DODGE TRUCK 1993 Service Repair Manual

19-20
STEERING

•
RECIRCULATING BALL POWER STEERING GEAR

INDEX

page

Adjuster
Plug Assembly Replacement
26
Check
Valve Replacement
32

Gear
Disassembly
Information
23

Housing
End
Plug
25

Pitman Shaft
and
Side Cover Replacement
25

Pitman Shaft
Seals
— in
Car
Replacement
..... 20
page

Pitman Shaft
Seals
and
Bearing Replacement
. . . 31

Rack
Piston
and
Worm Shaft Replacement
..... 29

Service
Information
20

Steering Gear Adjustments
22

Steering Gear Replacement
32

Valve
Replacement
27

SERVICE
INFORMATION
A recirculating-ball steering gear
is
used with
the

power (assisted) steering system.
The
power steering gear
can be
adjusted
and
internally serviced.

PITMAN
SHAFT
SEALS
- IN
CAR
REPLACEMENT

REMOVAL (1)
Remove pitman
arm
from gear. Refer
to
Pit­
man
Arm
Removal
in
Steering Linkage.

(2)
Clean exposed
end of
pitman shaft
and
housing.
Use
a
wire brush
to
clean
the
shaft splines. (3) Remove retaining ring with snap ring pliers
(Fig.
1).
RETAINING RING

BACKUP
WASHER
DOUBLE-UP SEAL

BACKUP
WASHER

SINGLE-LIP
SEAL

NEEDLE
BEARING
J8919-39

Fig.
1
Pitman Shaft
Seals

CAUTION:
Use
care
not to
score
the
housing bore
when prying
out
seals
and
washers.

(4) Remove backup washer
and
double
lip
seal
with screwdriver.
• Start
the
engine
and
turn
the
steering wheel fully
to
the
LEFT
to
force
out the
seals
and
washers. • Stop
the
engine.

(5)
Remove backup washer
and
single
lip
seal with
screwdriver.

(6)
Inspect
the
housing
for
burrs
and
remove
if

necessary. Inspect
the
pitman shaft seal surface
for

roughness
and
pitting.
If
pitted replace shaft.

INSTALLATION
(1)
Install single
lip
seal with Installer
or a
suit­
able size deep socket
(Fig. 2).

SPECIAL
TOOL
C4171

TOP
OF
TOOL
FLUSH
WITH
HOUSING

SPECIAL
TOOL
G4328
J9119-42

Fig.
2
Pitman Shaft
Seal
Installation

(2)
Coat
the
double
lip
seal
and
washer with
grease.
(3) Install
the
backup washer.
(4) Install
the
double
lip
seal.
(5)
Install
the
backup washer.

(6)
Install
the
retainer ring with snap ring pliers. (7) Center
the
steering gear.
(8) Install
the
pitman
arm.
Refer
to
Pitman
Arm

Installation
in
Steering Linkage. (9)
Add
power steering fluid. Refer
to
Power Steer­
ing Initial Operation.

19 - 22
STEERING
——— —
WORM THRUST BEARING PRELOAD
ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 4).

Fig.
4
Loosening
the Adjuster
Plug
Locknut

(2) Turn the adjuster in with Spanner Wrench

C-4381.
Tighten the plug and thrust bearing in the
housing until firmly bottomed in housing.
(3) Place an index mark on the housing even with
one of the holes in adjuster plug (Fig. 5). (4) Measure back (counterclockwise) 13 mm (0.50
in) and mark housing (Fig. 6). (5) Rotate adjustment cap back (counterclockwise)
with spanner wrench until hole is aligned with the
second mark (Fig. 7). (6) Install and tighten locknut to 109 N-m (80 ft.
lbs.) torque. Be sure adjustment cap does not turn
while tightening the locknut.
OVER-CENTER ADJUSTMENT (1) Rotate the stub shaft 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. 8). •

J8919-58

Fig.
5
Alignment
Marking On
Housing
Fig.
6 Remarking The
Housing

(3) Turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until extended, then turn
back in (CLOCKWISE) one full turn.
(4) 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 on center (Fig. 9).
(5) Turn the adjuster in until torque to turn stub
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more than
reading in Step 4.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster lock nut to 49 N-m (36 ft. lbs.).

STEERING
GEAR
ADJUSTMENTS

SERVICE
INFORMATION
Adjusting the steering gear in the vehicle is NOT
recommended. Remove the gear from the vehicle (Fig. 3) and mount in a vise. Drain the power steer­
ing fluid and make the following adjustments in this
order:
• FIRST - worm thrust bearing preload
• SECOND - over-center preload adjustment

•

FIRST

MARK

J9219-30
Fig. 7
Aligning
To The Second
Mark

GEAR
DISASSEMBLY
INFORMATION

CAUTION:
Cleanliness is extremely important when repairing a power steering gear.
Keep
the bench,

tools
and components clean at all times. Thor­
oughly
clean the exterior of the gear
with
cleaning

solvent
before
disassembly.
Drain as much of the
fluid as
possible.
Use protective vise jaws at all

times
when clamping components.
During
assem­
bly,
lubricate all components
with
power steering
fluid except when instructed otherwise (Fig. 10).
STEERING
19 - 23
Fig. 8
Steering
Gear
Centered

Fig. 9 Checking
Over-center
Rotation
Torque

TO
4^
m
rn
z
o
1 -
HOUSING,
STEERING
GEAR

2 - RACE,
THRUST
BEARING
(WORM)

3 -
BEARING
ASSY.,
ROLLER
THRUST
(WORM)

4 - RACE,
THRUST
BEARING
(WORM)

5 -
WORM,
STEERING
6 - SEAL "O" RING
(STUB
SHAFT)

7 - SHAFT, STUB
8 - SPOOL, VALVE
9 - SEAL, "O"
RING
(SPOOL)

10 - BODY, VALVE
11 -
RING,
VALVE
BODY
(3)
12 - SEAL, "O" RING (VALVE BODY) (3)
13 - RETAINER, BEARING (ADJUSTER)
14 - SPACER, THRUST BEARING
15 - RACE, UPPER THRUST BEARING
(SMALL)

16 - BEARING, UPPER THRUST
17 - RACE, UPPER THRUST BEARING (LARGE)
18 - SEAL, "O" RING (ADJUSTER)
19 - PLUG, ADJUSTER
20 - BEARING, NEEDLE
21 - SEAL, STUB SHAFT
22 - SEAL, STUB SHAFT DUST
23 - RING, RETAINING
24 - NUT, ADJUSTER PLUG LOCK 25 - BEARING
ASSY.,
NEEDLE (PITMAN SHAFT)
26 - SEAL, PITMAN SHAFT (SINGLE LIP)
27 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
28 - SEAL, PITAAAN SHAFT (DOUBLE LIP)
29 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
30 - RING, RETAINING (PITMAN SHAFT SEAL)
31 - WASHER, PITMAN SHAFT LOCK
32 - NUT, PITMAN SHAFT
33 - NUT, RACK PISTON
34 - BALL
35 - GUIDE, BALL RETURN (2)
36 - CLAMP, BALL RETURN GUIDE
37 - SCREW
ASSY.,
LOCKWASHER & (2)
38 - PLUG, RACK PISTON
39 - SEAL, "O" RING (RACK PISTON)
40 - RING, RACK
PISTON

41 - SEAL, "O" RING (HOUSING END PLUG)
42 - PLUG, HOUSING END
43 - RING, RETAINING (HOUSING END PLUG)
44 - GEAR
ASSY.,
PITMAN SHAFT
45 - SEAL
ASSY.,
GASKET
46 - COVER
ASSY.,
HOUSING SIDE
47 - BOLT, HEX. HEAD (SIDE COVER) (4)
48 - NUT, LASH ADJUSTER

J9219-64
Fig. 10
Power
Steering
Gear

•

STEERING
19 - 25
PITMAN
SHAFT AND SIDE COVER REPLACEMENT

REMOVE (1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section. (2) Remove pitman arm from steering gear. Refer
to Pitman Arm Removal in the Steering Linkage sec­
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
• Clean exposed end of pitman shaft and housing.
• Clean pitman shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear.
Remove side cover bolts. (3) Remove side cover, gasket and pitman shaft as
an assembly.
(4) Remove pitman shaft from the side cover (Fig.

11). Fig.
11
Side
Cover
and Pitman Shaft
ASSEMBLE
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover. (2) Install preload adjuster nut. Do not tighten
nut until after pitman shaft adjustment has been
made. (3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 N»m
(44 ft. lbs.). (6) Adjust pitman shaft, refer to Over-Center Ad­
justment.
INSTALL (1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this group.

HOUSING END PLUG

REMOVE (1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
• Rotate stub shaft back and forth to drain fluid. (1) Rotate retaining ring until one end is under
the hole in the housing. Unseat and force ring from groove (Fig. 12).
Fig.
12 End
Plug
Retaining
Ring

(2) Rotate stub shaft slowly COUNTER-CLOCK­
WISE to remove end plug out from housing (Fig. 13).

19
-26
STEERING

•
CAUTION:
Do not
turn
stub
shaft
any
further
than

necessary.
The
recirculating
balls
will
drop
out of

the
rack
piston
circuit
and fall
inside
the
rack
pis­

ton
chamber.

(3) Remove O-ring seal
(Fig. 13).

HOUSING
END
PLUG
O-RING
SEAL

HOUSING
END
PLUG

RETAINING
RING
J9319-30
Fig.
13 End
Plug
Components

ASSEMBLE
• Lubricate O-ring seal with power steering fluid. (1) Install O-ring into housing.
(2) Install plug,
tap
lightly with
a
plastic mallet
to

seat
it.
(3) Install retaining ring with open
end 25 mm (1

inch) from access hole
(Fig. 14).

Fig.
14
Installing
The
Retaining
Ring
(2) Install pitman
arm
onto steering gear. Refer
to

Steering Linkage
in
this group.

ADJUSTER
PLUG
ASSEMBLY
REPLACEMENT
REMOWE (1) Remove steering gear from vehicle. Refer
to

Power Steering Gear Replacement
in
this section.
DISASSEMBLE (1) Remove adjuster plug lock
nut
from housing.
(2) Remove adjuster plug from housing with Span­
ner Wrench C-4381
(Fig. 15).
SPECIAL
TOOL
C-4381
OR
J-7624

Fig.
15
Remove/Install Adjustment
Plug
(3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver
(Fig. 16).
BEARING
RETAINER

Fig.
16
Remove
Retainer
INSTALL
(1) Install steering gear. Refer
to
Power Steering
Gear Replacement
in
this section.

(4) Remove bearing spacer, races and thrust bear­
ing (Fig. 17).

RETAINING

SNAP
RING

f
STUB SHAFT DUST SEAL LARGE
THRUST
WASHER
SMALL
THRUST WASHER
NEEDLE
BEARING
ADJUSTMENT CAP
SPACER

RETAINING
RING

J8919-42

Fig.
17 Adjustment
Plug
(Cap)
Components
(5) Remove O-ring seal.
(6) Remove retaining snap ring. (7) Remove needle bearing, dust seal and lip seal
with an appropriate tool (Fig. 18).
NEEDLE
BEARING
REMOVAL
TOOL

J8919-43
Fig.
18 Needle Bearing
Removal

ASSEMBLE

CAUTION:
Needle bearing must
be
installed
with
identification
on
bearing facing tool
to
prevent dam­

age
to
bearing.
(1) Install needle bearing into adjuster plug with
an appropriate tool.
(2) Install lip seal and dust seal into adjuster plug
with an appropriate tool.
(3) Install retainer snap ring.
(4) Install O-ring seal to adjuster plug.
(5) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(6) Install thrust washer bearing retainer to ad­
juster plug (Fig. 19).
NEEDLE
BEARING PUNCH

SEAL

RETAINER
ADJUSTER PLUG
J9219-10

Fig.
19 Install Retainer

CAUTION:
When installing adjuster plug,

should
be
taken
NOT to cut the
seals.
care

(7) Install adjuster plug into housing with Spanner
Wrench C-4381.
(8) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(9) Install adjuster plug lock nut, and using a
punch (drift) in a notch, tighten securely (Fig. 20). Hold adjuster plug to maintain alignment of the
marks.
(10) Adjust pitman shaft. Refer to Over-Center Ad­
justment.
INSTALL (1.) Install steering gear. Refer to Power Steering
Gear Replacement in this section.

VALVE
REPLACEMENT
REMOVE (1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE (1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement.

19
- 28
STEERING

Fig.
20 Tighten
Lock
Nut
(2) Remove stub shaft and valve assembly (Fig.

GEAR,
MAKE
SURE
ANGLE
OF

THRUST
RACES
ARE
AS
SHOWN.
J9319-32

Fig.
21 Bearing, Worm and
Valve
Assembly
(3) Remove stub shaft from valve assembly, if nec­
essary.
• Tap stub shaft lightly on a block of wood to loosen shaft cap.
• Pull cap and valve body and disengage stub shaft
pin from hole in valve body (Fig. 22). (4) Remove valve assembly if necessary.
• Remove valve spool by pulling and rotating from
valve body (Fig. 23).
• Remove valve spool O-ring seal.
• Remove valve body teflon rings and O-ring seals (Fig. 24).
J9319-36

Fig.
22
Remove
and Install
Stub
Shaft

Fig.
23
Remove
and Install
Spool
ASSEMBLE

(1) Install valve spool O-ring seal to valve spool.
(2) Lubricate valve spool and O-ring seal with
power steering fluid.
(3) Install valve spool to valve body by pushing
and rotating. Hole in valve spool for stub pin must
be accessible from opposite end of valve body.
(4) Assemble stub shaft to valve spool, if necessary
and insert pin (Fig. 25).
• Notch in stub shaft cap MUST fully engage valve
body pin and seat against valve body shoulder.
(5) Install O-ring seals and teflon rings to valve
body. (6) Lubricate O-ring seals and teflon rings with
power steering fluid.

•

STEERING
19 - 29
RACK PISTON AND WORM SHAFT REPLACEMENT

J8919-48

Fig.
24
Remove
and install
Valve
Seals
NOTCH IN CAP
VALVE BODY PIN
liHiiiiiim J9319-38

Fig.
25
Stub
Shaft
Installation

(7) Install stub shaft and valve assembly to worm
shaft. Line up worm shaft to slot in the valve assem­
bly.
(8) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment. Refer to Steering Gear Ad­
justments in this section. REMOVE
(1) Remove steering gear from vehicle. Refer
Power Steering Gear Replacement in this section. to
DISASSEMBLE
(1) Remove pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing. (4) Remove rack piston plug (Fig. 26). EXTENSION END PLUG

RACK

PISTON J9219-9

Fig.
26
Remove
and Install
Rack
Piston
End
Plug
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 27). Hold tool tightly against worm shaft while
turning the stub shaft COUNTERCLOCKWISE.
The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(6) Remove the rack piston, rack balls, and tool to­
gether from housing. (7) Remove valve. Refer to Valve Replacement in
this section.
(8) Remove worm shaft. (9) Remove thrust bearing and races.
(10) Remove tool from rack piston.
(11) Remove rack piston balls.
(12) Remove screws, clamp and ball guide. (13) Remove teflon ring and O-ring seal (Fig. 28).

CLEAN
AND
INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
INSTALL

(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.