lower mount-ing nuts. Tighten all four mounting nuts to a torqueof 17 N·m (150 in. lbs.).

(7) If the vehicle is equipped with an automatictransaxle, connect the automatic transaxle ignitioninterlock cable to the steering column by pushing theend of the cable into the back side of the ignition cyl-inder housing until it snaps into place (Fig. 11).

(8) Position the steering column shaft in the cor-rect position for mounting to the lower coupling. Todo this, turn the steering wheel end of the shaft untilthe missing spline area on that end of the shaft facesstraight up.

(9) Verify the front wheels of vehicle are in theSTRAIGHT-AHEAD position.

NOTE: Do not tighten the coupling pinch bolt any-time the vehicle is not at curb riding height. It maycause unwanted conditions within the steering col-umn if the vehicle is suspended in any mannerwhen the pinch bolt is tightened.

(10) Reconnect the steering column lower couplingto the steering column upper coupling (Fig. 10).Install the coupling pinch bolt an tighten the pinch

Fig. 20 Ignition Switch Mounting1 – MOUNTING SCREW2 – IGNITION SWITCH

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olt nut to a torque of 28 N·m (250 in. lbs.). Installhe pinch bolt retainer pin.

(11) Install the upper and lower steering columnhrouds onto the steering column (Fig. 9). Snap thewo shrouds together and then install and tightenhe two screws securing the shrouds to the column.

(12) Install the steering column cover that mountselow the steering column on the instrument panely first aligning the retainer clips and snapping theover into place. Install the two screws along the bot-om of the steering column cover.

(13) Align the clips along the outer edge of thenstrument cluster bezel with the mounting holes inhe instrument panel and install the bezel.

(14) Align the clips on the bottom of the instru-ent panel top cover with the mounting holes in the

nstrument panel and install the top cover by push-ng it down into place.

(15) Install the screw securing the left end of theop cover to the instrument panel.

AUTION: If there is any question as to whetherhe clockspring is in the centered position, thelock spring needs to be recentered before install-ng the steering wheel. If the clockspring is not cen-ered, it may be overextended, causing thelockspring to become inoperative.

(16) Center the clockspring using the followingrocedure:• Using your fingers, rotate the clockspring rotor

n the CLOCKWISE DIRECTION to the end of theravel. Do not apply excessive torque.

• From the end of travel, rotate the rotor two fullurns and an additional half turn in the counter-lockwise direction. (The wires should end up at theottom of the clockspring).

AUTION: Do not install the steering wheel ontohe shaft of the steering column by driving it ontohe shaft.

(17) Feed the clockspring wiring leads through theole in the steering wheel (Fig. 6). Align the steeringheel’s wide mounting spline with the steering col-mn shaft missing spline area and push the wheelnto the shaft. Make sure the clockspring squares upith the back of the wheel and does not bind.(18) Install the steering wheel retaining nut and

ighten it until the steering wheel is fully installedn shaft. Tighten the steering wheel retaining nut totorque of 61 N·m (45 ft. lbs.).(19) Connect the clockspring electrical leads to the

peed control switches and reinstall the switches onhe steering wheel (Fig. 6).

(20) Install the airbag electrical lead from thelockspring into the connector on the back of the air-

bag module (Fig. 6). Be sure electrical connector fromclockspring is securely latched into airbag moduleconnector.

(21) Connect the horn switch electrical lead to theconnector on the back of the airbag module (Fig. 6).

CAUTION: The fasteners originally used for the air-bag components are specifically designed for theairbag system. They must never be replaced withany substitutes. Anytime a new fastener is needed,replace it with only the correct fastener listed in theparts book.

(22) Install the airbag module into the center ofthe steering wheel. Align the airbag module mount-ing holes with the bolt holes in steering wheel (Fig.6). Install only the two original or identical replace-ment airbag module mounting screws. Tighten thetwo air bag module attaching bolts to a torque of 10N·m (90 in. lbs.).

(23) Install the airbag mounting screw trim capson the steering wheel rear cover (Fig. 7). One belongson each side of the steering wheel.

NOTE: When reconnecting the battery on a vehiclethat has had the airbag module removed, the fol-lowing procedure should be used.

(24) Reconnect the ground cable to the negativepost of the battery in the following manor:

• Connect a scan tool (DRBIIIt) to the data linkdiagnostic connector located below the steering col-umn.

• Turn the ignition key to the ON position. Exitthe vehicle with the scan tool leaving the scan toolharness plugged in.

• Ensuring that there are no occupants in thevehicle, connect the ground (-) cable to the negativepost of the battery.

• Using the scan tool, read and record any faultcodes. Refer to the DRIVER AND PASSENGER AIR-BAG SYSTEM diagnostic manual if any faults arefound.

• Erase any stored faults if there are no activefault codes. If a problem exists, the fault code willnot erase.

• Reach around the back of the steering wheel (infront of the instrument cluster) and turn the ignitionkey to OFF, then back ON while observing theinstrument cluster airbag lamp. It should go on forsix to eight seconds, then go out. This will indicatethat the airbag system is functioning normally. If air-bag warning lamp fails to light, blinks on and off, orgoes on and stays on, there is an airbag system mal-function. Refer to the BODY DIAGNOSTIC PROCE-DURES manual to diagnose the system malfunction.

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(25) Turn the key to OFF and remove the scan toolrom the vehicle.

(26) Test the operation of the horn, wipers and anyther functions that are steering column operated. Ifpplicable, reset the radio and the clock.(27) If the steering column is a tilt column, verify

he tilt mechanism operates properly.(28) Road test the vehicle to ensure proper opera-

ion of the steering system and the speed control sys-em.

TEERING COLUMN LOWER COUPLING


NSTALLATION in this section and in STEERINGEAR.

EMOVAL(1) Place the steering wheel in the STRAIGHT-HEAD position. Using a steering wheel holder, lock

he steering wheel in place to keep it from rotatingFig. 21). This keeps the clockspring in the properrientation.

(2) Inside the passenger compartment, remove theteering column coupling retainer pin, back off theinch bolt nut, and remove the steering column cou-ling pinch bolt (Fig. 22) (the pinch bolt nut is cagedo the coupling and is not removable). Separate thepper and lower steering column couplings.(3) Raise the vehicle. Refer to HOISTING in the

UBRICATION AND MAINTENANCE group in thiservice manual for the correct lifting procedure.

Fig. 21 Steering Wheel Holder1 – STEERING WHEEL2 – STEERING WHEEL HOLDER3 – DRIVERS SEAT

(4) Release the locking tab on the wiring harnessconnector for the power steering fluid pressureswitch before connector removal. Remove the wiringharness connector from the power steering fluid pres-sure switch (Fig. 23).

(5) Remove the bolt mounting the engine torquestrut to the right forward corner of the front suspen-sion crossmember (Fig. 24).


Fig. 23 Power Steering Fluid Pressure Switch1 – WIRING HARNESS CONNECTOR2 – POWER STEERING GEAR3 – POWER STEERING FLUID PRESSURE SWITCH4 – REAR OF FRONT SUSPENSION CROSSMEMBER

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OTE: Before removing the front suspensionrossmember from the vehicle, the location of therossmember must be scribed on the body of theehicle (Fig. 9). Do this so that the crossmemberan be relocated upon reinstallation against theody of vehicle in the same location as beforeemoval. If the front suspension crossmember isot reinstalled in exactly the same location asefore removal, the preset front wheel alignmentettings (caster and camber) will be lost.

(6) Using an awl, scribe a line (Fig. 25) markinghe location of where the front suspension crossmem-er is mounted against the body of the vehicle.

Fig. 24 Mounting Bolts1 – FRONT SUSPENSION CROSSMEMBER MOUNTING BOLTS2 – ENGINE TORQUE ISOLATOR STRUT MOUNTING BOLT3 – FRONT SUSPENSION CROSSMEMBER

Fig. 25 Marking Crossmember Location1 – SCRIBED LINE2 – FRONT SUSPENSION CROSSMEMBER3 – AWL4 – BODY

(7) Position a transmission jack under the centerof the front suspension crossmember and raise it tosupport the bottom of the crossmember.

(8) Loosen and completely remove the two frontbolts (one right and one left) attaching the front sus-pension crossmember to the frame rails of vehicle.The right side bolt can be viewed in the mountingbolt figure (Fig. 24). The left side bolt is located inthe same location on the other side of the vehicle.

(9) Loosen the two rear bolts (one right and oneleft) attaching the front suspension crossmember andlower control arms to the body of the vehicle untilthey release from the threaded tapping plates in thebody of the vehicle. Do not completely remove therear bolts because they are designed to disengagefrom the body threads yet stay within the lower con-trol arm rear isolator bushing. This allows the lowercontrol arm to stay in place on the crossmember. Theright side bolt can be viewed in the mounting boltfigure (Fig. 24). The left side bolt is located in thesame location on the other side of the vehicle.

CAUTION: Lower the steering gear slowly, payingspecial attention to the power steering fluid hosescoming down from the power steering pump. Donot strain or over extend the hoses coming to thegear. Damage to the hoses or connecting hardwarecould occur.

(10) Lower the front suspension crossmemberusing the transmission jack enough to allow suffi-cient access to the steering column lower coupling(Fig. 26). When lowering front suspension crossmem-ber, do not let crossmember hang from lower controlarms or power steering hoses. The weight should besupported by the transmission jack.

(11) Remove the roll pin securing the steering col-umn lower coupling to the power steering gear pinionshaft using a roll pin punch (Fig. 27). Push the steer-ing column lower coupling up and off of the powersteering gear pinion shaft.

INSTALLATION(1) Push the column end of the steering column

lower coupling partway up through its hole in thedash panel, then match the flat on the inside of thesteering column lower coupling to the flat on thepower steering gear pinion shaft and slide the cou-pling onto the top of the pinion shaft. Align the rollpin hole in the coupling with the groove in the pinionshaft and install the roll pin through the couplinguntil it is centered (Fig. 27).

(2) Center the power steering gear rack in itstravel.

(3) Using the transmission jack, raise the frontsuspension crossmember and power steering gearuntil the crossmember contacts its mounting spot

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gainst the body and frame rails of the vehicle. Ashe crossmember is raised, carefully guide the steer-ng column lower coupling up through its hole in theash panel.(4) Start the two rear crossmember mounting bolts

nto the tapping plates mounted in the body. Theight side bolt can be viewed in the mounting boltigure (Fig. 24). The left side bolt is located in theame location on the other side of the vehicle. Next,nstall the two front mounting bolts attaching frontuspension crossmember to frame rails of vehicle.ightly tighten all four mounting bolts to a approxi-

Fig. 26 Crossmember Lowered1 – STEERING COLUMN LOWER COUPLING2 – POWER STEERING GEAR3 – FRONT SUSPENSION CROSSMEMBER4 – TRANSMISSION JACK

Fig. 27 Coupling Roll Pin1 – STEERING COLUMN LOWER COUPLING2 – POWER STEERING GEAR PINION SHAFT3 – ROLL PIN4 – ROLL PIN PUNCH

mately 2 N·m (20 in. lbs.) to hold the front suspen-sion crossmember in position.

NOTE: When reinstalling the front suspensioncrossmember back in the vehicle, it is very impor-tant that the crossmember be attached to the bodyin exactly the same spot as when it was removed.Otherwise, the vehicle’s wheel alignment settings(caster and camber) will be lost.

(5) Using a soft face hammer, tap the front suspen-sion crossmember back-and-forth or side-to-side untilit is aligned with the previously scribed positioningmarks on the body of the vehicle (Fig. 25). Once thefront suspension crossmember is correctly positioned,tighten the rear two crossmember mounting bolts toa torque of 203 N·m (150 ft. lbs.), then tighten thefront two crossmember mounting bolts to a torque of142 N·m (105 ft. lbs.).

(6) Fasten the engine torque strut to the right for-ward corner of the front suspension crossmemberusing its mounting bolt (Fig. 24). Follow the proce-dure described in the ENGINE service manual groupto properly align and tighten the torque strut mount-ing bolts.

(7) Reconnect the wiring harness connector to thepower steering fluid pressure switch (Fig. 23). Besure the locking tab on the wiring harness connectoris securely latched.

(8) Lower the vehicle to ground level.(9) Install the dash-to-lower coupling seal in place

over the lower coupling’s plastic collar.

NOTE: Verify that grease is present on the lip ofthe dash-to-coupling seal where it contacts the cou-pling’s plastic collar.

(10) Inside the passenger compartment, reconnectthe steering column lower coupling to the steeringcolumn upper coupling (Fig. 22). Install the couplingpinch bolt an tighten the pinch bolt nut to a torque of28 N·m (250 in. lbs.). Install the pinch bolt retainerpin.

(11) Remove the steering wheel holder.(12) While looking under the instrument panel at

the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does notsqueak against the dash-to-coupling seal.

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PECIFICATIONS

TEERING COLUMN FASTENER TORQUEPECIFICATIONS

DESCRIPTION TORQUESTEERING WHEEL:

Retaining Nut . . . . . . . . . . . . 61 N·m (45 ft. lbs.)Airbag Mounting Screws . . . . 10 N·m (90 in. lbs.)Speed Control Switch Screws . 2 N·m (20 in. lbs.)

STEERING COLUMN:Mounting Nuts . . . . . . . . . . 17 N·m (150 in. lbs.)SKIM Mounting Screws . . . . . 3 N·m (25 in. lbs.)

STEERING COLUMN LOWER COUPLING:Pinch Bolt . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)

steering - ertyu.org · 2004. 9. 24. · steering column lower bearing spring retainer slipped on...

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