CHRYSLER VOYAGER 1996 Service Manual

SPECIAL TOOLS
POWER STEERING PUMP
Installer C-4063B
Puller C-4333
P/S System Analyzer 6815
NSSTEERING 19 - 25

POWER STEERING GEAR
INDEX
page page
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION . 26
DIAGNOSIS AND TESTING
POWER STEERING GEAR................. 27
REMOVAL AND INSTALLATION
STEERING GEAR....................... 27
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD END................... 33STEERING GEAR INNER TIE ROD BOOT..... 31
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS...................... 34
SPECIAL TOOLS
POWER STEERING GEAR................. 35
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION
NOTE: The power steering gear (Fig. 1) should NOT
be serviced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced.
If a steering gear boot needs to be replaced due to
damage, refer to the power steering gear service sec-
tion in this manual for proper procedure.
The power steering system consists of these four
major components. Power Steering Gear, Power
Steering Pump, Pressure Hose, and Return Line.Turning of the steering wheel is converted into linear
travel through the meshing of the helical pinion
teeth with the rack teeth. Power assist steering is
provided by an open center, rotary type control valve
which directs oil from the pump to either side of the
integral rack piston.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This move-
ment directs oil behind the integral rack piston,
which, in turn, builds up hydraulic pressure and
assists in the turning effort.
Fig. 1 Power Steering Gear Assembly
19 - 26 STEERINGNS

The drive tangs on the pinion mate loosely with a
stub shaft to permit manual steering control to be
maintained if the drive belt on the power steering
pump should break. However, under these conditions,
steering effort will be increased.
DIAGNOSIS AND TESTING
POWER STEERING GEAR
The following procedure can be used to test the
operation of the power steering system on this vehi-
cle. This test will provide the flow rate for the power
steering system along with the maximum relief pres-
sure of the power steering pump. This test is to be
performed any time a power steering system problem
is present to determine if the power steering pump or
power steering gear is not functioning properly. The
following pressure and flow test is performed using
Pressure/Flow Tester, Special Tool 6815 (Fig. 2).
POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE
(1) Check power steering pump drive belt tension
and adjust as necessary.
(2) Disconnect power steering fluid pressure hose,
at power steering pump. Use a container for dripping
fluid.
(3) Connect Pressure Gauge, Special Tool from kit
6815 to both hoses using adapter fittings. Connect
spare pressure hose, to power steering pump pres-
sure hose fitting.
(4) Completely open valve on Special Tool 6815.
(5) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test
and get air out of fluid. Then shut off engine.
(6) Check power steering fluid level, and add fluid
as necessary. Start engine again and let idle.
(7) Pressure gauge should read below 862 kPa
(125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure readingshould be in the range of 345-552 kPa (50-80 psi).
The flow meter should read between 1.3 and 1.9
GPM
CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.
(8) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be within the specifications and
within 345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres-
sure is 9653 to 10342 kPa (1400 to 1500 psi.).
²If power steering pump pressures are within
specifications but not within 345 kPa (50 psi) of each
other, then replace power steering pump.
²If pressures are within 345 kPa (50 psi) of each
other but below specifications, then replace power
steering pump.
CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test valve. Turn steering wheel to the
extreme left and right positions until against the
stops, recording the highest indicated pressure at
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.REMOVAL AND INSTALLATION
STEERING GEAR
NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear assembly must
be replaced.
REMOVE
CAUTION: Positioning the steering column in the
locked position will prevent the clockspring from
being accidentally over-extended when the steering
column is disconnected from the intermediate
steering coupler.
Fig. 2 Power Steering Pump Flow/Pressure Tester
NSSTEERING 19 - 27
DESCRIPTION AND OPERATION (Continued)

(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 3).
(5) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(6) Remove the front tires.
(7) Raise the heat sleeve (Fig. 4) on the power
steering return hose to expose the return hose to
steel tube connection. Remove the return hose from
the metal tube of the power steering fluid return line
(Fig. 4). Then allow the remaining power steering
fluid to drain from the system through the hose and
metal tube.
(8) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 5).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(9) Remove both tie rod ends from steering knuck-
les, using Puller Special Tool MB-990635 or
MB-991113 (Fig. 6).
Fig. 3 Steering Column Shaft To Intermediate Shaft
Attachment
Fig. 4 Power Steering Fluid Return Hose
Connection
Fig. 5 Removing/Installing Tie Rod End Attaching
Nut
Fig. 6 Tie Rod End Removal From Steering Knuckle
19 - 28 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(10) Remove the 2 bolts and loosen the third (Fig.
7) attaching the antilock brakes hydraulic control
unit (HCU) to the front suspension cradle. Then
rotate the HCU rearward to allow access to the cra-
dle plate attaching nut and bolt just forward of the
HCU.
(11) Remove the 10 nuts and bolts (Fig. 8) attach-
ing the cradle plate to the bottom of the front sus-
pension cradle. Then remove the cradle plate from
the cradle.
(12) Remove the bracket (Fig. 9) attaching the
power steering fluid tubes to the front suspension
cradle.
(13) Using a 18mm crowfoot, (Fig. 10) remove the
power steering fluid pressure and return lines (Fig.
10) from the power steering gear.
(14) Remove the 3 bolts and nuts (Fig. 11) mount-
ing the steering gear to the front suspension cradle.
Fig. 7 HCU Bracket Attaching Bolts
Fig. 8 Front Suspension Cradle Plate And Attaching
Bolts
Fig. 9 Power Steering Tube Bracket
Fig. 10 Power Steering Fluid Pressure And Return
Hoses At Steering Gear
Fig. 11 Steering Gear Mounting To Suspension
Cradle
NSSTEERING 19 - 29
REMOVAL AND INSTALLATION (Continued)

NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(15) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 12). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 12). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(16) Separate the intermediate coupler from the
shaft of the steering gear.
(17) Remove the steering gear assembly from the
front suspension cradle.
INSTALL
(1) Install the steering gear up in the front sus-
pension cradle, leaving room to install intermediate
coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 13). Hold threaded rod station-
ary while turning nut, this will pull the roll pin into
the intermediate coupler.
(4) Install steering gear assembly on the front sus-
pension cradle. Install the 3 steering gear to front
suspension cradle mounting bolts and nuts (Fig. 11).CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Tighten the 3 steering gear to suspension cra-
dle mounting bolts to a torque of 183 N´m (135 ft.
lbs.).
(6) Attach the power steering fluid pressure and
return lines (Fig. 10) to the proper fittings on the
steering gear. Tighten the power steering fluid line
tube nuts to a torque of 31 N´m (275 in. lbs.).
(7) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod end
stationary using a 11/32 socket, (Fig. 5) tighten tie
rod end to steering knuckle attaching nut. Then
using a crowfoot and 11/32 socket (Fig. 14), tighten
the tie rod end attaching nut to a torque of 54 N´m
(40 ft. lbs.).
Fig. 12 Removing Roll Pin From Intermediate
Coupler
Fig. 13 Installing Roll Pin In Intermediate Coupler
Fig. 14 Torquing Tie Rod End Attaching Nut
19 - 30 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Proper torque on the cradle plate to
suspension cradle mounting bolts is very impor-
tant.
(8) Install cradle plate on front suspension cradle
and install the 10 cradle plate to cradle attaching
bolts and nuts (Fig. 8). Tighten all attaching bolts to
a torque of 165 N´m (123 ft. lbs.).
(9) Install the bracket (Fig. 9) attaching the power
steering fluid tubes to the front suspension cradle.
CAUTION:
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 4).
(11) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamp is installed on return tube past the upset
bead on the tube.Tighten the screw clamp to a
torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 4). This is required
to prevent the power steering hoses from being
overheated.
(12) When used, properly position the protective
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(13) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 129
N´m (95 ft. lbs.).
(14) Lower the vehicle to a level were the interior
of vehicle is accessible.
(15) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering column
shaft coupler (Fig. 3) onto the steering gear interme-
diate coupler. Install steering column coupler to
intermediate shaft retaining pinch bolt (Fig. 3).
Tighten the pinch bolt nut to a torque of 28 N´m (250
in. lbs.).
CAUTION: Do not use automatic transmission fluid
in the power steering system. Only use Mopar,
Power Steering Fluid or an exact equivalent prod-
uct.
(16) Fill power steering pump fluid reservoir to the
proper level.
(17) Start the engine and let run for a few seconds.
Then turn the engine off.(18) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(19) Raise front wheels of vehicle off the ground.
(20) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops. Then turn the engine off.
(21) Add power steering fluid if necessary.
(22) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(23) Stop the engine. Check the fluid level and
refill as required.
(24) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(25) Fill power steering reservoir to correct level
with Mopart, Power Steering Fluid, or equivalent.
(26) Adjust toe (Refer to Group 2 Suspension).
DISASSEMBLY AND ASSEMBLY
STEERING GEAR INNER TIE ROD BOOT
DISASSEMBLE
NOTE: The removal and installation of the inner tie
rod boot must be performed with the steering gear
assembly removed from the vehicle.
(1) Loosen the inner to outer tie rod jam nut (Fig.
15). Remove the outer tie rod from the inner tie rod.
(2) Remove nut attaching the outer tie rod end to
the steering knuckle (Fig. 16).Nut is to be
removed from tie rod end using the following
procedure, hold tie rod end stud with an 11/32
socket, while loosening and removing nut with
wrench.
Fig. 15 Inner To Outer Tie Rod Jam Nut
NSSTEERING 19 - 31
REMOVAL AND INSTALLATION (Continued)

(3) Remove the tie rod end from the steering
knuckle using Remover, Special Tool MB-991113 (Fig.
17) or MB-990635.
(4) Remove jam nut (Fig. 15) from inner tie rod.
(5) Using pliers expand tie rod boot, to inner tie
rod clamp (Fig. 18) and remove from steering gear
boot.
(6) Remove inner tie rod boot to steering gear
clamp (Fig. 19).
NOTE: After removing inner boot clamps. Use a
very small screwdriver to lift boot from its retaining
groove in steering gear. Then the boot can be
removed from steering gear.
ASSEMBLE
(1) Install tie rod boot to steering gear clamp on
tie rod boot.
(2) Install tie rod boot and clamp on inner tie rod.
(3) Install tie rod boot over steering gear housing
and onto the end of the breather tube (Fig. 19).
(4) Crimp inner tie rod boot to steering gear clamp
using Crimper, Special Tool C4975A (Fig. 20). When
installing clamp, Special Tool C4975A must have bot-
tom bolt tightened until their is no gap between the
2 bars of the tool (Fig. 20)
(5) Lubricate inner tie rod boot groove with sili-
cone type lubricant, then install outer boot seal to
inner tie rod clamp (Fig. 18). (Clamp will have to be
loosened for toe adjustment.)
(6) Install inner to outer tie rod jam nut (Fig. 15)
on inner tie rod.
(7) Install outer tie rod on inner tie rod. Do not
tighten jam nut.
(8) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
Fig. 16 Removing Tie Rod End Attaching Nut
Fig. 17 Tie Rod End Removal From Steering
Knuckle
Fig. 18 Tie Rod Boot To Tie Rod Clamp
Fig. 19 Tie Rod Boot To Steering Gear Clamp
19 - 32 STEERINGNS
DISASSEMBLY AND ASSEMBLY (Continued)

end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 17). Then using a crow-
foot and 11/32 socket (Fig. 21), torque tie rod end
attaching nut to 54 N´m (40 ft. lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(9) Make toe adjustment by turning inner tie rod.
(10) Tighten the inner to outer tie rod jam nut to
75 N´m (55 ft. lbs.) torque. Lubricate tie rod boot
groove with silicone type lubricant, before installing
outer boot clamp, making sure boot is not twisted.
OUTER TIE ROD END
DISASSEMBLE
(1) Loosen inner tie rod to outer tie rod jam nut
(Fig. 22).
(2) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 23).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(3) Remove the tie rod end stud from steering
knuckle arm, using Remover, Special Tool,
MB-991113 (Fig. 24) or MB-990635.
(4) Remove outer tie rod end from inner tie rod by
un-threading it from the inner tie rod.
Fig. 20 Installing Tie Rod Boot To Steering Gear
Clamp
Fig. 21 Torquing Tie Rod End Attaching Nut
Fig. 22 Inner To Outer Tie Rod Jam Nut
Fig. 23 Tie Rod End Attaching Nut
NSSTEERING 19 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLE
(1) Install outer tie rod onto inner tie rod.Make
sure jam nut (Fig. 22) is on inner tie rod.
(2) Do not tighten jam nut.
(3) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 23). Then using a crow-
foot and 11/32 socket (Fig. 25), torque tie rod end
attaching nut to 54 N´m (40 ft. lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(4) Adjust the front Toe setting on the vehicle.
Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
manual. Refer to the Specifications Section at the
end of this group for the desired front Toe specifica-
tion.
(5) Tighten tie rod jam nut (Fig. 22) to 55 N´m (75
ft. lbs.) torque.(6) Adjust the steering gear to inner tie rod boots
at inner tie rod if they became twisted during Toe
adjustment.
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STEERING GEAR:
To Suspension Cradle Bolts. . . .183 N´m (135 ft. lbs.)
Tie Rod To Steering
Knuckle Nut...............54N´m(40ft.lbs.)
Outer To Inner Tie Rod
JamNut..................75N´m(55ft.lbs.)
Power Steering Hose
Tube Nuts...............31N´m(275 in. lbs.)
Coupler Pinch Bolt...........28N´m(250 in. lbs.)
SUSPENSION CRADLE:
Cradle Plate To Cradle
Attaching Bolts...........165 N´m (123 ft. lbs.)
Fig. 24 Tie Rod End Removal From Steering
KnuckleFig. 25 Torquing Tie Rod End Attaching Nut
19 - 34 STEERINGNS
DISASSEMBLY AND ASSEMBLY (Continued)