gear DODGE RAM 1500 1998 2.G Workshop Manual

CAUTION: Use care not to score the housing bore
when removing seals.
(15) Remove the snap ring with snap ring pliers
(Fig. 16).
(16) Using special tool slide hammer C-3752 with
adapter 8990 remove the oil seal (Fig. 17).
INSTALLATION
(1) Inspect the piston teflon seals for damage.
Replace if needed.
NOTE: To replace the teflon seals, use a pick to
remove the teflon o-ring and the rubber o-ringunderneath. Install a new rubber o-ring in the piston
seal grove and a new teflon o-ring over the top of it.
(2) Install the valve into the valve housing.
(3) Thread the retainer ring into the valve housing
(Fig. 18). Tighten to 97 N´m (72 ft. lbs.)
NOTE: It is very important to make sure to compen-
sate for the added length of the torque wrench
when torquing to proper specifications.
(4) Install the retainer ring set screw. Tighten to
2.26 N´m (20 in. lbs.)
(5) Clean the steering gear housing.
CAUTION: Valve assembly must be centered to the
housing (Fig. 19).
(6) Install the valve assembly into the steering
gear (Fig. 19). Tighten the new bolts to 54 N´m (40 ft.
lbs.)
Fig. 16 SNAP RING REMOVAL
1 - SNAP RING PLIERS
2 - SNAP RING
3 - VALVE HOUSING
Fig. 17 OIL SEAL REMOVAL
1 - SPECIAL TOOL
8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSING
Fig. 18 RETAINER RING INSTALLATION
1 - VALVE HOUSING
2 - SPECIAL TOOL
3 - TORQUE WRENCH
Fig. 19 CENTERED GEAR TEETH
1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN
HOLE
2 - VALVE HOUSING
DRGEAR - LINK/COIL 19 - 29
STEERING GEAR INPUT SHAFT SEAL (Continued)

(7) Install the input shaft seal protector 8986 (Fig.
20).
(8) Coat the new seal inhigh temp greaseand
Install the new oil seal using special tool 8987 driver
and C-4171 handle (Fig. 21).
NOTE: Drive the oil seal into the housing until the
outer edge does not quite clear the snap ring
groove.
(9) Insert the snap ring into the housing. Using
special tool 8987 driver and C-4171 handle push the
snap ring and oil seal together until the snap ring
seats in the groove.NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(10) Install the new dust seal usinghigh temp
grease, special tool C-4171 (driver) and 8987 (han-
dle).
(11) Check to make sure the gear is centered in
the middle tooth before installing the pitman shaft
(Fig. 19).
(12) Install the pitman shaft into the steering gear
(Refer to 19 - STEERING/GEAR/PITMAN SHAFT -
INSTALLATION).
(13) Perform over-center meshload adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(14) Install the steering gear to the vehicle (Refer
to 19 - STEERING/GEAR - INSTALLATION).
(15) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
PITMAN SHAFT
REMOVAL
REMOVAL - GAS
(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the steering wheel from stop to stop and
count the number of turns.
(4) Center the steering wheel by rotating it from
the stop back 1 1/2 turns to achieve center position.
(5) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove the pitman shaft from the gear (Fig.
22).
(7) Remove the cover if needed by loosing the
adjuster nut, Then removing the cover from the pit-
man shaft.
REMOVAL - DIESEL
(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
Fig. 20 INPUT SHAFT SEAL PROTECTOR
1 - INPUT SHAFT
2 - SPECIAL TOOL 8986
Fig. 21 INPUT SHAFT SEAL INSTALLATION
1 - VALVE HOUSING
2 - SPECIAL TOOL 8987
3 - SPECIAL TOOL C-4171
19 - 30 GEAR - LINK/COILDR
STEERING GEAR INPUT SHAFT SEAL (Continued)

(4) Clean exposed end of pitman shaft and housing
with a wire brush.
(5) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns (Fig.
23).
(6) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 23).
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(8)
Remove the pitman shaft from the gear (Fig. 24).
(9) Remove the cover if needed by loosing the
adjuster nut, Then removing the cover from the pit-
man shaft.
INSTALLATION
INSTALLATION - GAS
(1) Coat the seal withpower steering fluid.
(2) Install pitman shaft into the steering gear until
it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(4) Perform over-center meshload adjustment,
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(5) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(6) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
INSTALLATION - DIESEL
(1) Coat the seal withpower steering fluid.
(2) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(4) Perform over-center meshload adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(5) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(6) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(7) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 22 PITMAN SHAFT
1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT
Fig. 23 CENTERING STEERING GEAR
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
Fig. 24 PITMAN SHAFT
1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT
DRGEAR - LINK/COIL 19 - 31
PITMAN SHAFT (Continued)

LINKAGE - LINK/COIL
TABLE OF CONTENTS
page page
LINKAGE - LINK/COIL
DESCRIPTION.........................34
STANDARD PROCEDURE - LUBRICATION....34
SPECIFICATIONS
TORQUE CHART......................35
SPECIAL TOOLS
STEERING LINKAGE...................35
DAMPER
REMOVAL.............................36
INSTALLATION.........................36
DRAG LINK
REMOVAL.............................36INSTALLATION.........................36
PITMAN ARM
REMOVAL.............................36
INSTALLATION.........................37
TIE ROD END
REMOVAL.............................37
INSTALLATION.........................37
TRACK BAR
REMOVAL.............................38
INSTALLATION.........................38
LINKAGE - LINK/COIL
DESCRIPTION
The steering linkage is comprised of a tie rod end, tie
rod, drag link, steering damper and pitman arm (Fig. 1).
CAUTION: If any steering components are replaced
or serviced an alignment must be performed.
NOTE: To avoid damaging ball stud seals, use
Puller C-3894±A or an appropriate puller to remove
tie rod ends (Fig. 2).
STANDARD PROCEDURE - LUBRICATION
Periodic lubrication of the steering system compo-
nents is required. Refer to Lubrication And Mainte-
nance for the recommended maintenance schedule.
The following components must be lubricated:
²Tie rod
²Tie rod end
²Drag link
Fig. 1 LINK/COIL FRONT SUSPENSION
1 - STABILIZER BAR
2 - PITMAN ARM
3 - STEERING GEAR
4 - STABILIZER LINK
5 - TIE ROD ENDS
6 - LOWER SUSPENSION ARMS
7 - DRAG LINK
8 - TRACK BAR
9 - DAMPER
10 - UPPER SUSPENSION ARM
Fig. 2 Ball Stud Puller
1 - CLAMP
2 - ADJUSTMENT SLEEVE
3 - PULLER TOOL C-3894±A
4 - SEAL
5 - TIE-ROD END
19 - 34 LINKAGE - LINK/COILDR

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Pitman Arm
Gear Shaft Nut300 225 Ð
Drag Link
Pitman Arm88 65 Ð
Drag Link
Tie Rod108 80 Ð
Drag Link
Adjuster Clamp61 45 Ð
Tie Rod End
Knuckle108 80 Ð
Tie Rod End
Adjuster Clamp61 45 Ð
Stabilizer Bar Link to Axle 68 50 Ð
Steering Damper
Axle95 70 Ð
Steering Damper
Tie Rod81 60 Ð
SPECIAL TOOLS
STEERING LINKAGE
Remover Ball Stud MB-991113
Puller Tie Rod C-3894-A
Remover Ball Joint C-4150A
DRLINKAGE - LINK/COIL 19 - 35
LINKAGE - LINK/COIL (Continued)

(2) Mark the pitman arm and shaft positions for
installation reference. Remove the nut and washer
from the pitman arm (Fig. 5). Remove the pitman
arm with Puller C-4150A.
INSTALLATION
(1) Align reference marks and install pitman arm.
(2) Install the lock washer and retaining nut on
the pitman shaft and tighten nut to 251 N´m (185 ft.
lbs.).
(3) Install the drag link to the pitman arm (Fig. 6).
Install the nut and tighten to 108 N´m (80 ft. lbs.).(4) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N´m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain-
ing bolt is located on the bottom side of the sleeve.
TIE ROD END
REMOVAL
(1) Remove tie rod nuts (Fig. 7).
(2) Remove tie rod from drag link and left knuckle
with Puller C-4150A.
INSTALLATION
(1) Install tie rod to the left steering knuckle and
drag link. Install the nuts and tighten to 108 N´m
(80 ft. lbs.).
(2) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
(3) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N´m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain-
ing bolt is located on the bottom side of the sleeve.
Fig. 5 PITMAN ARM REMOVAL/INSTALLATION
1 - STEERING GEAR
2 - PITMAN ARM
3 - NUT
4 - WASHER
Fig. 6 PITMAN ARM INSTALLED
1 - DRAGLINK
2 - STEERING GEAR
3 - SWAYBAR
4 - NUT/WASHER
5 - PITMAN ARM
Fig. 7 TIE ROD ENDS
1 - NUT
2 - TIE ROD ENDS
DRLINKAGE - LINK/COIL 19 - 37
PITMAN ARM (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................39
OPERATION...........................40
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 40
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....40
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............40
REMOVAL
REMOVAL - GAS......................41
REMOVAL - DIESEL...................41
INSTALLATION
INSTALLATION - GAS..................42
INSTALLATION - DIESEL................42
SPECIFICATIONS
TORQUE CHART......................42
FLUID
DESCRIPTION.........................43
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......43
FLUID COOLER
REMOVAL.............................43
INSTALLATION.........................43
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................44
REMOVAL - PRESSURE HOSE...........44
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................44INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................44
INSTALLATION - PRESSURE HOSE.......44
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............44
HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................45
REMOVAL - PRESSURE HOSE...........45
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................45
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................45
INSTALLATION - PRESSURE HOSE.......45
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............45
POWER STEERING PRESSURE SWITCH
DESCRIPTION.........................46
OPERATION...........................46
REMOVAL - 3.7L & 5.7L..................46
INSTALLATION - 3.7L & 5.7L...............46
PULLEY
REMOVAL.............................47
INSTALLATION.........................47
RESERVOIR
REMOVAL.............................47
INSTALLATION.........................47
PUMP
DESCRIPTION
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
DRPUMP 19 - 39

OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump (Fig.
1). The power steering pumps are constant flow rate
and displacement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steeringpump and system if any other fluid is used, and do
not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
Fig. 1 POWER STEERING PUMP
1 - 3.7L & 4.7L (6 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.7L,5.9L & 8.0L (7 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.9L DIESEL (8 GROOVE)
STEEL PULLEY
2 - PUMP ASSEMBLY
3 - RESERVOIR
4 - CAP
19 - 40 PUMPDR
PUMP (Continued)

HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the return hose at the cooler.
(4) Disconnect the return hose at the gear (Fig. 6).
(5) Remove the return hose from the routing clamp
at the fan shroud and then remove from the vehicle.
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the pressure hose at the pump.
(4)
Disconnect the pressure hose at the gear (Fig. 6).
(5) Remove the pressure hose from the vehicle.
REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Disconnect the return hose at the reservoir.
(3) Raise and support the vehicle.
(4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler.
(6) Remove the hose from the vehicle.
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reconnect the return hose at the gear. Tighten
the hose to 71 N´m (52 ft. lbs.) (Fig. 6).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the gear.
Tighten the hose to 32 N´m (23 ft. lbs.) (Fig. 6).
(3) Reconnect the pressure hose at the pump.
Tighten the hose to 36 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
(5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).Fig. 6 HOSE CONNECTIONS
1 - RETURN HOSE
2 - PRESSURE HOSE
19 - 44 PUMPDR

HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the return hose at the cooler.
(4) Disconnect the return hose at the gear (Fig. 7).
(5) Remove the return hose from the routing clamp
at the fan shroud and then remove from the vehicle.
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the pressure hose at the pump.
(4)
Disconnect the pressure hose at the gear (Fig. 8).
(5) Remove the pressure hose from the vehicle.
REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Disconnect the return hose at the reservoir.
(3) Raise and support the vehicle.
(4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler.
(6) Remove the hose from the vehicle.
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reconnect the return hose at the gear. Tighten
the hose to 51 N´m (38 ft. lbs.) (Fig. 7).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the gear.
Tighten the hose to 32 N´m (23 ft. lbs.) (Fig. 8).
(3) Reconnect the pressure hose at the pump.
Tighten the hose to 36 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
(5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reattach the hose to the routing clip at the fan
shroud.
Fig. 7 POWER STEERING HOSES TO STEERING GEAR
1 - HIGH PRESSURE HOSE
2 - RETURN HOSE
3 - STEERING GEAR
Fig. 8 HOSES INSTALLED
1 - LOWER COUPLING BOLT
2 - HIGH PRESSURE HOSE
3 - RETURN HOSE
4 - STEERING GEAR
5 - PITMAN ARM
DRPUMP 19 - 45