servo CHRYSLER VOYAGER 2005 Manual Online

CONDITION POSSIBLE CAUSES CORRECTION
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. Loose clamp on fluid supply hose. 4. Tighten or replace hose clamp.
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. Seal lubrication inadequate. 4. Lube seal (if external).
5. Steering gear internally noisy. 5. Replace steering gear (if no other
cause can be found).
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.
* NOTE: There is some noise in all power steering
systems. One of the most common is a hissing
sound evident when turning the steering wheel
when at a standstill or when parking and the steer-
ing wheel is at the end of its travel. Hiss is a very
high frequency noise similar to that experienced
while slowly closing a water tap. The noise is
present in every valve and results when high veloc-
ity fluid passes valve orifice edges. There is no
relationship between this noise and the perfor-
mance of the steering system.** NOTE: A light clunk may be felt or heard during
steering wheel reversal while vehicle is stationary.
This results from internal steering gear rack move-
ment at the bushings and in no way affects the per-
formance of the steering system. This movement
may be felt in the steering components during
steering wheel reversal.
*** NOTE: Power steering pump growl/moan/groan
results from the development of high pressure fluid
flow. Normally this noise level should not be high
enough to be objectionable.
RSSTEERING19-5
STEERING (Continued)

STEERING WHEEL FEEL
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL/
COLUMN CLICKING,
CLUNKING OR RATTLING.1. Loose steering coupling pinch
bolt.1. Replace pinch bolt and torque to
specifications.
2. Steering column bearings. 2. Replace steering column.
3. Excessive intermediate shaft
coupling free-play.3. Replace intermediate shaft.
STEERING WHEEL HAS
FORE AND AFT
LOOSENESS.1. Steering wheel retaining nut not
properly tightened and torqued.1. Tighten the steering wheel retaining nut
to its specified torque.
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.2. Replace steering column.
3. Loose steering column to
instrument panel fasteners.3. Tighten fasteners to specified torque.
STEERING WHEEL, DASH
OR VEHICLE VIBRATES
DURING LOW SPEED OR
STANDSTILL STEERING
MANEUVERS.1. Air in the fluid of the power
steering system.1. Bleed air from system following the
power steering pump initial operation
service procedure.*
2. Tires not properly inflated. 2. Inflate tires to the specified pressure.
3. Excessive engine vibration. 3. Ensure that the engine is tuned properly.
4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut
to the specified torque.
5.Overcharged air conditioning
system.5.Check air conditioning pump head
pressure and correct as necessary.
6. Grounded engine mount. 6. Repair as necessary.
7. Loose outer tie rod. 7. Replace outer tie rod.
STEERING CATCHES,
SURGES OR STICKS IN
CERTAIN POSITIONS OR
IS DIFFICULT TO TURN. ***1. Low power steering fluid level. 1. Fill power steering fluid reservoir to
specified level and check for leaks.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified pressure.
3. Lack of lubrication in front lower
control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace ball
joint.
4. Worn or binding lower control arm
ball joint.4. Replace lower control arm ball joint.
5. Lack of lubrication in steering gear
outer tie rod ends.5. Lubricate tie rod ends if they are not a
lubricated-for-life type. If tie rod end is a
lubricated-for-life type, replace tie rod end.
19 - 6 STEERINGRS
STEERING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
AERATED FLUID.* 1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level.
2. Air leak at supply hose, power
steering fluid reservoir or pump.2. Inspect for proper sealing. Repair as
necessary.
3. Cracked power steering pump
housing.3. Replace the power steering pump.
RESERVOIR FLUID
OVERFLOW AND FLUID
THAT IS MILKY IN COLOR1. Water contamination of power
steering fluid.1. Drain the power steering fluid from the
system. Flush the system with fresh clean
power steering fluid, drain, then refill to the
proper level.
* NOTE: Extremely cold temperatures may cause
power steering fluid aeration. Aeration should sub-
side as fluid warms.
SPECIFICATIONS
POWER STEERING FASTENER TORQUE
DESCRIPTION TORQUE
Power Steering Pump:
Flow Control Valve
Pressure Fitting75 N´m (55 ft. lbs.)
Mounting Bolts 54 N´m (40 ft. lbs.)
Rear Bracket To Engine
Mounting Bolts54 N´m (40 ft. lbs.)
Steering Gear:
Mounting Bolt - Size-M14 183 N´m (135 ft. lbs.)
Mounting Bolts -
Size-M1295 N´m (70 ft. lbs.)
Tie Rod Steering Knuckle
Nut75 N´m (55 ft. lbs.)
Tie Rod Jam Nut 75 N´m (55 ft. lbs.)
Coupling Pinch Bolt 28 N´m (250 in. lbs.)
Power Steering Fluid
Hoses:
Hose Tube Nuts 31 N´m (275 in. lbs.)
Routing Bracket Bolts 23 N´m (200 in. lbs.)
SPECIAL TOOLS
POWER STEERING
Power Steering Analyzer 6815
Adapters, Power Steering Analyzer 6893
Hose, Power Steering Analyzer 6959
RSSTEERING19-9
STEERING (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

(14) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove lower rear bushings,
then the reinforcement.
(15) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit as necessary
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT).
(16) Remove tube nuts and power steering pres-
sure and return hoses from the power steering gear
(Fig. 7).
(17) Remove the 3 bolts and nuts mounting the
steering gear to the front suspension cradle (Fig. 8).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.
(18) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 9). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 9). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(19) Separate the coupler from the shaft of the
steering gear.
(20) Remove the power steering gear from the
vehicle.
REMOVAL - RHD 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.
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 ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(5) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front wheel and tire assemblies.
(8) If power steering cooler equipped, remove a
hose at power steering cooler and allow fluid to
drain.
(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.
Fig. 6 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
RSGEAR19-29
GEAR (Continued)

(11) Remove both tie rod ends from steering
knuckles using Puller, Special Tool C-3894±A (Fig. 5).
Fig. 7 Hoses To Power Steering Gear - 3.3L/3.8L Engine
1 - RETURN HOSE (TO RESERVOIR)
2 - PRESSURE HOSE (FROM PUMP)
3 - CRADLE CROSSMEMBER
4 - PRESSURE HOSE ROUTING CLAMP
5 - RETURN HOSE ROUTING CLAMP
6 - PRESSURE HOSE TUBE NUT7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP
Fig. 8 Steering Gear Mounting To Suspension Cradle
1 - POWER STEERING GEAR
2 - MOUNTING BOLTS (12 MM)
3 - MOUNTING BOLT (14 MM)
4 - FRONT SUSPENSION CRADLE CROSSMEMBER
Fig. 9 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
19 - 30 GEARRS
GEAR (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION
DESCRIPTION - PUMP (2.4L/3.3L/3.8L
ENGINE)............................36
DESCRIPTION - PUMP (DIESEL).........37
OPERATION...........................37
WARNING.............................37
CAUTION.............................37
STANDARD PROCEDURE - POWER
STEERING PUMP INITIAL OPERATION.....37
REMOVAL
REMOVAL - PUMP (2.4L ENGINE).........38
REMOVAL - PUMP (3.3L/3.8L ENGINE).....40
REMOVAL - PUMP (DIESEL).............41
DISASSEMBLY - PUMP (PULLEY)..........41
ASSEMBLY - PUMP (PULLEY).............42
INSTALLATION
INSTALLATION - PUMP (2.4L ENGINE).....43
INSTALLATION - PUMP (3.3L/3.8L ENGINE) . 43
INSTALLATION - PUMP (DIESEL).........43
SPECIAL TOOLS
POWER STEERING PUMP..............44
FLUID
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......44
FLUID COOLER
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................45
HOSE - POWER STEERING PRESSURE
REMOVAL
REMOVAL - 2.4L ENGINE...............46REMOVAL - 3.3L/3.8L ENGINE...........46
INSTALLATION
INSTALLATION - 2.4L ENGINE...........47
INSTALLATION - 3.3L/3.8L ENGINE........48
HOSE - POWER STEERING RETURN
REMOVAL
REMOVAL - 2.4L ENGINE...............49
REMOVAL - 3.3L/3.8L ENGINE...........49
INSTALLATION
INSTALLATION - 2.4L ENGINE...........50
INSTALLATION - 3.3L/3.8L ENGINE........50
HOSE - POWER STEERING SUPPLY
REMOVAL
REMOVAL - 2.4L ENGINE...............51
REMOVAL - 3.3L/3.8L ENGINE...........51
INSTALLATION
INSTALLATION - 2.4L ENGINE...........51
INSTALLATION - 3.3L/3.8L ENGINE........52
RESERVOIR - POWER STEERING FLUID
DESCRIPTION
DESCRIPTION - 2.4L/3.3L/3.8L ENGINE....52
DESCRIPTION - DIESEL................52
OPERATION...........................52
REMOVAL
REMOVAL - 2.4L ENGINE...............52
REMOVAL - 3.3L/3.8L ENGINE...........52
REMOVAL - DIESEL...................52
INSTALLATION
INSTALLATION - 2.4L ENGINE...........53
INSTALLATION - 3.3L/3.8L ENGINE........53
INSTALLATION - DIESEL................53
PUMP
DESCRIPTION
DESCRIPTION - PUMP (2.4L/3.3L/3.8L
ENGINE)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
on the back side of the engine on all engine applica-
tions. The pumps are different depending on the
engine option. The pump for the 2.4L engine is madeout of cast iron and steel (Fig. 1). The pump used on
the 3.3L/3.8L engine is made of aluminum (Fig. 2).
The pump for the 3.3L/3.8L engine does not have a
return fitting as the pump for the 2.4L engine does.
The power steering return hose on the 3.3L/3.8L
engine goes to the reservoir instead of the pump.
19 - 36 PUMPRS

DESCRIPTION - PUMP (DIESEL)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
front lower right corner of the engine (Fig. 13).
The pump has a supply fitting for fluid coming
from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.
OPERATION
The power steering pump is a constant displace-
ment vane type pump. The 2.4L pump has an inte-
gral fluid reservoir and there is a secondary remote
non-flow reservoir which acts only as a fluid fill and
check point. The 3.3L/3.8L pump houses very little
fluid and is therefore supplied by a remote flow
through reservoir.
WARNING
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
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.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
WARNING: FLUID LEVEL SHOULD BE CHECKED
AND ADJUSTED WITH ENGINE OFF TO PREVENT
INJURY FROM MOVING ENGINE COMPONENTS.
CAUTION: Use only MoparTAutomatic Transmis-
sion Fluid (MS-9602) in power steering system. Use
of other MoparTpower steering fluids (MS5931 and
MS9933) should be avoided to ensure peak perfor-
mance of the power steering system under all oper-
ating conditions. Do not overfill.
Fig. 1 POWER STEERING PUMP (2.4L)
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING
4 - RETURN FITTING
5 - SUPPLY FITTING
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING
2 - PRESSURE FITTING
3 - PULLEY
RSPUMP19-37
PUMP (Continued)

Read the fluid level through the side of the power
steering fluid reservoir. The fluid level should indi-
cateªFILL RANGEºwhen the fluid is at a temper-
ature of approximately 21ÉC to 27ÉC (70ÉF to 80ÉF).
(1) Wipe the filler cap and area clean, then remove
the cap.
(2) Fill the fluid reservoir to the proper level and
let the fluid settle for at least two (2) minutes.
(3) Start the engine and let run for a few seconds,
then turn the engine off.
(4) Add fluid if necessary. Repeat the above steps
until the fluid level remains constant after running
the engine.
(5) Raise the front wheels off the ground.
(6) Start the engine.
(7) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops.
(8) Add fluid if necessary.
(9) Lower the vehicle, then turn the steering wheel
slowly from lock-to-lock.
(10) Stop the engine. Check the fluid level and
refill as required.
(11) If the fluid is extremely foamy, allow the vehi-
cle to stabilize a few minutes, then repeat the above
procedure.
REMOVAL
REMOVAL - PUMP (2.4L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the cap from the power steering fluid
reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise the vehicle on jack stands or centered on
a frame contact type hoist. See Hoisting in Lubrica-
tion and Maintenance.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness at the rear engine
mount bracket.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.(6) Remove the four bolts and flag nuts securing
the catalytic converter from the exhaust manifold
(Fig. 3).
(7) Disconnect all the exhaust system isolators/
hangers from the brackets on the exhaust system (2
at the mufflers and 1 at the resonator) (Fig. 4).
(8) Remove the exhaust system by moving it as far
rearward, then lowering the front below the cross-
member and out of the vehicle.
(9) Remove the power steering fluid supply hose
from the fitting on the power steering pump. Drain
off excess power steering fluid from hose.
(10) Move the heat sleeve on the power steering
return hose to expose the hose connection at the
pump (Fig. 5). Remove the hose from the power
steering Pump. Allow the remaining power steering
fluid to drain from the power steering pump and res-
ervoir through the removed return hose.
(11) Remove the power steering fluid pressure line
from the power steering pump (Fig. 6). Drain excess
power steering fluid from tube.
Fig. 3 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
19 - 38 PUMPRS
PUMP (Continued)

(12) Remove the fasteners, then the accessory
drive splash shield.
(13) Remove the adjuster nut attaching rear of
power steering pump to the cast mounting bracket.
(Fig. 7)
(14) Remove the front adjuster nut and the lower
pivot bolt (Fig. 8) attaching power steering pump
bracket to cast bracket.
(15) Remove the drive belt from the power steering
pump pulley.
(16) Remove the power steering pump and the
front bracket from the cast bracket on the engine as
an assembly through the exhaust tunnel.(17) Remove the 3 bolts attaching the front
bracket to the power steering pump and separate the
power steering pump from the front bracket.
(18) If the power steering pump pulley needs to be
transferred, (Refer to 19 - STEERING/PUMP - DIS-
ASSEMBLY).
REMOVAL - PUMP (3.3L/3.8L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL).
(3) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove the drive belt splash shield.
(5) Remove the pressure hose routing bracket bolt
(Fig. 9).
(6) lower the vehicle.
(7) Remove cap from power steering fluid reser-
voir.
(8) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(9) Disconnect the pressure hose from the pump
(Fig. 10).
(10) Disconnect the fluid supply hose from the
pump (Fig. 10).
Fig. 7 Power Steering Pump Attaching Nut
1 - POWER STEERING PUMP MOUNTING BRACKET
2 - FRONT SUSPENSION CRADLE
3 - POWER STEERING PUMP
4 - ADJUSTER NUT
Fig. 8 Pump Front Mounting
1 - ADJUSTER NUT
2 - PIVOT BOLT
3 - PUMP
Fig. 9 Pressure Hose Routing Clamp
1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
3 - CRADLE CROSSMEMBER
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET
19 - 40 PUMPRS
PUMP (Continued)