DODGE RAM 2002 Service Repair Manual

SPECIAL TOOLS
POWER STEERING GEAR
PITMAN BEARING
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Remove preload adjuster nut (Fig. 11).
(3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
(5) Remove side cover bolts and remove side cover,
gasket and pitman shaft as an assembly (Fig. 11).
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove pitman shaft from the side cover.
(7) Remove dust seal from the housing with a seal
pick (Fig. 12).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
(9) Remove washer from the housing.
Remover/Installer, Steering Plug C-4381
Remover, Pitman Arm C-4150A
Remover/Installer Steering Rack Piston C-4175
Fig. 11 Side Cover and Pitman Shaft
1 - SIDE COVER BOLTS
2 - PRELOAD ADJUSTER NUT
3 - SIDE COVER
4 - GASKET SEAL
5 - PITMAN SHAFT GEAR
6 - HOUSING ASSEMBLY
Fig. 12 Pitman Shaft Seals & Bearing
1 - BEARING
2 - WASHER
3 - DUST SEAL
4 - RETAINER
5 - OIL SEAL
19 - 22 GEARBR/BE
GEAR (Continued)

(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 13).
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 14). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 15).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment, (Refer to 19 - STEERING/GEAR - DIAGNOSIS
AND TESTING).
Fig. 13 Needle Bearing Removal
1 - REMOVER
2 - SIDE COVER AREA
Fig. 14 Upper Pitman
1 - DRIVER
2 - UPPER BEARING
Fig. 15 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
BR/BEGEAR 19 - 23
PITMAN BEARING (Continued)

PITMAN SHAFT
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Remove preload adjuster nut (Fig. 16).
(3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
(5) Remove side cover bolts and remove side cover,
gasket and pitman shaft as an assembly (Fig. 16).
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove pitman shaft from the side cover.
(7) Remove dust seal from the housing with a seal
pick (Fig. 17).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.(9) Remove washer from the housing.
(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 18).
Fig. 16 Side Cover and Pitman Shaft
1 - SIDE COVER BOLTS
2 - PRELOAD ADJUSTER NUT
3 - SIDE COVER
4 - GASKET SEAL
5 - PITMAN SHAFT GEAR
6 - HOUSING ASSEMBLY
Fig. 17 Pitman Shaft Seals & Bearing
1 - BEARING
2 - WASHER
3 - DUST SEAL
4 - RETAINER
5 - OIL SEAL
Fig. 18 Needle Bearing Removal
1 - REMOVER
2 - SIDE COVER AREA
19 - 24 GEARBR/BE

INSTALLATION
(1) Install pitman shaft bearing into housing with
a bearing driver and handle.
(2) Coat the oil seal and washer withspecial
greasesupplied with the new seal.
(3) Install the oil seal with a driver and handle.
(4) Install backup washer.
(5) Install the retainer ring with snap ring pliers.
(6) Coat the dust seal withspecial greasesup-
plied with the new seal.
(7) Install dust seal with a driver and handle.
(8) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(9) Install preload adjuster nut.Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(10) Install gasket to side cover and bend tabs
around edges of side cover (Fig. 11).
(11) Install pitman shaft assembly and side cover
to housing.
(12) Install side cover bolts and tighten to 60 N´m
(44 ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment, (Refer to 19 - STEERING/GEAR - ADJUST-
MENTS).
PITMAN SHAFT SEAL
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Remove preload adjuster nut (Fig. 19).
(3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
(5) Remove side cover bolts and remove side cover,
gasket and pitman shaft as an assembly (Fig. 19).
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove pitman shaft from the side cover.
(7) Remove dust seal from the housing with a seal
pick (Fig. 20).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
(9) Remove washer from the housing.
(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 21).
Fig. 19 Side Cover and Pitman Shaft
1 - SIDE COVER BOLTS
2 - PRELOAD ADJUSTER NUT
3 - SIDE COVER
4 - GASKET SEAL
5 - PITMAN SHAFT GEAR
6 - HOUSING ASSEMBLY
Fig. 20 Pitman Shaft Seals & Bearing
1 - BEARING
2 - WASHER
3 - DUST SEAL
4 - RETAINER
5 - OIL SEAL
BR/BEGEAR 19 - 25
PITMAN SHAFT (Continued)

INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 22). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 23).Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment, (Refer to 19 - STEERING/GEAR - ADJUST-
MENTS).
SPOOL VALVE
REMOVAL
(1) Remove lock nut (Fig. 24).
(2) Remove adjuster nut with Spanner Wrench
C-4381.
Fig. 21 Needle Bearing Removal
1 - REMOVER
2 - SIDE COVER AREA
Fig. 22 Upper Pitman Shaft Bearing
1 - DRIVER
2 - UPPER BEARING
Fig. 23 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
19 - 26 GEARBR/BE
PITMAN SHAFT SEAL (Continued)

(3) Remove thrust support assembly out of the
housing (Fig. 25).
(4) Pull stub shaft and valve assembly from the
housing (Fig. 26).
(5) Remove stub shaft from valve assembly by
lightly tapping shaft on a block of wood to loosen
shaft. Then disengage stub shaft pin from hole in
spool valve and separate the valve assembly from
stub shaft (Fig. 27).
(6) Remove spool valve from valve body by pulling
and rotating the spool valve from the valve body (Fig.
28).
Fig. 24 Lock Nut and Adjuster Nut
1 - ADJUSTER NUT
2 - STEERING GEAR
3 - LOCK NUT
4 - PUNCH
Fig. 25 Thrust Support Assembly
1 - STUB SHAFT
2 - HOUSING
3 - THRUST SUPPORT ASSEMBLY
Fig. 26 Valve Assembly With Stub Shaft
1 - GEAR
2 - THRUST SUPPORT
3 - LOCK NUT
4 - ADJUSTER NUT
5 - STUB SHAFT
6 - VALVE ASSEMBLY
Fig. 27 Stub Shaft
1 - STUB SHAFT
2 - VALVE BODY
3 - HOLE IN SPOOL
4 - SHAFT PIN
5 - 6mm (1/49)
BR/BEGEAR 19 - 27
SPOOL VALVE (Continued)

(7) Remove spool valve O-ring and valve body
teflon rings and O-rings underneath the teflon rings
(Fig. 29).
(8) Remove the O-ring between the worm shaft
and the stub shaft.
INSTALLATION
NOTE: Clean and dry all components, then lubricate
with power steering fluid.
(1) Install spool valve spool O-ring.
(2) Install spool valve in valve body by pushing
and rotating. Hole in spool valve for stub shaft pin
must be accessible from opposite end of valve body.
(3) Install stub shaft in valve spool and engage
locating pin on stub shaft into spool valve hole (Fig.
30).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
(4) Install O-rings and teflon rings over the
O-rings on valve body.
(5) Install O-ring into the back of the stub shaft
cap (Fig. 31).
(6) Install stub shaft and valve assembly in the
housing. Line up worm shaft to slots in the valve
assembly.
(7) Install thrust support assembly.
NOTE: The thrust support is serviced as an assem-
bly. If any component of the thrust support is dam-
aged the assembly must be replaced.
Fig. 28 Spool Valve
1 - SPOOL VALVE
2 - ROTATE VALVE TO REMOVE
3 - VALVE BODY
Fig. 29 Valve Seals
1 - O-RING SEALS
Fig. 30 Stub Shaft Installation
1 - NOTCH IN CAP
2 - VALVE BODY PIN
19 - 28 GEARBR/BE
SPOOL VALVE (Continued)

(8) Install adjuster nut and lock nut.
(9) Adjust Thrust Bearing Preload and Over-Cen-
ter Rotating Torque, (Refer to 19 - STEERING/GEAR
- ADJUSTMENTS).
STEERING GEAR HOUSING
PLUG
REMOVAL
(1) Unseat and remove retaining ring from groove
with a punch through the hole in the end of the
housing (Fig. 32).
(2) Slowly rotate stub shaft with 12 point socket
COUNTER-CLOCKWISE to force the end plug out
from housing.
CAUTION: Do not turn stub shaft any further than
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far.
(3) Remove O-ring from the housing (Fig. 33).
Fig. 31 Stub Shaft Cap O-Ring
1 - VALVE BODY
2 - STUB SHAFT CAP
3 - O-RING
Fig. 32 End Plug Retaining Ring
1 - RETAINING RING
Fig. 33 End Plug Components
1 - HOUSING ASSEMBLY
2 - HOUSING END PLUG O-RING SEAL
3 - HOUSING END PLUG
4 - RETAINING RING
BR/BEGEAR 19 - 29
SPOOL VALVE (Continued)

INSTALLATION
(1) Lubricate O-ring with power steering fluid and
install into the housing.
(2) Install end plug by tapping the plug lightly
with a plastic mallet into the housing.
(3) Install retaining ring so one end of the ring
covers the housing access hole (Fig. 34).
WORM SHAFT
REMOVAL
(1) Remove housing end plug, (Refer to 19 -
STEERING/GEAR/STEERING GEAR HOUSING
PLUG - REMOVAL).
(2) Remove rack piston plug (Fig. 35).
(3) Remove side cover and pitman shaft.
(4) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 36) and hold tool tightly against worm shaft.
(6) Turn the stub shaft with a 12 point socket
COUNTERCLOCKWISE, this will force the rack pis-
ton onto the tool and hold the rack piston balls in
place.
(7) Remove the rack piston and tool together from
housing.
(8) Remove tool from rack piston.
(9) Remove rack piston balls.
(10) Remove clamp bolts, clamp and ball guide
(Fig. 37).
Fig. 34 Installing The
1 - RING CAP
2 - PUNCH ACCESS HOLE
3 - RETAINER RING
Fig. 35 Rack Piston End Plug
1 - EXTENSION
2 - END PLUG
3 - RACK PISTON
4 - RATCHET
Fig. 36 Rack Piston with Arbor
1 - RACK PISTON
2 - SPECIAL TOOL C-4175
19 - 30 GEARBR/BE
STEERING GEAR HOUSING PLUG (Continued)

(11) Remove teflon ring and O-ring from the rack
piston (Fig. 38).
(12) Remove the adjuster lock nut and adjuster
nut from the stub shaft.
(13) Pull the stub shaft with the spool valve and
thrust support assembly out of the housing.
(14) Remove the worm shaft from the housing
(Fig. 39).
INSTALLATION
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, nicks or burrs on the rack
piston finished surface. Slight wear is normal on the
worm gear surfaces.
(2) Install O-ring and teflon ring on the rack pis-
ton.
(3) Install worm shaft in the rack piston and align
worm shaft spiral groove with rack piston ball guide
hole (Fig. 40).
Fig. 37 Rack Piston
1 - CLAMP
2 - BALLS
3 - RACK PISTON
4 - BALL GUIDE
Fig. 38 Rack Piston Teflon Ring and O-Ring
1 - TEFLON SEAL
2 - BACK-UP O-RING MUST BE INSTALLED UNDER PISTON
RING
3 - RACK PISTON NUT
Fig. 39 Worm Shaft
1 - GEAR HOUSING
2 - BEARING RACE
3 - WORM SHAFT
4 - BEARING
Fig. 40 Installing Balls in Rack Piston
1 - INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING
WORM COUNTER CLOCKWISE
2 - WORM FLANGE
BR/BEGEAR 19 - 31
WORM SHAFT (Continued)