wheel CHRYSLER VOYAGER 1996 Service Manual

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)

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)

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)

STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION......... 36
DIAGNOSIS AND TESTING
STEERING COLUMN..................... 38
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS........................... 38REMOVAL AND INSTALLATION
STEERING COLUMN ASSEMBLY............ 38
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS...................... 45
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION
The steering column (Fig. 1) has been designed to
be serviced only as a complete assembly, if a compo-
nent of the steering column is defective. The only
replaceable components of the steering columnassembly are the key cylinder, ignition switch, multi-
function switch, clockspring, halo lamp, speed control
switches, driver airbag, trim shrouds and steering
wheel. These replaceable components of the steering
column can be serviced without requiring removal of
the steering column from the vehicle.
Fig. 1 Steering Column Assembly Components
19 - 36 STEERINGNS

DIAGNOSIS AND TESTING
STEERING COLUMN
For diagnosis of conditions relating to the steering
column, refer to the steering system diagnosis charts,
in the diagnosis and testing section at the beginning
of this group.
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE 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 IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
NOTE: Safety goggles should be worn at all times
when working on steering columns.
CAUTION: Disconnect negative (ground) cable
from the battery, before servicing any column com-
ponent.CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
REMOVAL AND INSTALLATION
STEERING COLUMN ASSEMBLY
To service the steering wheel and its components
or the air bag, refer to Group 8M, Restraint Systems.
Follow all WARNINGS.
To service the switches, refer to the appropriate
section of Group 8, Electrical.
To replace the steering column assembly, refer to
the steering column removal procedure.
REMOVE
(1) Make sure the front wheels of the vehicle are
in thestraight aheadposition before beginning the
column removal procedure.
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove the screws attaching the lower steer-
ing column cover to the instrument panel (Fig. 2).
Remove the lower trim panel from the lower instru-
ment panel.
(4) Remove the park brake pedal release cable
from the park brake release lever (Fig. 3).
(5) Remove the 10 bolts attaching the steering col-
umn cover liner (Fig. 4) to the instrument panel.
Remove the steering column cover liner from the
lower instrument panel.
(6) Rotate key cylinder to the lock position and
remove key. Rotate the steering wheel a half turn to
the left until the steering column lock engages keep-
ing the steering column in the locked position (Fig.
5).
Fig. 2 Lower Steering Column Cover Attachment
Locations
19 - 38 STEERINGNS

(7) Remove the 3 bolts (1 in each spoke of the
steering wheel) attaching the air bag module to thesteering wheel. Remove air bag module from steering
wheel.
(8) Remove wiring harness connectors from air
bag, horn switch wire, and speed control switches
(Fig. 6). Remove the wiring harness routing clip (Fig.
6) from the air bag module studs.
(9) Remove the steering wheel retaining nut (Fig.
7) from the steering column shaft.
(10) Remove the steering wheel damper (Fig. 7)
from the steering wheel.
CAUTION: Do not bump or hammer on steering
column or steering column shaft when removing
steering wheel from steering column shaft.
Fig. 3 Park Brake Release Cable Attachment To
Release Lever
Fig. 4 Lower Steering Column Cover Attachment
Fig. 5 Steering Wheel In Locked Position
Fig. 6 Air Bag Module Wiring Connections
Fig. 7 Steering Wheel Retaining Nut
NSSTEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)

CAUTION: When installing steering wheel puller
bolts in steering wheel, (Fig. 8) do not thread bolt
into steering wheel more than a half inch. If bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(11) Remove the steering wheel from steering col-
umn shaft using Puller, Special Tool, Snap-On
CJ2001JP or an equivalent (Fig. 8).
CAUTION: The upper and lower steering column
shrouds are held together using retaining clips.
When separating and removing the shrouds from
the steering column be careful not to break the
retaining clips off the shrouds
(12) Remove the 3 screws (Fig. 9) attaching the
upper and lower shrouds to the steering column.
Then remove the upper and lower shrouds (Fig. 9)
from the steering column.(13) Remove the vehicle wiring harness connectors
(Fig. 10) from the clock spring assembly.
CAUTION: Do not rotate the clock spring after it is
removed from the multifunction switch.
(14) Remove the clock spring from the multi-func-
tion switch.
(15) Remove the vehicle wiring harness connector
from the top of the multi-function switch (Fig. 11).
(16) Remove the screw (Fig. 12) attaching the
multi-function switch housing to the tilt head of the
steering column assembly.
(17) Remove the multi-function switch (Fig. 12)
from the tilt head of the steering column assembly.
(18) Remove the vehicle wiring harness connector
from the key cylinder halo light (Fig. 13).
(19) Remove the 3 wiring harness connectors from
the ignition switch (Fig. 14).
Fig. 8 Removing Steering Wheel From Steering
Column Shaft
Fig. 9 Steering Column Shrouds
Fig. 10 Wiring Harness Connections To Clock
Spring
Fig. 11 Wiring Harness Connection To Multi-
Function Switch
19 - 40 STEERINGNS
REMOVAL AND INSTALLATION (Continued)