DODGE RAM 2002 Service Repair Manual

REMOVAL
(1) Remove the key lock cylinder.
(2) Remove the three ignition mounting screws
(Fig. 11).
(3) Gently pull the switch away from the column.
Disconnect the electrical connector (Fig. 12).
(4) Disconnect the halo lamp wiring connector
(Fig. 12).
INSTALLATION
(1) Rotate the flag on the rear of the ignition
switch to the RUN position (Fig. 13). This step must
be done to allow the tang (Fig. 14) on the key cylin-
der to fit into the slots (Fig. 11)within the ignition
switch.
(2) With the key into the key lock cylinder, rotate
the key clockwise until the retaining pin can be
depressed (Fig. 14) or (Fig. 15).
(3) Install the key cylinder into the ignition switch
by aligning the retaining pin slot. Push the key cyl-
inder into the switch until the retaining pin engages.
After the pin engages, rotate the key to the OFF or
LOCK position.
(4) Check for proper retention of the key cylinder
by attempting to pull the cylinder from the switch.
(5) Automatic Transmission Only: Before attaching
the ignition switch to the steering column, the trans-
mission shifter must be in the PARK position. The
park lock dowel pin on the rear of the ignition switch
(Fig. 16) must also be properly indexed into the park
lock linkage (Fig. 17) before installing the switch.
(6) The flag at the rear of the ignition switch
must be properly indexed into the steering column
before installing the switch. This flag is used to oper-
ate the steering wheel lock lever in the steering col-
umn (Fig. 18). This lever allows the steering wheel
position to be locked when the key is in the LOCK
position.
(7) Place the ignition switch in the LOCK position.
The switch is in the LOCK position when the column
lock flag is parallel to the ignition switch terminals
(Fig. 16).
Fig. 11 SWITCH MOUNTING SCREWS
1 - IGNITION SWITCH
2 - SLOTS NOT ALIGNED
3 - SLOTS ALIGNED
4 - IGNITION SWITCH MOUNTING SCREWS
Fig. 12 IGNITION SWITCH AND HALO
CONNECTORS
1 - KEY-IN SWITCH & HALO LIGHT
2 - MULTI-FUNCTION SWITCH
3 - TURN SIGNAL SWITCH & LEVER
4 - IGNITION SWITCH
5 - SPEED CONTROL
Fig. 13 FLAG IN RUN POSITION
1 - REAR OF IGNITION SWITCH
2 - PARK LOCK DOWEL PIN (RUN POSITION)
3 - FLAG (RUN POSITION)
19 - 12 COLUMNBR/BE
IGNITION SWITCH (Continued)

(8) Automatic Transmissions Only: Apply a light
coating of grease to the park lock dowel pin and park
lock slider linkage. Before installing the switch, push
the park lock slider linkage (Fig. 17)forward until it
bottoms. Do a final positioning by pulling it rear-
wards about one-quarter inch.
(9) Apply a light coating of grease to both the col-
umn lock flag and shaft at the end of the flag.
(10) Place the ignition switch into the openings on
the steering column(a) Automatic Transmissions Only: Be sure the
park lock dowel pin on the rear of the ignition
switch enters the slot in the park lock slider link-
age (Fig. 17).
(b) Be sure the flag on the rear of the switch is
positioned above the steering wheel lock lever (Fig.
18).
(c) Align the dowel pins on the rear of the switch
into the holes on the side of the steering column.
(d) Install the three ignition mounting screws.
Tighten the screws to 2 N´m (17 in. lbs.).
Fig. 14 KEY CYLINDER --- REAR VIEW
1 - IGNITION KEY LOCK CYLINDER
2 - PUSH PIN
3 - RETAINING PIN SLOT
4 - RETAINING PIN
5 - DRIVER
Fig. 15 INSTALLING KEY CYLINDER INTO SWITCH
1 - IGNITION SWITCH
2 - DRIVER
3 - IGNITION KEY LOCK CYLINDER
4 - RETAINING PIN
5 - RETAINING PIN SLOT
Fig. 16 IGNITION SWITCH VIEW FROM COLUMN
1 - REAR OF IGNITION SWITCH
2 - PARK LOCK DOWEL PIN (LOCK POSITION)
3 - FLAG (LOCK POSITION)
Fig. 17 PARK LOCK LINKAGE -- AUTOMATIC
TRANSMISSION -- TYPICAL
1 - DOWEL LOCATING HOLES (2)
2 - PARK LOCK SLIDER LINKAGE
3 - IGNITION SWITCH MOUNTING PAD
4 - STEERING COLUMN
5 - SLOT
BR/BECOLUMN 19 - 13
IGNITION SWITCH (Continued)

(e) After installing the ignition switch rotate the
ignition key from the LOCK to the ON position.
Verify that the park lock slider moves in the slider
slot, allowing the gear shift lever to be moved out
of PARK (automatic transmissions only). If the
slider does not move , and the gear shift lever is
locked in PARK, the ignition switch park lock
dowel pin, on the rear of the ignition switch, is not
properly installed in the slot of the park lock slider
linkage. Remove the ignition switch and reinstall.
(11) Connect the electrical connectors for the igni-
tion switch and halo lamp.
(12) Install the steering column shrouds. Tighten
the screws to 2 N´m (17 in. lbs.).
(13) Install the tilt column lever. (if equipped).
(14) Connect the battery.
(15) Automatic Transmissions Only: The shifter
should lock in the PARK position when the key is in
the LOCK position (if equipped with a shift lock
device). The shifter should unlock when the key is
rotated to the ON position.
(16) Check for proper operation of the ignition
switch in ACCESSARY, LOCK, OFF, ON, RUN and
start positions.
(17) The steering wheel should lock when the key
is in the LOCK position. Rotate the steering wheel at
least 180É to verify. The steering wheel should unlock
when the key is rotated to the ON position.GEAR SHIFT LEVER
REMOVAL
(1) Remove the tilt lever.
(2) Remove the upper and lower shrouds.
(3) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(4) Remove the steering column mounting nuts.
(5) Lower the steering column to remove the sec-
ondary shrouds.
(6) Raise the steering column back on the mount-
ing bolts and finger tighten the nuts.
(7) Disconnect over drive switch wiring.
(8) Using a drift of the appropriate size drive the
knurled pin out of the steering column and gear shift
lever. Remove the gear shift lever from the steering
column assembly.
CAUTION: The pin can only be removed from the
direction shown (Fig. 19).
Fig. 18 STEERING WHEEL LOCK LEVER
1 - STEERING COLUMN
2 - STEERING WHEEL LOCK LEVER
3 - LOCATER (SHAFT AT END OF FLAG)
Fig. 19 Gear Shift Lever Removal
1 - IGNITION SWITCH
2 - KNURLED PIN
3 - GEARSHIFT LEVER
4 - SOCKET
5 - DRIFT
6 - HAMMER
19 - 14 COLUMNBR/BE
IGNITION SWITCH (Continued)

INSTALLATION
(1) Install the gear shift lever into the steering col-
umn assembly. Align the pin holes in the gear shift
lever and the steering column assembly.
CAUTION: The pin must be installed in the original
direction.
(2) Carefully Install the pin into the steering col-
umn assembly and through the shift lever. If the pin
binds check the alignment on the holes. Be sure pin
is fully installed into the steering column assembly.
(3) Connect over drive switch wiring.
(4) Lower the steering column to install the sec-
ondary shrouds.
(5) Install the steering column mounting nuts.
Tighten the nuts to 12 N´m (105 in. lbs.).
(6) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-ING COLUMN OPENING COVER - INSTALLA-
TION).
(7) Install the upper and lower shrouds.
(8) Install the tilt lever.
STEERING WHEEL
REMOVAL
For steering wheel removal procedure,(Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
For steering wheel installation procedure,(Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
BR/BECOLUMN 19 - 15
GEAR SHIFT LEVER (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................16
OPERATION...........................16
DIAGNOSIS AND TESTING - POWER
STEERING GEAR LEAKAGE.............16
REMOVAL.............................18
INSTALLATION.........................18
ADJUSTMENTS........................18
SPECIFICATIONS
POWER STEERING GEAR..............21
TORQUE CHART......................21
SPECIAL TOOLS
POWER STEERING GEAR..............22
PITMAN BEARING
REMOVAL.............................22
INSTALLATION.........................23PITMAN SHAFT
REMOVAL.............................24
INSTALLATION.........................25
PITMAN SHAFT SEAL
REMOVAL.............................25
INSTALLATION.........................26
SPOOL VALVE
REMOVAL.............................26
INSTALLATION.........................28
STEERING GEAR HOUSING PLUG
REMOVAL.............................29
INSTALLATION.........................30
WORM SHAFT
REMOVAL.............................30
INSTALLATION.........................31
GEAR
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 17.5:1 and
14:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and abearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
DIAGNOSIS AND TESTING - POWER STEERING
GEAR LEAKAGE
(1) Possible power steering gear leakage areas.
(Fig. 2).
19 - 16 GEARBR/BE

Fig. 1 Power Steering Gear
1 - THRUST BEARING
2 - O-RING SEAL
3 - INLET
4 - OUTLET
5 - SEAL
6 - TORSION BAR
7 - STUB SHAFT
8 - ADJUSTER PLUG
9 - THRUST BEARING10 - TEFLON SEALS
11 - SPOOL VALVE
12 - VALVE BODY
13 - WORMSHAFT
14 - PIN
15 - PITMAN SHAFT
16 - RACK PISTON
17 - TEFLON RING
BR/BEGEAR 19 - 17
GEAR (Continued)

REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
(2) Disconnect and cap the fluid hoses from steer-
ing gear.
(3) Remove coupler pinch bolt at the steering gear
and slide shaft off gear (Fig. 3).
(4) Mark the pitman shaft and pitman arm for
installation reference. Remove the pitman arm from
the shaft with Puller C-4150A (Fig. 4).(5) Remove steering gear retaining bolts and nuts.
Remove the steering gear from the vehicle.INSTALLATION
(1) Position the steering gear on the frame rail and
install the bolts. Tighten mounting bolts to specifica-
tions.
(2) Align steering coupler on gear shaft. Install
pinch bolt and tighten to 49 N´m (36 ft. lbs.) torque.
(3) Align and install the pitman arm.
(4) Install the washer and retaining nut on the pit-
man shaft. Tighten the nut to 251 N´m (185 ft. lbs.).
(5) Connect fluid hoses to steering gear, tighten to
31 N´m (23 ft. lbs.). Add fluid, (Refer to 19 - STEER-
ING/PUMP - STANDARD PROCEDURE).
ADJUSTMENTS
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
Fig. 2 STEERING GEAR
Fig. 3 Column Shaft
1 - STEERING GEAR
2 - STEERING COUPLER
Fig. 4 Pitman Arm
1 - PITMAN ARM
2 - SPECIAL TOOL C-4150-A
3 - WRENCH
19 - 18 GEARBR/BE
GEAR (Continued)

WORM THRUST BEARING PRELOAD
(1) Mount the gear carefully into a vise.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Remove adjuster plug locknut (Fig. 5).
(3) Rotate the stub shaft back and forth with a 12
point socket to drain the remaining fluid.
(4) Turn the adjuster in with Spanner Wrench
C-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed in the housing about
28-31 N´m (20-23 ft. lbs.).
(5) Place an index mark on the housing even with
one of the holes in adjuster plug (Fig. 6).
(6) Measure back (counterclockwise) 18 mm (0.70
in) and mark the housing (Fig. 7).
(7) Rotate adjustment cap back (counterclockwise)
with spanner wrench until hole is aligned with the
second mark (Fig. 8).
(8) Install and tighten lock nut to 108 N´m (80 ft.
lbs.). Be sure adjustment cap does not turn while
tightening the lock nut.
PITMAN SHAFT OVER-CENTER PRELOAD
NOTE: Before performing this procedure, the worm
bearing preload adjustment must be performed.
(1) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(2) Starting at either stop, turn the stub shaft
back 1/2 the total number of turns. This is the center
of the gear travel (Fig. 9).(3) Place the torque wrench in the vertical position
on the stub shaft. Rotate the wrench 45 degrees each
side of the center and record the highest rotational
torque in this range (Fig. 10). This is the Over-Cen-
ter Rotating Torque.
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
Fig. 5 Adjuster Lock Nut
1 - ADJUSTER NUT
2 - STEERING GEAR
3 - LOCK NUT
4 - PUNCH
Fig. 6 Alignment Marking On Housing
1 - INDEX
Fig. 7 Second Marking On Housing
1 - REFERENCE MARK
BR/BEGEAR 19 - 19
GEAR (Continued)

(4) Rotate the stud shaft between 180É and 270É to
the left of center and record the left off-center pre-
load. Repeat this to the right of center and record the
right off-center preload. The average of these two
recorded readings is the Preload Rotating Torque.
(5) The Over-Center Rotating Torque should be
0.23-0.68 N´m (2-6 in. lbs.)higherthan the Preload
Rotating Torque.
(6) If an adjustment to the Over-Center Rotating
Torque is necessary, first loosen the adjuster lock
nut. Then turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until fully extended, then
turn back in (CLOCKWISE) one full turn.
(7) Remeasure Over-Center Rotating Torque. If
necessary turn the adjuster screw and repeat mea-
surement until correct Over-Center Rotating Torque
is reached.
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.
(8) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 49 N´m (36 ft. lbs.).
Fig. 8 Aligning To The Second Mark
1 - FIRST MARK
2 - SECOND MARK
3 - SPANNER WRENCH
Fig. 9 Steering Gear Centered
1 - ADJUSTMENT SCREW
2 - MASTER SPLINE
Fig. 10 Checking Over-center Rotation Torque
1 - CENTER
19 - 20 GEARBR/BE
GEAR (Continued)

SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Steering Gear
TypeRecirculating Ball
DESCRIPTION SPECIFICATION
Gear Code & Ratio
AM17.5:1
Gear Code & Ratio
HC/FW14:1
Gear Code & Ratio
JZ16-13:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Wormshaft Bearing
Preload0.85-1.64 Ð 7.5-14.5
Pitman Shaft Overcenter Drag
New Gear (under 400 miles)0.23-0.68 Ð 2-6
+ Wormshaft Preload
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Steering Gear Mounting
Frame Bolts176 130 Ð
Line Fittings
Pressure31 23 Ð
Line Fittings
Return31 23 Ð
Steering Gear
Adjustment Cap Locknut108 80 Ð
Steering Gear
Adjustment Screw Locknut49 36 Ð
Steering Gear
Pitman Shaft Nut251 185 Ð
Steering Gear
Rack Piston Plug150 111 Ð
Steering Gear
Side Cover Bolts60 44 Ð
Steering Gear
Return Guide Clamp Bolt4.8 Ð 43
BR/BEGEAR 19 - 21
GEAR (Continued)