suspension CHRYSLER VOYAGER 2001 Manual PDF

NOTE: Power steering pump maximum relief pres-
sure is 9,653 to 10,342 kPa (1,400 to 1,500 psi.).
(9) Close analyzer valve fully three times and
record highest pressure indicated each time. All three
readings must be above specifications and within 345
kPa (50 psi) of each other.
²If power steering pump pressures are above
specifications, but not within 345 kPa (50 psi) of each
other, replace pump.
²If power steering pump pressures are within 345
kPa (50 psi) of each other, but are below specifica-
tions, replace pump.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time
because, pump damage will result.
(10) Completely open the valve on the Power
Steering Analyzer. Turn the steering wheel to theextreme left until the stop in the steering gear is
met, then turn the steering wheel to the right until
the right stop is met. Record the highest indicated
pressure at each position. Compare the recorded
readings to the specifications. If the highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover POWER STEERING NOISE, STEERING
WHEEL FEEL, and POWER STEERING FLUID.
POWER STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONABLE HISS
OR WHISTLE*1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.1. Reposition or replace steering
column shaft/coupling dash panel seal.
2. Noisy valve in power steering
gear.2. Replace power steering gear.
3. Mis-routed power steering hose. 3. Check routing of power steering
hoses. Ensure hoses do not come in
unwanted contact with other
components and objects.
RATTLE OR CLUNK 1. Power steering gear loose on front
suspension crossmember.1. Inspect power steering gear
mounting bolts. Replace as necessary.
Tighten to the specified torque.
2. Front suspension crossmember
mounting fasteners loose at frame.2. Tighten the front suspension
crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting bolts to
the specified torques.
5. Lower control arm pivot bushing
worn.5. Replace lower control arm pivot
bushing.
6. Loose strut assembly mounting
fasteners at tower.6. Tighten strut assembly fasteners to
the specified torque.
7. Power steering fluid pressure
hose touching the body of the
vehicle.7. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing.
RSSTEERING19-3
STEERING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
8. Internal power steering gear
noise.8. Replace power steering gear.
9. Damaged front suspension
crossmember.9. Replace front suspension
crossmember.
10. Stabilizer bar link ball joints
worn.10. Replace stabilizer bar link.
POPPING NOISE 1. Worn outer tie rod. 1. Replace outer tie rod.
CHIRP OR SQUEAL
(POWER STEERING
PUMP)1. Loose power steering pump drive
belt.1. Check and adjust power steering
pump drive belt to specifications or
replace automatic tensioner where
applicable. Replace belt if worn or
glazed.
WHINE, GROWL, MOAN
OR GROAN (POWER
STEERING PUMP)**1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level and check for leaks (make
sure all air is bled from the system
fluid).
2. Power steering hose touching
vehicle body or frame.2. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extreme wear of power steering
pump internal components.3. Replace power steering pump and
flush system as necessary.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid return hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power steering
hose connection.2. Inspect connection and replace
O-Ring as required.
3. Low power steering fluid level. 3. Fill power steering fluid reservoir to
proper level and check for leaks.
4. Air leak between power steering
fluid reservoir and power steering
pump.4. Replace power steering pump (with
reservoir).
SQUEAK OR RUBBING
SOUND1. Steering column shroud rubbing. 1. Realign shrouds as necessary.
2. Steering column shaft rubbing. 2. Move or realign item rubbing shaft.
3. Clockspring noisy. 3. Remove clockspring. Reinstall wheel.
If noise is gone, replace clockspring.
4. Steering gear internally noisy. 4. Replace steering gear.
SCRUBBING OR
KNOCKING NOISE.1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel
with size used as original equipment.
2. Interference between steering
gear and other vehicle components.2. Check for bent or misaligned
components and correct as necessary.
3. Steering gear internal stops worn
excessively allowing tires to be
steered excessively far.3. Replace steering gear.
19 - 4 STEERINGRS
STEERING (Continued)

WARNING: 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 compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
DIAGNOSIS AND TESTING
For diagnosis of conditions relating to the steering
column (Refer to 19 - STEERING - DIAGNOSIS AND
TESTING) and (Refer to 19 - STEERING - DIAGNO-
SIS AND TESTING).
REMOVAL
To service the steering wheel components or the
airbag (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL). Follow all WARN-
INGS AND CAUTIONS.
(1) Make sure the front wheels of the vehicle are
in the STRAIGHT AHEAD position before beginning
the column removal procedure.
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove the lower shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - REMOV-
AL).
(4) Remove the traction off switch.
(5) Remove the upper shroud.
(6) Remove the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).(7) Remove the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(8) Remove the parking brake handle link.
(9) Remove the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(10) Remove the airbag (Refer to 8 - ELECTRI-
CAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(11) Remove the steering wheel retaining nut.
(12) Remove the vibration damper weight.
(13) Remove the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
REMOVAL). (Fig. 3)
(14) Disconnect the wiring harness connectors
from the clockspring, multi-function switch, halo
lamp, SKIM module, ignition switch and BTSI sole-
noid.
(15) Disconnect the shift cable at the lever. (Fig. 4)
1 - CLOCKSPRING WIRING
2 - STEERING WHEEL
3 - UPPER SHROUD
4 - FIXED SHROUD
5 - SCREW
6 - STEERING COLUMN MOUNTING PLATE
7 - NUT
8 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
9 - STUDS 4
10 - STEERING COLUMN LOCKING PIN
11 - NUT/WASHER ASSEMBLY
12 - STEERING COLUMN ASSEMBLY
13 - LOWER SHROUD
14 - SCREWS
15 - STEERING WHEEL RETAINING NUT16 - STEERING WHEEL DAMPER
17 - CLOCKSPRING
18 - SCREW
19 - MULTI-FUNCTION SWITCH MOUNTING/HOUSING
20 - PINCH BOLT
21 - STEERING COLUMN COUPLER
22 - PINCH BOLT RETAINING PIN
23 - DASH PANEL
24 - SILENCER SHELL
25 - INTERMEDIATE SHAFT SHIELD AND SEAL
26 - INTERMEDIATE SHAFT
27 - ROLL PIN
28 - STEERING GEAR
29 - FRONT SUSPENSION CRADLE
Fig. 3 STEERING WHEEL REMOVAL
1 - STEERING WHEEL
2 - PULLER
19 - 12 COLUMNRS
COLUMN (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION...........................17
OPERATION.............................17
CAUTION...............................18
REMOVAL..............................18INSTALLATION...........................20
SPECIAL TOOLS.........................21
OUTER TIE ROD END
REMOVAL..............................22
INSTALLATION...........................22
GEAR
DESCRIPTION
This vehicle is equipped with a rack and pinion
power steering gear (Fig. 1). It is mounted to the
underside of the front suspension cradle/crossmem-
ber.
The steering column is attached to the gear
through the use of an intermediate shaft and cou-
plers. The outer ends of the power steering gear's
outer tie rods connect to the steering knuckles.NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced. Only the outer tie rod ends may be
replaced.
OPERATION
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth in the steer-
Fig. 1 Power Steering Gear (Typical)
1 - OUTER TIE ROD JAM NUT
2 - INNER TIE ROD
3 - STEERING GEAR MOUNTING BRACKET
4 - POWER STEERING GEAR FLUID LINES
5 - STEERING GEAR TO STEERING COLUMN INTERMEDIATE
COUPLER
6 - INNER TIE ROD7 - TIE ROD END
8 - OUTER TIE ROD JAM NUT
9 - STEERING GEAR BOOT
10 - STEERING GEAR BOOT BREATHER TUBE
11 - STEERING GEAR BOOT
12 - TIE ROD END
RSGEAR19-17

ing gear. This travel pushes and pulls the tie rods to
change the direction of the vehicle's front wheels.
Power assist steering provided by the power steer-
ing pump is controlled by an open center, rotary type
control valve which directs oil from the pump to
either side of the integral rack piston upon demand.
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.
Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
SERVICE WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND 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.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
REMOVAL - GEAR
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.
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much 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. 2).(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 front wheel and tire assemblies.
(7) Remove hoses at power steering cooler and
allow fluid to drain.
(8) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 3).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(9) Remove both tie rod ends from steering knuck-
les, using Puller, Special Tool C-3894±A (Fig. 4).
(10) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(11) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 5). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(12) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
Fig. 2 Steering Column Shaft To Intermediate Shaft
Attachment
1 - STEERING COLUMN SHAFT COUPLER
2 - NUT
3 - SAFETY PIN
4 - INTERMEDIATE SHAFT
5 - PINCH BOLT
19 - 18 GEARRS
GEAR (Continued)

(13) Using a crowfoot wrench, remove the power
steering fluid pressure and return lines (Fig. 6) from
the power steering gear.(14) Remove the 3 bolts and nuts (Fig. 7) mount-
ing the steering gear to the front suspension cradle.
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. 8). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 8). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(16) Separate the coupler from the shaft of the
steering gear.
Fig. 3 Removing/Installing Tie Rod End Attaching Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 4 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 5 CRADLE CROSSMEMBER REINFORCEMENT
ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
RSGEAR19-19
GEAR (Continued)

(17) Remove the steering gear assembly from the
vehicle.
INSTALLATION - GEAR
(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 itinto 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. 9). Hold threaded rod station-
ary while turning nut, this will pull the roll pin into
the intermediate coupler.
Fig. 6 Power Steering Fluid Pressure And Return
Hoses At Steering Gear
1 - CROWFOOT
2 - POWER STEERING FLUID PRESSURE LINE
3 - FRONT SUSPENSION CRADLE
4 - STEERING GEAR
5 - POWER STEERING FLUID RETURN LINE
Fig. 7 Steering Gear Mounting To Suspension Cradle
1 - STEERING GEAR
2 - MOUNTING BOLTS
3 - MOUNTING BOLT
4 - FRONT SUSPENSION CRADLE
Fig. 8 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
Fig. 9 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - SUSPENSION CRADLE
3 - KNURLED NUT
4 - ROLL PIN
5 - STEERING GEAR
19 - 20 GEARRS
GEAR (Continued)

(4) Install steering gear assembly on the front sus-
pension cradle. Install the 3 steering gear mounting
bolts and nuts (Fig. 7).
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. 6) 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 socket (Fig. 3), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 10), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(8) If the vehicle is equipped with All-Wheel-Drive,
install the power transfer unit (Refer to 21 - TRANS-
MISSION/TRANSAXLE/POWER TRANSFER UNIT -
INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.(9) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 5). Tighten the M-14 size bolts to a torque of
163 N´m (120 ft. lbs.). Tighten the M-12 size bolts to
a torque of 108 N´m (80 ft. lbs.).
(10) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten bolts to
a torque of 61 N´m (45 ft. lbs.).
(11) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 5). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(12) Install the power steering cooler hoses on the
cooler inlet and outlet tubes. Install the clamps.
(13) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 135
N´m (100 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 onto the steering gear intermediate
coupler (Fig. 2). Install steering column coupler to
intermediate shaft retaining pinch bolt. Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).
(16) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(17) Inspect for leaks.
(18) Adjust front toe (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).
SPECIAL TOOLS
POWER STEERING GEARFig. 10 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
Puller C-3894A
RSGEAR19-21
GEAR (Continued)

end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 12). Then using a crow-
foot and 11/32 socket (Fig. 14), torque tie rod end
attaching nut to 54 N´m (40 ft. lbs.).(4) Tighten tie rod jam nut (Fig. 11) to 55 N´m (75
ft. lbs.) torque.
CAUTION: During this procedure do not allow the
steering gear boot to become twisted.
(5) Adjust the front toe setting on the vehicle
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 14 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
RSGEAR19-23
OUTER TIE ROD END (Continued)

(5) Loosen (do not remove) the pump bracket thru-
bolt (#3 in figure) (Fig. 9).
(6) Remove the pressure hose routing bracket bolt
(Fig. 10).
(7) lower the vehicle.
(8) Remove cap from power steering fluid reser-
voir.
(9) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(10) Disconnect the fluid supply hose from the
pump (Fig. 11)(11) Disconnect the pressure hose from the pump
(Fig. 11)
(12) Remove the mounting bolt from the rear of
the pump using care not to lose the spacer between
the pump and bracket (Fig. 9).
(13) Remove the three front mounting bolts
through the pulley (Fig. 9)
(14) Remove the pump through the engine com-
partment rocking it over the aluminum bracket.
Fig. 6 Power Steering Fluid Pressure And Return
Hose
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 7 Power Steering Pump Attaching Nut
1 - POWER STEERING PUMP MOUNTING BRACKET
2 - FRONT SUSPENSION CRADLE
3 - POWER STEERING PUMP
4 - NUT
Fig. 8 PUMP FRONT MOUNTING
1 - NUT
2 - BOLT
3 - PUMP
Fig. 9 PUMP MOUNTING
1 - REAR PUMP BOLT
2 - PUMP MOUNTING BOLT
3 - BRACKET THRU BOLT
4 - PUMP BELT PULLEY
5 - POWER STEERING PUMP
6 - BRACKET
RSPUMP19-27
PUMP (Continued)