service DODGE NEON 2000 Service Repair Manual

STEERING
TABLE OF CONTENTS
page page
POWER STEERING......................... 1
POWER STEERING PUMP.................. 16STEERING GEAR.......................... 21
STEERING COLUMN....................... 29
POWER STEERING
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER STEERING SYSTEM................1
POWER STEERING FLUID HOSES............2
POWER STEERING FLUID COOLER...........2
POWER STEERING FLUID PRESSURE
SWITCH...............................3
DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS......4
POWER STEERING SYSTEM FLOW AND
PRESSURE TEST........................9
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL
CHECK...............................11REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........11
POWER STEERING FLUID PRESSURE HOSE . . . 11
POWER STEERING FLUID RETURN HOSE.....12
POWER STEERING FLUID COOLER..........13
POWER STEERING FLUID PRESSURE
SWITCH..............................14
SPECIFICATIONS
POWER STEERING FASTENER TORQUE
SPECIFICATIONS.......................15
SPECIAL TOOLS
POWER STEERING.......................15
DESCRIPTION AND OPERATION
POWER STEERING SYSTEM
Turning of the steering wheel is converted into lin-
ear travel through the meshing of the helical pinion
teeth with the rack teeth within the steering gear.
Power assist steering is provided by an open-cen-
ter, rotary-type control valve. It is used to direct
power steering fluid from the power steering pump to
either side of the integral steering rack piston. Road
feel is controlled by the diameter of a torsion bar
which initially steers the vehicle. As steering effort
increases as in a turn, the torsion bar twists, causing
relative rotary motion between the rotary valve body
and valve spool. This movement directs fluid behind
the integral rack piston, which in turn builds up
hydraulic pressure and assists in the turning effort.
This vehicle comes with power steering as stan-
dard equipment and it is the only steering systemavailable. The power steering system consists of
these major components:
²POWER STEERING PUMP
²POWER STEERING GEAR
²POWER STEERING FLUID RESERVOIR
(mounted on the pump)
²POWER STEERING FLUID PRESSURE HOSE
²POWER STEERING FLUID RETURN HOSE
²POWER STEERING FLUID COOLER (on some
models)
For information on the first two components, refer
to their respective sections within this service man-
ual group. Information on the third component can
be found in POWER STEERING PUMP. Information
on all other components can be found in this section
of this service manual group.
PLSTEERING 19 - 1

STEERING WHEEL FEEL
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL/
COLUMN CLICKING,
CLUNKING OR RATTLING.1. Steering column preload is not set
properly.1. Loosen steering column coupling pinch
bolt to reset steering column preload.
Replace pinch bolt and torque to
specifications.
2. Loose steering coupling pinch
bolt.2. Replace pinch bolt and torque to
specifications.
3. Steering column bearings. 3. Replace steering column.
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 preload is not set
properly.2. Loosen steering column coupling pinch
bolt to reset steering column preload.
Replace pinch bolt and torque to
specifications.
3. Steering column lower bearing
spring retainer slipped on steering
column shaft.3. Replace steering column.
STEERING WHEEL OR
DASH 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 running
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.
STEERING CATCHES,
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
suspension 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 or control arm.
4. Lack of lubrication in steering gear
outer tie rod ends.4. 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.
5. Loose power steering pump drive
belt.5. Check and replace automatic belt
tensioner as necessary. If drive belt is worn
or glazed, replace belt.
19 - 6 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Damaged, mis-positioned or
un-lubricated steering column
coupler to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding upper strut bearing. 7. Disassemble strut assembly. Correct
binding condition in strut bearing or replace
bearing.
8. Tight shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on front
suspension crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling worn,
broken or loose.3. Replace steering column coupling.
4. Free play in steering column. 4. Check all components of the steering
system and repair or replace as required.
5. Worn control arm ball joints. 5. Replace ball joint or control arm as
required.
6. Loose steering knuckle to ball joint
stud pinch bolt.6. Inspect pinch bolts, replace as
necessary, and tighten to specified torque.
7. Front wheel bearings loose or
worn.7. Replace wheel bearing or knuckle as
necessary.
8. Loose outer tie rod ends. 8. Replace outer tie rod ends that have
excessive free play.
9. Loose inner tie rod ends. 9. Replace power steering gear.
10 Defective steering gear rotary
valve.10. Replace power steering gear.
NOTE: * Steering shudder can be expected in new
vehicles and vehicles with recent steering system
repairs. Shudder should dissipate after the vehicle
has been driven several weeks.
NOTE: ** To evaluate this condition, it may be nec-
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or
listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note thefollowing. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotate
steering wheel more than one revolution in either
direction and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
19 - 8 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
as pump damage may result.
(6) Completely open the valve on the Power Steer-
ing Analyzer flow meter. Turn the steering wheel to
the extreme 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
pressure reading against one stop is within 50 psi of
the highest reading at the other stop, the steering
gear is leaking internally and must be replaced.
If the power steering gear requires replacement,
refer to the section POWER STEERING GEAR
within this group for the removal and installation
procedure.
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL
CHECK
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
Before opening power steering system, wipe the
reservoir filler cap free of dirt and debris. Remove
the cap and check the fluid level on its dipstick.
When the fluid is at normal ambient temperature,
approximately 21ÉC to 27ÉC (70ÉF to 80ÉF), the dip-
stick level should indicateCOLD. Do not overfill the
power steering system. In all power steering systems,
use only Mopar Power Steering Fluid, or its equiva-
lent.
NOTE: Do not use any type of automatic transmis-
sion fluid in the power steering system.
REMOVAL AND INSTALLATION
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.
NOTE: Do not use any type of automatic transmis-
sion fluid in the power steering system.
POWER STEERING FLUID PRESSURE HOSE
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(1) Siphon as much fluid as possible from the
power steering fluid reservoir.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(3) Back out the tube nut securing the power
steering fluid pressure hose to the gear (Fig. 6).
Fig. 6 Power Steering Hoses At Gear
1 ± PRESSURE HOSE TUBE NUT
2 ± RETURN HOSE
3 ± POWER STEERING GEAR
4 ± FRONT SUSPENSION CROSSMEMBER
PLSTEERING 19 - 11
DIAGNOSIS AND TESTING (Continued)

(4) Open the routing clips on the right side of the
power steering gear and remove the power steering
fluid pressure hose tube from the routing clips. At
the same time, remove the pressure hose tube from
the gear.
(5) Lower the vehicle.
(6) Remove the bolt securing the hose routing clip
in place on the right engine motor mount (Fig. 7).
Remove the power steering fluid pressure hose from
the routing clip.
(7) Back out the tube nut securing the power
steering fluid pressure hose to the power steering
pump and remove the hose from the pump (Fig. 7).
(8) Remove the power steering pressure hose from
the engine compartment.
INSTALLATION
(1) Install the power steering pressure hose into
the engine compartment from the top. First, guide
the pump end of the hose under the pump, then
route the rest of the hose along the right side of the
engine. Guide the gear end of the hose down behind
the back of the engine towards the power steering
gear.
(2) Using a lint free towel, wipe clean the open
power steering hose end and the power steeringpump port. Replace the used O-ring with new. Lubri-
cate the O-ring with power steering fluid.
(3) Attach the power steering fluid pressure hose
to the outlet fitting on the bottom of the power steer-
ing pump (Fig. 7). Tighten the pressure hose tube
nut to a torque of 34 N´m (25 ft. lbs.).
(4) Install the power steering fluid pressure hose
in the routing clip and attach the clip to the right
engine mount (Fig. 7). Tighten the hose routing clip
bolt to a torque of 12 N´m (105 in. lbs.).
(5) Raise the vehicle.
CAUTION: The power steering fluid hoses must
remain away from the exhaust system, vehicle com-
ponents, and unfriendly surfaces that can cause
possible damage to the power steering hoses.
(6) Using a lint free towel, wipe clean the open
power steering hose end and the power steering gear
port. Replace the used O-ring with new. Lubricate
the O-ring with power steering fluid.
(7) Attach the power steering fluid pressure hose
to the port on the power steering gear (Fig. 6). Start
the tube nut threads into the gear, but do not tighten
it at this time.
(8) Open the routing clips on the right side of the
power steering gear and install the power steering
fluid pressure hose into the routing clips. Close the
clips.
(9) Tighten the pressure hose tube nut at the gear
to a torque of 34 N´m (25 ft. lbs.).
(10) Lower the vehicle.
(11) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure which can be
found in the POWER STEERING PUMP section of
this group to properly fill and bleed the power steer-
ing system.
(12) Check for leaks at all hose connections.
POWER STEERING FLUID RETURN HOSE
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(1) Siphon as much fluid as possible from the
power steering fluid reservoir.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(3) If the vehicle is equipped with a power steering
fluid cooler, remove the hose clamp securing the
return hose to the cooler. Slide the hose off the end of
the cooler tube.
Fig. 7 Power Steering Hoses At Pump
1 ± HOSE ROUTING CLIP
2 ± RETURN HOSE CLAMP
3 ± POWER STEERING PUMP AND RESERVOIR
4 ± PRESSURE HOSE TUBE NUT
19 - 12 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

(4) If the vehicle is not equipped with a power
steering fluid cooler:
²Remove the hose clamp securing the return hose
to the steel fitting in the outlet port on the power
steering gear (Fig. 6).
²Slide the hose off the end of the steel fitting.
²Pull the hose loose from the C-clamps on the two
routing clips located on the front of the steering gear
(Fig. 6).
(5) Lower the vehicle.
(6) Remove the bolt securing the hose routing clip
in place on the right engine mount (Fig. 7). Remove
the power steering fluid return hose from the routing
clip.
(7) Remove the hose clamp securing the return
hose to the power steering fluid reservoir (Fig. 7).
Slide the hose off the end of the reservoir fitting.
(8) Remove the power steering return hose from
the engine compartment.
INSTALLATION
(1) Slide a hose clamp onto the power steering
pump end of the hose far enough to clear the fitting
on the power steering fluid reservoir once the hose is
installed.
(2) Install the power steering return hose into the
engine compartment from the top. First, guide the
pump end of the hose onto the fitting on the power
steering fluid reservoir, then route the rest of the
hose along the right side of the engine (Fig. 7). Guide
the gear end of the hose down behind the back of the
engine towards the power steering gear.
(3) Expand the hose clamp and slide it onto the
fluid reservoir fitting. Secure the clamp once it is
past the bead formed into the fluid reservoir fitting.
(4) Install the power steering fluid return hose in
the hose routing clip and attach the clip to the right
engine mount (Fig. 7). Tighten the hose routing clip
bolt to a torque of 12 N´m (105 in. lbs.).
(5) Raise the vehicle.
CAUTION: The power steering fluid hoses must
remain away from the exhaust system, vehicle com-
ponents, and unfriendly surfaces that can cause
possible damage to the power steering hoses.
(6) Using a lint free towel, wipe clean the open
power steering hose end and the power steering gear
port fitting or power steering fluid cooler port.
(7) Install a hose clamp onto the end of the hose
far enough to clear the fitting on the steering gear or
cooler once the hose is installed.
(8) If the vehicle is equipped with a power steering
fluid cooler, slide the hose onto the end of the cooler
tube. Install the hose clamp past the bead formed
into the cooler tube and secure in place.(9) If the vehicle is not equipped with a power
steering fluid cooler:
²Slide the hose onto the end of the steel fitting in
the steering gear outlet port (Fig. 6).
²Install the hose clamp past the bead formed into
the steel fitting and secure in place.
²Align and attach the hose to the C-clamps on
the two routing clips located on the front of the steer-
ing gear (Fig. 6).
(10) Lower the vehicle.
(11) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure which can be
found in the POWER STEERING PUMP section of
this group to properly fill and bleed the power steer-
ing system.
(12) Check for leaks at all hose connections.
POWER STEERING FLUID COOLER
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(1) Siphon as much fluid as possible from the
power steering fluid reservoir.
(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(3) Remove the hose clamp, attaching the power
steering fluid return hose to the power steering fluid
cooler. Remove the return hose from the cooler.
(4) Remove the hose clamp attaching the power
steering cooler fluid hose to the steel fitting in the
power steering gear outlet port (Fig. 8).
(5) Remove the two screws securing the cooler to
the front suspension crossmember. They are located
behind the cooler. They can be accessed from above.
(6) Open the routing clip on the right front of the
power steering gear housing and remove the cooler
tube from it.
(7) Remove the cooler from the vehicle.
INSTALLATION
(1) Slide a hose clamp onto the end of the power
steering cooler fluid hose far enough to clear the steel
fitting on the power steering gear once the hose is
installed.
(2) Slide the hose (with cooler attached) onto the
fitting on the steering gear, then align the tube on
back of the cooler with the open routing clip on the
right front of the power steering gear housing, and
snap it into place. Close the clip.
PLSTEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)

(3) Install the hose clamp on the power steering
cooler fluid hose past the bead formed into the steel
fitting and secure in place.
(4) Install the two screws attaching the cooler to
the front suspension crossmember. Tighten the cooler
attaching screws to a torque of 10 N´m (90 in. lbs.).
(5) Install the power steering fluid return hose on
the power steering fluid cooler tube. Install the hose
clamp on the power steering return hose securing it
to the power steering cooler. Be sure the hose clamp
is installed on the return hose past the bead on the
end of the cooler tube.
(6) Lower the vehicle.
(7) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure which can be
found in the POWER STEERING PUMP section of
this group to properly fill and bleed the power steer-
ing system.
(8) Check for leaks at all connections.
POWER STEERING FLUID PRESSURE SWITCH
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(1) Disconnect negative battery cable from the neg-
ative post of the battery. Be sure cable is isolated
from negative post on battery.(2) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group in this
service manual for the correct lifting procedure.
(3) Locate the power steering fluid pressure switch
on the back side of the power steering gear (Fig. 9).
(4) Remove the vehicle wiring harness connector
from the power steering fluid pressure switch.
NOTE: When removing and installing the power
steering pressure switch, use a 7/8 inch deep well
socket. The deep well socket will prevent damage
to the plastic electrical connector area of the power
steering fluid pressure switch.
(5) Unscrew and remove the power steering fluid
pressure switch from the power steering gear.
INSTALLATION
(1) By hand, screw the power steering pressure
switch into the power steering gear until it is fully
seated (Fig. 9). Tighten the power steering pressure
switch to a maximum torque of 8 N´m (70 in. lbs.).
Over-torquing will result in stripping the threads out
of the power steering pressure switch port in the
steering gear.
(2) Install the vehicle wiring harness connector. Be
sure the latch on the wiring harness connector is
fully engaged with the locking tab on the power
steering pressure switch.
(3) Lower the vehicle.
(4) Fill the power steering fluid reservoir to the
correct fluid level. Use only MopartPower Steering
Fluid, or equivalent.
(5) Connect the negative cable to the negative post
of the battery.
Fig. 8 Power Steering Fluid Cooler
1 ± POWER STEERING FLUID COOLER
2 ± TRANSAXLE
3 ± CLAMP
4 ± AIR DAM
5 ± CROSSMEMBER
Fig. 9 Switch Location
1 ± WIRING HARNESS CONNECTOR
2 ± POWER STEERING GEAR
3 ± POWER STEERING FLUID PRESSURE SWITCH
4 ± REAR OF FRONT SUSPENSION CROSSMEMBER
19 - 14 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

POWER STEERING PUMP
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
POWER STEERING PUMP.................16
POWER STEERING FLUID RESERVOIR.......17
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL
OPERATION...........................17
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS........17
POWER STEERING PUMP.................17DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP (PULLEY).........19
SPECIFICATIONS
POWER STEERING PUMP FLOW
SPECIFICATIONS.......................20
POWER STEERING FASTENER TORQUE
SPECIFICATIONS.......................20
SPECIAL TOOLS
POWER STEERING PUMP.................20
DESCRIPTION AND OPERATION
POWER STEERING PUMP
The hydraulic pressure for operation of the power
steering gear is provided by a belt driven power
steering pump (Fig. 1) manufactured by TTA. The
TTA power steering pump is a constant flow rate and
displacement vane-type pump.
In the event of a power steering pump drive belt
failure, manual steering control of the vehicle can
still be maintained. However, under these conditions,
steering effort will be significantly increased.No repair procedures are to be done on the internal
components of the power steering pump. The only
serviceable components of the power steering pump
are the power steering pump pulley and the pump
itself. The power steering fluid reservoir is serviced
with the pump.
Because of unique shaft bearings, flow control lev-
els or pump displacements, power steering pumps
may be used only on specific vehicle applications. Be
sure that all power steering pumps are only replaced
with a pump that is the correct replacement for that
specific application.
Hydraulic pressure is provided for operation of the
power steering gear by the belt driven power steering
pump (Fig. 1). It is a constant displacement, vane
type pump. The power steering pump is connected to
the steering gear by a power steering fluid pressure
hose and return hose.
Rectangular pumping vanes in the shaft driven
rotor move power steering fluid from the intake to
the cam ring pressure cavities of the power steering
pump. As the rotor begins to turn, centrifugal force
throws the vanes against the inside surface of the
cam ring to pickup residual oil. This oil is then forced
into the high pressure area. As more oil is picked up
by the vanes, the additional oil is forced into the cav-
ities of the thrust plate through two crossover holes
in the cam ring and pressure plate. The crossover
holes empty into the high pressure area between the
pressure plate and the housing end cover.
As the high pressure area is filled, oil flows under
the vanes in the rotor slots, forcing the vanes to fol-
low the inside surface of the cam ring. As the vanes
reach the restricted area of the cam ring, oil is forced
out from between the vanes. When excess oil flow is
generated during high-speed operation, a regulated
amount of oil returns to the pump intake side
through a flow control valve. The flow control valve
Fig. 1 Power Steering Pump
1 ± POWER STEERING FLUID RESERVOIR
2 ± POWER STEERING PUMP
3 ± PULLEY
4 ± PUMP PRESSURE FITTING
19 - 16 STEERINGPL

reduces the power required to drive the pump and
holds down temperature build-up.
When steering conditions exceed maximum pres-
sure requirements, such as when the wheels are
turned against the stops, the pressure built up in the
steering gear exerts pressure on the spring end of the
flow control valve. The high pressure lifts the relief
valve ball from its seat and allows oil to flow through
a trigger orifice located in the outlet fitting. This
reduces pressure on the spring end of the flow con-
trol valve which then opens and allows the oil to
return to the intake side of the pump. This action
limits maximum pressure output of the pump to a
safe level.
Under normal power steering pump operating con-
ditions, pressure requirements of the pump are below
maximum, causing the pressure relief valve to
remain closed.
POWER STEERING FLUID RESERVOIR
The power steering fluid reservoir is mounted on
the power steering pump using 3 bolts (Fig. 1). It
stores fluid for the power steering system.
The power steering fluid reservoir is considered an
integral part of the power steering pump and is not
serviced separately.
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only MoparTPower Steering Fluid. Do
not use automatic transmission fluid. Do not over-
fill.
Wipe the filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature, approximately 21ÉC to 27ÉC
(70ÉF to 80ÉF).
(1) Fill the power steering fluid reservoir to the
proper level and let the fluid settle for at least two
minutes.
(2) Start the engine and let run for a few seconds,
then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
REMOVAL AND INSTALLATION
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.
NOTE: Do not use any type of automatic transmis-
sion fluid in the power steering system.
POWER STEERING PUMP
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
REMOVAL
(1) Remove battery cable from the negative post on
the battery.
(2) Siphon as much fluid as possible from the
power steering fluid reservoir.
(3) Remove the power steering pump drive belt
from the power steering pump pulley. Refer to
ACCESSORY DRIVE BELTS in the COOLING SYS-
TEM service manual group for the required removal
and installation procedure.
(4) Remove the hose clamp securing the return
hose to the power steering fluid reservoir. Slide the
hose off the end of the reservoir fitting. (Fig. 2).
(5) Back out the tube nut securing the power
steering fluid pressure hose to the power steering
pump and remove the hose from the pump (Fig. 2).
PLSTEERING 19 - 17
DESCRIPTION AND OPERATION (Continued)

SORY DRIVE BELTS in the COOLING SYSTEM
service manual group for the required removal and
installation procedure.
(6) Using a lint free towel, wipe clean all open
power steering hose ends and power steering pump
fittings.
(7) Install a new O-ring on the end of the power
steering pressure hose. Lubricate the O-ring using
clean power steering fluid.
(8) Attach the power steering fluid pressure hose
to the pressure fitting on the lower end of the power
steering pump (Fig. 2). Thread the tube nut securing
the power steering fluid pressure hose into the power
steering pump pressure fitting. Tighten the tube nut
to at torque of 34 N´m (25 ft. lbs.).
(9) Slide the power steering fluid return hose onto
the fluid reservoir fitting (Fig. 2). Position the hose
clamp so it is installed on the hose past the bead
formed into the fluid reservoir fitting.
(10) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure found in this
section of this group to properly fill and bleed the
power steering system.
(11) Check for leaks.
DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP (PULLEY)
The only serviceable part of the power steering
pump is the pulley. The following procedure is for the
removal and installation of the pulley from the
pump.
The power steering pump must be removed from
the vehicle for power steering pump pulley service.
Refer to POWER STEERING PUMP in REMOVAL
AND INSTALLATION for the required procedure.
CAUTION: Use care when removing and installing
the power steering pump pulley. It is made of plas-
tic composite, except for the center shank. The spe-
cial tools are to be used in the shank area only as
described in the following procedure.
DISASSEMBLY
CAUTION: Do not hammer on the power steering
pump pulley or shaft to remove the power steering
pump pulley. This will damage the pulley and the
power steering pump.
(1) Install Puller, Special Tool C-4333, or an equiv-
alent, on the steering pump pulley as shown (Fig. 5).
Tighten the puller screw drive and remove the pulley
from the power steering pump shaft.NOTE: Replace the power steering pump pulley if it
is cracked or loose.
(2) Remove the puller from the power steering
pump pulley.
ASSEMBLY
(1) Place the power steering pump pulley squarely
on end of the power steering pump shaft. Mount
Installer, Special Tool C-4063, or an equivalent, in
the internal threads of the power steering pump
shaft and against power steering pump pulley (Fig.
6).
Fig. 5 Pulley Removal
1 ± PULLEY
2 ± C-4333
3 ± POWER STEERING PUMP
Fig. 6 Pulley Installation
1 ± C-4063
2 ± PULLEY
3 ± POWER STEERING PUMP
PLSTEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)