Steering CHRYSLER VOYAGER 2005 Service Manual

(6) Remove ignition switch mounting screw (Fig.
25) with a #10 Torxttamper proof bit.
(7) Depress retaining tab (Fig. 21) or (Fig. 26) and
gently pry ignition switch from steering column (Fig.
27).
(8) Disconnect electrical connectors from ignition
switch and remove switch (Fig. 28).
INSTALLATION
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig.
20). For ignition switch terminal and circuit identifi-
cation, refer to the Wiring Diagrams section.
(1) Ensure the ignition switch is in the RUN posi-
tion and the actuator shaft in the lock housing is in
the RUN position.(2) Install electrical connectors to ignition switch.
(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 29).
Install mounting screw (Fig. 25).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
Fig. 25 Ignition Switch Mounting Screw
1 - MOUNTING SCREW
2 - IGNITION SWITCH
Fig. 26 Ignition Switch Retaining Tab
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 27 Removing Ignition Switch
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 28 Ignition Switch Connectors
1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
RSCOLUMN19-19
IGNITION SWITCH (Continued)

(6) Connect negative cable to battery.
(7) Check for proper operation of ignition switch
and key-in warning switch.
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 30) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining
screws.
(3) Remove screws holding steering column
shrouds and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab on the bottom of the lock
housing and remove key cylinder.
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 31).
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing.
(4) Turn the key to the Off position. Remove the
key.
(5) Install lower steering column shroud.
(6) Install steering column cover.
(7) Connect negative cable to battery.
Fig. 29 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 30 Ignition Lock Cylinder Detents
Fig. 31 Socket in Lock Cylinder Housing
1 - LOCK CYLINDER HOUSING
2 - SOCKET
19 - 20 COLUMNRS
IGNITION SWITCH (Continued)

SHROUD - LOWER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws fastening the upper to lower shrouds (Fig.
32).
(2) Using hands on each side of the column, gently
press inward at seams between the two shrouds at
points of contact to disengage inner locking tabs.(3) Remove the lower shroud-to-column mounting
screw (Fig. 33).
(4) If equipped with adjustable pedals, disconnect
the wiring connector for the switch (Fig. 34).
(5) Remove the lower shroud from the steering col-
umn.
(6) If equipped with adjustable pedals, depress the
retaining tabs on the switch and remove the switch
from the lower shroud (Fig. 34).
INSTALLATION
(1) If the vehicle is equipped with adjustable ped-
als:
(a) Pass the wiring through the mounting hole
and install the switch into the lower shroud (Fig.
34), snapping it into place.
(b) Connect the switch wiring connector to the
column wiring harness.
(2) Position the lower shroud under the steering
column and install the lower shroud-to-column
mounting screw (Fig. 33). Tighten the screw to 2 N´m
(17 in. lbs.) torque.
(3) Align the upper shroud with the lower, then
snap shrouds together at locking tab locations on
both sides of column.
(4) Install the two shroud-to-shroud mounting
screws (Fig. 32). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(5) Inspect shroud mating surfaces for excessive
gaps and correct as necessary.
(6) Check operation of any previously disconnected
switches.
Fig. 32 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
Fig. 33 Lower Shroud Mounting
1 - STEERING COLUMN
2 - LOWER SHROUD
3 - MOUNTING SCREW
Fig. 34 Adjustable Pedals Switch Mounting
1 - LOWER SHROUD
2 - ADJUSTABLE PEDALS SWITCH
3 - WIRING CONNECTOR
RSCOLUMN19-21

SHROUD - UPPER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws fastening the upper to lower shrouds (Fig.
35).
(2) Using hands on each side of the column, gently
press inward at seams between the two shrouds at
points of contact to disengage inner locking tabs.(3) If the vehicle is equipped with traction control,
remove the lower shroud-to-column mounting screw
(Fig. 36).
(4) If the vehicle is equipped with traction control,
disconnect the switch wiring connector from the col-
umn wiring harness (Fig. 37).
(5) If the vehicle is equipped with power foldaway
mirrors (Export), disconnect wiring connector at mir-
ror switch pig tail.
(6) Remove the upper shroud from the steering col-
umn.
(7) If the vehicle is equipped with traction control,
remove the switch wiring from the routing clip
attached to the upper shroud (Fig. 38).
(8) If the vehicle is equipped with traction control,
remove the traction control switch from the upper
shroud (Fig. 39).
(9) If the vehicle is equipped with power foldaway
mirrors (Export), remove power foldaway switch from
upper shroud.
INSTALLATION
(1) If the vehicle is equipped with power foldaway
mirrors (Export), install the power foldaway switch
in the upper shroud.
(2) If vehicle is equipped with traction control,
install the traction control switch in the upper
shroud (Fig. 39).
(3) If the vehicle is equipped with traction control,
attach the switch wiring to the routing clip attached
to the upper shroud (Fig. 38).
Fig. 35 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
Fig. 36 Lower Shroud Mounting
1 - STEERING COLUMN
2 - LOWER SHROUD
3 - MOUNTING SCREW
Fig. 37 Traction Control And Autostick Wiring
Connections
1 - TRACTION CONTROL WIRING CONNECTOR
2 - ROUTING CLIP
3 - AUTOSTICK WIRING CONNECTOR
4 - COLUMN WIRING HARNESS
19 - 22 COLUMNRS

(4) Position the upper shroud on the column (Fig.
35).
(5) If equipped with traction control, route the
switch wiring down around the column. Connect the
wiring connector from the column wiring harness to
the traction control switch wiring (attached to upper
shroud) (Fig. 37).
(6) If removed, position the lower shroud on the
column (Fig. 36). Install the lower shroud mounting
screw. Tighten the screw to 2 N´m (17 in. lbs.) torque.(7) Align the upper shroud with the lower, then
snap shrouds together at locking tab locations on
both sides of column.
(8) Install the two shroud-to-shroud mounting
screws (Fig. 35). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(9) Inspect shroud mating surfaces for excessive
gaps and correct as necessary.
(10) Check operation of any previously discon-
nected switches.
STEERING WHEEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS - WARNING).
(1) Disconnect and isolate the negative (ground)
cable from the battery. Wait at least two minutes for
the airbag system reserve capacitor to discharge
before beginning any steering column, instrument
panel, or airbag system/component service.
WARNING: WHEN AN UNDEPLOYED AIRBAG IS TO
BE REMOVED FROM THE VEHICLE, FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. ALLOW THE AIRBAG SYSTEM
RESERVE CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE BEGINNING ANY AIRBAG SYS-
TEM OR COMPONENT SERVICE. PERSONAL
INJURY MAY RESULT IF THIS PROCEDURE IS NOT
FOLLOWED.
Fig. 38 Traction Control Switch Routing Clip
1 - ROUTING CLIP
2 - SWITCH WIRING
Fig. 39 Traction Control Switch Mounting
1 - TRACTION CONTROL SWITCH
2 - UPPER SHROUD
Fig. 40 Driver Airbag Mounting
1 - DRIVER AIRBAG
2 - MOUNTING SCREWS
RSCOLUMN19-23
SHROUD - UPPER (Continued)

(2) Remove the driver airbag mounting screws
(Fig. 40).
(3) Lift the airbag from its mount and disconnect
two airbag squib, speed control and horn connectors
(Fig. 41). Remove driver airbag. Properly store the
driver airbag out of the way. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - WARNING)(4) Remove the steering wheel retaining bolt (Fig.
42).
(5) Remove damper (Fig. 42).
(6) If equipped, disconnect the remote audio con-
trol switch wiring from the clockspring (Fig. 42).
CAUTION: Do not bump or hammer on steering col-
umn or steering column shaft when removing steer-
ing wheel from steering column shaft.
CAUTION: When installing steering wheel puller
bolts in steering wheel, do not thread bolt into
steering wheel more than a half inch. If the bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(7) While holding the steering wheel firmly in the
straight-aheadposition, remove the steering wheel
from steering column shaft using a steering wheel
puller (Fig. 43).
(8) Remove the puller from the steering wheel.
(9) If the remote audio switches need removed
from the steering wheel, (Refer to 8 - ELECTRICAL/
AUDIO/REMOTE SWITCHES - REMOVAL).
INSTALLATION
(1) If the remote radio switches need to be
installed on the steering wheel, (Refer to 8 - ELEC-
TRICAL/AUDIO/REMOTE SWITCHES - INSTALLA-
TION).
CAUTION: Do not force steering wheel onto steer-
ing column shaft by driving it on. Pull steering
wheel down onto shaft using only the steering
wheel retaining nut.
Fig. 41 Driver Airbag Wiring Connections
1 - DRIVER AIRBAG
2 - SQUIB CONNECTORS
3 - SPEED CONTROL/HORN WIRING CONNECTOR
4 - CLOCKSPRING
Fig. 42 Steering Wheel Mounting
1 - STEERING WHEEL
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF
EQUIPPED)
3 - RETAINING BOLT
4 - DAMPER
Fig. 43 Steering Wheel Removal
1 - STEERING WHEEL
2 - PULLER
19 - 24 COLUMNRS
STEERING WHEEL (Continued)

(2) Feed and route wiring from clockspring
through upper access hole in steering wheel.
(3) Align master serrations in steering wheel with
omitted spline on steering column shaft (at 12 o'clock
position). Slide the steering wheel onto the steering
column shaft by hand (Fig. 42). Use care not to pinch
any wiring.
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on the damper is not deteriorated or damaged.
If the damper is installed with a damaged isolator, a
buzz, squeak or rattle condition may develop.
(4) Install the damper on the steering wheel (Fig.
42).
(5) Install the steering wheel retaining bolt.
Tighten the steering wheel retaining bolt to 61 N´m
(45 ft. lbs.) torque.(6) If the steering wheel is equipped with remote
audio controls, connect the wiring connector to the
clockspring (Fig. 42).
(7) Connect the airbag squib wiring connectors to
the airbag and the horn and speed control switch
connector to the clockspring (Fig. 41).
(8) Install the driver airbag in the steering wheel
(Fig. 40). Install and tighten the airbag attaching
screws to 10 N´m (90 in. lbs.) torque.
(9) Connect the battery negative (ground) cable to
battery post following special Diagnosis And Testing
procedure. (Refer to 8 - ELECTRICAL/RESTRAINTS
- DIAGNOSIS AND TESTING)
(10) Check operation of all steering wheel mounted
components.
(11) Road test vehicle to ensure proper operation of
steering.
RSCOLUMN19-25
STEERING WHEEL (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................26
OPERATION...........................26
WARNING
WARNINGS AND CAUTIONS.............26
REMOVAL
REMOVAL - LHD GEAR.................26
REMOVAL - RHD GEAR................29INSTALLATION
INSTALLATION - LHD GEAR.............31
INSTALLATION - RHD GEAR.............33
SPECIAL TOOLS
POWER STEERING GEAR..............34
OUTER TIE ROD
REMOVAL.............................34
INSTALLATION.........................35
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 unless DaimlerChrysler Corpora-
tion authorizes. If a malfunction or oil leak occurs,
the complete steering gear should be replaced.
Only the outer tie rods may be replaced separately
from the rest of the gear.
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-
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 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.
WARNING
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
REMOVAL - LHD GEAR
(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.Use
care not to damage the filter mesh below the
fluid surface.
19 - 26 GEARRS

CAUTION: Locking the steering column in the
straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) Position the steering wheel in the STRAIGHT-
AHEAD position. Lock the steering wheel in place
using a steering wheel holding tool.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
(5) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(6) Remove front wheel and tire assemblies.
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove a single hose at power steering cooler
and allow fluid to drain.
Fig. 1 Power Steering Gear (Typical)
1 - TIE ROD JAM NUT
2 - INNER TIE ROD
3 - STEERING GEAR MOUNTING BRACKET
4 - POWER STEERING GEAR FLUID LINES
5 - STEERING COLUMN INTERMEDIATE SHAFT
6 - INNER TIE ROD7 - OUTER TIE ROD
8 - TIE ROD JAM NUT
9 - BOOT/BELLOWS
10 - STEERING GEAR BOOT BREATHER TUBE
11 - BOOT/BELLOWS
12 - OUTER TIE ROD
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
RSGEAR19-27
GEAR (Continued)

(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.(11) Remove bolts fastening leak detection pump to
cradle crossmember reinforcement. (Refer to 25 -
EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/LEAK DETECTION PUMP - REMOVAL)
(12) Remove both outer tie rods from steering
knuckles, using Puller, Special Tool C-3894±A (Fig.
5).
(13) 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.
Fig. 3 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 4 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 5 Tie Rod Removal With Tool C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
19 - 28 GEARRS
GEAR (Continued)