shaft CHRYSLER VOYAGER 1996 Service Manual

LOOSE STEERING
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE STEERING WHEEL
KICKBACK OR TOO MUCH
STEERING WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Fill power steering fluid reservoir
to the specified level. Perform
procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front
suspension crossmember.2. Check steering gear to front
suspension crossmember mounting
bolt torque. Tighten to specified
torque if found to be loose.
3. Worn, broken or loose steering
column to steering gear coupler.3. Check for worn universal joint,
broken isolator or loose fasteners.
4. Free play in steering column. 4.Check components of steering
system and repair or replace as
required. Note: Inspect steering
column with steering wheel installed
and steering column shaft
disconnected from intermediate
coupler. Verify that steering wheel
attaching nut is tightened to the
specified torque. Verify that the 4
mounting nuts for the steering
column are tightened to the specified
torque.
5. Loose lower control arm ball joint. 5. Check and or replace the ball joint
or control arm as required.
6. Loose steering knuckle to lower
ball joint stud attaching nut.6. Check attaching nut and tighten if
required to specified torque.
7. Front wheel bearings loose or
worn.7. Tighten hub nut to specified
torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10. Defective steering gear rotary
valve.10. Replace steering gear assembly.
11. Intermediate steering shaft
coupler flex joint binding.11. Replace intermediate steering
shaft/coupler.
19 - 6 STEERINGNS
DIAGNOSIS AND TESTING (Continued)

VEHICLE LEADS TO THE SIDE
POWER STEERING FLUID LEAK
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT
WANT RETURN TO CENTER
POSITION.1. Radial tire lead. 1.Rotate tires as recommended in
the Tire And Wheel Group of this
service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
4. Unbalanced steering gear valve.
(If this is the cause, the steering
efforts will be very light in direction
of lead and heavier in the opposite
direction.4. Replace steering gear.
STEERING WHEEL HAS FORE
AND AFT LOOSENESS.1. Steering wheel to steering column
shaft retaining nut not properly
tightened and torqued.1. Tighten the retaining nut to its
specified torque specification.
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.2. Replace steering column.
3. Loose steering column to
instrument panel mounting nuts.3. Verify that the 4 mounting nuts for
the steering column are tightened to
the specified torque.
4. Binding intermediate steering
shaft coupler.4. Disconnect intermediate steering
coupler and see if looseness no
longer exists. If yes replace
intermendiate steering coupler.
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH: NO
VISIBLE SIGNS OF A LEAK ON
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.1. Overfilled power steering pump
fluid reservoir.1. Adjust the power steering fluid fill
to the correct level.
LOW FLUID LEVEL WITH:
VISIBLE LEAK ON STEERING
GEAR, POWER STEERING
PUMP, FLOOR OR ANYWHERE
ELSE.2. Power steering hose connections
at the power steering pump or
steering gear.2. Check for loose fittings and if
found, tighten the fitting to its
specified torque. If fittings are tight
examine the fittings for damaged or
missing O-ring seals and replace as
required.
3. Power steering pump or power
steering gear leaking.3. Identify the location of the leak
and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.
NSSTEERING 19 - 7
DIAGNOSIS AND TESTING (Continued)

DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP PULLEY
DISASSEMBLY
(1) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 or C-4068 (Fig.
33).
CAUTION: Do not hammer on power steering
pump pulley. This will damage the pulley and the
power steering pump.
(2) Replace pulley if it is found to be bent, cracked,
or loose.
ASSEMBLY
(1) Install the pulley with Installer C-4063 (Fig.
34). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.(3) Force pulley flush with the end of the power
steering pump shaft (Fig. 35).
(4) With serpentine belts, run engine until warm
(5 min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.).Be
careful that pulley does not contact mounting
bolts.
POWER STEERING PUMP FLOW CONTROL VALVE
SEAL
DISASSEMBLE
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(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) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the heat sleeve (Fig. 36) on the power
steering return hose to expose the return hose to
steel tube connection. Remove hose clamp from
power steering fluid return hose (Fig. 36). Remove
power steering return hose from steel tube and allow
remaining power steering fluid to drain from power
steering pump and reservoir.
(5) Remove the power steering fluid pressure line
from the power steering pump pressure fitting (Fig.
37). Drain excess power steering fluid from hose.
Fig. 33 Pulley Removal
Fig. 34 Pulley Installation
Fig. 35 Pulley To Pump Shaft Location
NSSTEERING 19 - 23

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)

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)

SPECIAL TOOLS
POWER STEERING GEAR
Remover Tie Rod End MB±991113
Remover/Installer Steering Shaft Roll Pin 6831A
P/S System Analyzer 6815
Installer Boot Clamp C-4975A
NSSTEERING 19 - 35

(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)