Cylinder DODGE RAM 1500 1998 2.G Workshop Manual

INSTALLATION
(1)Inspect fuel injector:
(a) Look for burrs on injector inlet.
(b) Check nozzle holes for hole erosion or plug-
ging.
(c) Inspect end of nozzle for burrs or rough
machine marks.
(d) Look for cracks at nozzle end.
(e) If any of these conditions occur, replace injec-
tor.
(2) Thoroughly clean fuel injector cylinder head
bore. Blow out bore hole with compressed air.
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of acertain thickness (Fig. 20). A new shim with correct
thickness must always be re-installed after removing
injector. Measure thickness of injector shim (Fig. 21).
Shim Thickness: 1.5 mm (.060º)
(4) Install new shim (washer) to bottom of injector.
Apply light coating of clean engine oil to washer. This
will keep washer in place during installation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
Fig. 18 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
Fig. 19 FUEL INJECTOR REMOVER - #9010
Fig. 20 FUEL INJECTOR SEALING WASHER (SHIM)
LOCATION
1 - FUEL INJECTOR
2 - COPPER SEALING WASHER (SHIM)
Fig. 21 MEASURING INJECTOR SEALING WASHER
(SHIM)
1 - SHIM
DRFUEL INJECTION - DIESEL 14 - 77
FUEL INJECTOR (Continued)

(6) Install injector into cylinder head with male
connector port facing the intake manifold. Push down
on fuel injector mounting flange to engage o-ring and
seat injector.
(7) Tightening Sequence:
(a) Install fuel injector holdown clamp (mount-
ing flange) bolts.Do a preliminary tightening
of these bolts to 5 N´m (44 in. lbs.) torque.
This preliminary tightening insures the fuel
injector is seated and centered.
(b) After tightening, relieve bolt torque, but
leave both bolts threaded in place.
(c) Install high-pressure connector and retaining
nut. Do a preliminary tightening to 15 N´m (11 ft.
lbs.) torque.
(d) Alternately tighten injector holdown bolts to
10 N´m (89 in. lbs.) torque.
(e) Do a final tightening of the high-pressure
connector and retaining nut. Tighten to 50 N´m (37
ft. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.25
N´m (11 in. lbs.) torque.Be very careful not to
overtighten these nuts as damage to fuel injec-
tor will occur.
(9) Install exhaust rocker arm assembly. Refer to
Engine.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure fuel line. Refer to Torque
Specifications.Be sure to use a secondary
back-up wrench on the connector nut (fitting)
while torquing fuel line fitting.Refer to Fuel Line
Installation for additional information.
(12) Install valve cover. Refer to Engine.
(13) Install breather assembly.
(14) Connect negative battery cables to both bat-
teries.
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing.Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing.Do not bend lines while remov-
ing.
(8) Remove fuel line connecting injector pump to
fuel rail.
(9) Remove 3 injector rail mounting bolts (Fig. 22).
(10) Remove rail from top of intake manifold.
INSTALLATION
(1) Clean any dirt/debris from top of intake mani-
fold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Refer to Torque Specifications.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Install and tighten fuel limiting valve banjo
bolt. Refer to Torque Specifications.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
14 - 78 FUEL INJECTION - DIESELDR
FUEL INJECTOR (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
DIAGNOSIS AND TESTING - STEERING
COLUMN.............................7
REMOVAL.............................7
INSTALLATION..........................9
IGNITION SWITCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................9
REMOVAL.............................10
INSTALLATION.........................11
KEY-IN IGNITION SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......11
KEY CYLINDER
REMOVAL.............................12
INSTALLATION.........................12GEAR SHIFT LEVER
REMOVAL.............................12
INSTALLATION.........................12
UPPER STEERING COUPLING
REMOVAL.............................13
INSTALLATION.........................13
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD...................14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD.................................14
INSTALLATION - 4X4 HD................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
TILT LEVER KNOB RELEASE
REMOVAL.............................16
INSTALLATION.........................16
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT INACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
19 - 6 COLUMNDR

NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col-
lapsed. Inspect the column mounting capsules visu-
ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the front wheelsstraight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the two switches from the steering
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98±1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever.
(8) Remove the column shrouds (Fig. 2).
(9) Remove the clock spring, (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
(10) Disconnect the wiring harness to the column.
Fig. 1 STEERING COLUMN
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DRCOLUMN 19 - 7
COLUMN (Continued)

(17) Remove the steering column assembly from
the vehicle. (Fig. 7)
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install anewbolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N´m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N´m (42 ft. lbs.).(6) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(7) Install the shifter cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column.
(9) Install the SKIM module.
(10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds.
(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(13) Align the spline on the wheel hub to shaft.
(14) Then install the steering wheel and install a
newbolt. Tighten the bolt to 61 N´m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches.
(17) Install the tilt lever handle.
(18) Install the negative battery terminal.
(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.
IGNITION SWITCH
DESCRIPTION
The ignition switch is located on the steering col-
umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
Fig. 7 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DRCOLUMN 19 - 9
COLUMN (Continued)

HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.
REMOVAL
SERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped
with an automatic transmission is not equipped
with an internal locking shaft with the ignition cyl-
inder. Alternative methods of locking the steering
wheel for service will have to be used.
The tilt and standard column (Fig. 8) have been
designed to be serviced as an assembly; without wir-
ing, switches, shrouds, steering wheel, etc. Most
steering column components can be serviced without
removing the steering column from the vehicle.
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag,
Refer to Electrical Restraints and follow all WARN-
INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG ANDPOSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism.
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) Remove the negative (ground) cable from the
battery.
(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(3) Remove the lower and upper shrouds.
(4) Remove key cylinder. (Refer to 19 - STEER-
ING/COLUMN/LOCK CYLINDER HOUSING -
REMOVAL).
(5) Disconnect the lower clockspring connectors.
(6) Remove the wire retainer from the tilt lever
bracket.
(7) Remove the tilt lever mounting screws to gain
access to the ignition switch mounting screws. (Fig.
9)
Fig. 8 STEERING COLUMN
1 - KEY CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - IGNITION SWITCH
Fig. 9 IGNITION SWITCH WITH TILT
1 - IGNITION SWITCH
2 - TILT LEVER MECHANISM
19 - 10 COLUMNDR
IGNITION SWITCH (Continued)

(8) For columns without tilt remove the bracket to
gain access to the ignition switch mounting screws.
(Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
(10) Remove ignition switch mounting screw.
(11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.(2) Connect the electrical connector to rear of the
ignition switch. Make sure that locking tabs are fully
seated into wiring connector.
(3) Position switch to column and install the
mounting screw. Tighten screw to 3 N´m (26 in. lbs.).
(4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N´m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N´m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
(7) Reconnect the lower clockspring connectors.
(8) Install the key cylinder.
(9) Install steering column upper and lower
shrouds.
(10) Enable the airbag system. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION).
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition key cylinder and the driver
door ajar switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition key cylinder.
The ground path is also opened when the driver door
ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri-
cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
Fig. 10 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 11 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
DRCOLUMN 19 - 11
IGNITION SWITCH (Continued)

KEY CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
(1) Disconnect negative cable from battery.
(2) Remove upper and lower covers (shrouds) from
steering column.
(3) Place shifter in PARK position.
(4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.
(a) Rotate key to RUN position.
(b) Press in on retaining pin while pulling key
cylinder from ignition switch (Fig. 13).
INSTALLATION
The ignition key must be in the key cylinder for
cylinder installation.
(1) Install the key cylinder into the housing using
care to align the end of the key cylinder with the
ignition switch.
(2) Push the key cylinder in until it clicks.
(3) Replace the upper and lower shrouds.
(4) Reconnect the battery.
GEAR SHIFT LEVER
REMOVAL
(1) Remove the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER -
REMOVAL).
(2) Remove the upper and lower column shroud.
(3) Remove and discard the brake light switch.
(4) Loosen the column bolts and lower the column
enough to allow clearance for the gear shift lever
removal.
(5) Disconnect the overdrive switch harness (if
equipped).
(6) Disconnect the shift cable from the shift lever.
(7) Remove the SKIM.
(8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)
(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).
INSTALLATION
(1) Install the lever assembly using care to install
the pin in the blocker to slider slot (Fig. 15) and
install the mounting screws and tighten to 12 N´m
(105 in. lbs.).
Fig. 12 KEY CYLINDER
1 - KEY
2 - KEY CYLINDER
3 - RETAINING PIN HOLE
Fig. 13 KEY CYLINDER
1 - KEY CYLINDER
2 - PUNCH
Fig. 14 GEAR SHIFT LEVER
1 - PARK INHIBIT BLOCKER SPRING
2 - GEAR SHIFT LEVER
19 - 12 COLUMNDR

(2) Cycle the key from ACC to RUN and ensure
that the blocker does not stick or bind.
(3) Turn the key to the OFF position and ensure
that the shifter will not pull from the PARK position.
(4) Connect the over drive switch harness (if
equipped).
NOTE: Route and tie off harness to original loca-
tion.
(5) Connect the shift cable to the lever.
(6) Ensure the gear shift lever and transmission
are in the PARK position and snap the cable adjust
clip in place.
(7) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(8) Install the SKIM and halo.
(9) Install the upper and lower column shroud.
(10) Install the column back into place and
tighten.
(11) Install the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
UPPER STEERING COUPLING
REMOVAL
(1) Disconnect the negative battery cable.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.(2) Lock the steering wheel with the tire in the
straight position.
(3) Remove and discard the lower pinch bolt.
(4) Lower the steering coupler shaft from the col-
umn.
(5) Remove the upper steering coupling shaft seal
by pushing in the four tags securing it to the panel
(Fig. 16).
(6) Remove and discard the lower coupler pinch
bolt from the lower steering coupling shaft (Fig. 17).
(7) Remove the upper steering coupling shaft from
the vehicle (Fig. 17).
INSTALLATION
(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).
Fig. 15 GEAR SHIFT LEVER SPRING
1 - BLOCKER TO INHIBIT LINK SLOT
2 - GEAR SHIFT LEVER
Fig. 16 RELEASE TANGS
1 - RELEASE TANGS (4)
2 - UPPER STEERING COUPLER SHAFT
Fig. 17 UPPER STEERING COUPLER SHAFT
1 - LOWER STEERING COUPLER
2 - RELEASE TANGS (4)
3 - UPPER STEERING COUPLER SHAFT
DRCOLUMN 19 - 13
GEAR SHIFT LEVER (Continued)

(2) Install the upper steering coupling shaft seal
by pushing it in securing the four tangs to the panel
(Fig. 16).
NOTE: Note: A new steering coupling shaft pinch
bolt for the upper and lower shafts must be used.
(3) Install the steering coupler shaft to the column
(Fig. 17).
(4) Install the upper pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(5) Install the shaft to the lower coupler (Fig. 17).
(6) Install the lower pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(7) Unlock the steering wheel.
(8) Reconnect the negative battery cable.
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly.
(5) Mark both coupler connections for proper
installation.
(6) Remove and discard the upper coupler pinch
bolt.
(7) Remove and discard the lower coupler pinch
bolt.
(8) Remove the lower steering shaft coupler (Fig.
18).
REMOVAL - 4X4 HD
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly.
(5) Remove and discard the upper coupler pinch
bolt (Fig. 20).
(6) Remove and discard the lower coupler pinch
bolt (Fig. 19).
(7) Remove the lower steering shaft coupler (Fig.
20).
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD
(1) Install the coupler to the steering rack & pin-
ion using the marks made in the removal process.
Fig. 18 LOWER STEERING COUPLER
Fig. 19 LOWER COUPLER PINCH BOLT
1 - INTERMEDIATE STEERING SHAFT
2 - LOWER COUPLING BOLT
3 - STEERING GEAR
19 - 14 COLUMNDR
UPPER STEERING COUPLING (Continued)