1993 CHEVROLET PLYMOUTH ACCLAIM wheel bolts

(15) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.3 & 3.8 LITER
REMOVE
(1) Remove the (-) negative battery cable from the
battery and isolate cable. (2) Remove the serpentine accessory drive belt
from engine (Fig. 10). See Cooling, Group 7 for de-
tailed removal procedure.
(3) Raise vehicle See Hoisting, Group 0.
(4) Remove vehicle's wiring harness connector (if
applicable to vehicle being serviced) from the power
steering pressure switch (Fig. 11).
(5) Put oil drain pan under vehicle to catch power
steering fluid. Remove hose clamp and low pressure
fluid hose from power steering pump (Fig. 12). (6) Remove hose clamp and hose to the power steer-
ing pump, from the remote fluid reservoir (Fig. 13).
Drain off excess power steering fluid from hoses.
(7) Remove the power steering, fluid pressure line
(Fig. 12) from the power steering pump. Drain excess
power steering fluid from tube. (8) Remove right front wheel and tire from vehicle.
This will aid in access to the power steering pump
mounting bolts. (9) Remove the 3 bolts holding the power steering
pump to the generator, power steering and belt ten-
sioner mounting bracket (Fig. 14). (10) Remove nut and bolt holding the engine block,
to power steering pump support strut. Remove strut
from engine and power steering pump (Fig. 14) Lay
the power steering pump assembly down on top
of the steering gear. It will be removed later from
the top. (11) Remove nut which holds serpentine drive belt
tensioner to its mounting bracket (Fig. 15). Remove
tensioner assembly from bracket.
Fig. 10 Serpentine Drive Belt Routing
Fig. 11 Power Steering Pressure Switch Location 3.3 & 3.8L
Fig. 12 Power Steering Hose Routing 3.3 & 3.8L
Fig. 13 Power Steering Remote Fluid Reservoir And Tube
19 - 16 STEERING Ä

INSTALL (1) Install power steering pump back in vehicle,
laying it on the steering gear. Do not mount it to the
power steering pump bracket. (2) Install generator back on the lower generator
bracket and install bolt and nut (Fig. 19). Do not
tighten bolt at this time. (3) Install the generator bracket back on engine and
intake manifold. Loosely install the 4 generator
bracket to engine attaching bolts (Fig. 19). Be sure
the SPACER (Fig. 18) is installed between the
engine mounting strut and the generator
bracket. (4) Temporarily install the serpentine belt tensioner
bolt through both generator brackets. This will align
all generator bracket mounting holes (Fig. 15). Then
torque the 4 generator bracket to engine and intake manifold mounting bolts to 54 N
Im (40 ft.
lbs.). Then remove the serpentine belt tensioner from
bracket. It will be installed on the bracket in a
later step. (5) Tighten the bolt holding the engine bracket as-
sembly to the engine support assembly (Fig. 18) to 150
N Im (110 ft. lbs.).
(6) Attach the engine wiring harness routing clip to
the generator bracket. (7) Install the generator to generator bracket attach-
ing bolt (Fig. 19). Torque bolt to 54 N Im (40 ft. lbs.).
Tighten the lower generator pivot bolt to 54 N Im (40 ft.
lbs.). (8) Install the power steering pump fluid reservoir
and tube/hose assembly onto the power steering pump
bracket and generator bracket (Fig. 17). Torque the 2
bolts holding the reservoir to the generator bracket to
5N Im (45 in. lbs.). Torque the 1 bolt holding the
tube/hose assembly to the power steering pump
bracket to 12 N Im (105 in. lbs.).
(9) Raise vehicle See Hoisting, Group 0.
(10) Install the strut assembly power
steering/generator bracket to engine (Fig. 16). Torque
the nut and bolt holding the strut assembly to bracket
and the exhaust manifold stud to 54 N Im (40 ft. lbs).
(11) Install the serpentine drive belt tensioner onto
the power steering/generator bracket (Fig. 15). Install
the tensioner to bracket retaining nut and torque to 54
N Im (40 ft. lbs.).
(12) Install the power steering pump on bracket, by
aligning the 3 mounting holes in pump with mounting
holes in bracket (Fig. 14). Install the 3 power steering
pump to bracket mounting bolts. Torque power steer-
ing pump mounting bolts to 54 N Im (40 ft. lbs.).
(13) Install the support strut, engine block to power
steering pump on pump stud (Fig. 14). Install the nut
and bolt holding the strut to the power steering pump
and engine block and torque to 54 N Im (40 ft. lbs.).
(14) Install the power steering fluid pressure line
onto the output fitting of the power steering pump (Fig.
12). Torque the pressure line pump fitting nut to 31
N Im (275 in. lbs.). Before connecting the pressure
line to power steering pump inspect the O-ring
on the pressure line for damage. (15) Install vehicle's wiring harness connector (if
applicable to vehicle being serviced) onto the power
steering pressure switch (Fig. 11). (16) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 12). Then install the hose from the remote
reservoir onto the power steering pump (Fig. 13). Be
sure all hose clamps are properly reinstalled. (17) Install right front tire and wheel on vehicle.
Install the wheel stud nuts and torque to 129 N Im (95
ft. lbs.).
Fig. 18 Engine Bracket Support Assembly
Fig. 19 Generator Mounting
19 - 18 STEERING Ä

(18) Lower vehicle.
(19) Install the serpentine drive belt. Refer to (Fig.
10) for correct serpentine belt routing. See Cooling,
Group 7 for detailed installation procedure.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(20) Fill power steering pump reservoir to correct
fluid level. (21) Connect the negative battery cable on the
negative battery post. (22) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
TURBO III
REMOVE
(1) Disconnect the battery (-) negative cable from
the battery and isolate cable. (2) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering
fluid. (3) Remove the right front underhood splash shield
for access to the serpentine belt tensioner. (4) Release the tension on the serpentine drive belt
tensioner and remove drive belt from power steering
pump pulley (Fig. 20). Drive belt does not have to be
fully removed from engine.
(5) Remove the power steering fluid return hose at
the steering gear metal tube. Let power steering
fluid drain from the hose and power steering pump
into drain pan. (6) Remove the high pressure fluid line banjo bolt
fitting from the power steering pump. Remove high
pressure power steering fluid line from the power
steering pump. (7) Remove the lower power steering pump to
bracket mounting nut and fluid hose routing clip. Re-
move the 2 bolts and the stud attaching the power
steering pump to its mounting bracket (Fig. 21).
(8) Lower vehicle.
(9) Remove the wiring harness electrical connector
from the H-valve on the air conditioning fluid lines. (10) Remove the power steering pump from the ve-
hicle out through the area between the cylinder head
and the dash panel (Fig. 22).
(11) Transfer the required components from the
failed power steering pump to the replacement power
steering pump. See the appropriate area of this ser-
vice manual section for the component replacement
procedures.
Fig. 20 Turbo III Accessory Drive Belt Routing
Fig. 21 Power Steering Pump Mounting
Fig. 22 Power Steering Pump Removal From Vehicle
Ä STEERING 19 - 19

INSTALL (1) Install the power steering pump back into the
vehicle in the reverse order of removal, between cyl-
inder head and dash panel (Fig. 20). (2) Install the wiring harness connector back on
the H-valve located on the air conditioning fluid
lines (Fig. 20). (3) Raise vehicle See Hoisting, Group 0.
(4) Install the power steering pump on its mount-
ing bracket, and the hose locator bracket. Install the
bolt/stud and 2 bolts attaching the power steering
pump to its mounting bracket, and the bolts attach-
ing the hose locator bracket (Fig. 19). Torque all fas-
teners to 31 N Im (280 in. lbs.).
(5) Install the power steering fluid pressure hose,
banjo bolt and seal washer onto power steering pump
(Fig. 4). Pressure hose is to be installed so it is
routed to the left of the hose locator bracket (Fig.
19). Torque the banjo bolt to 31 N Im (275 in. lbs.).
Inspect the O-rings on the banjo bolt to ensure
they are not damaged and located correctly. (6) Install the low pressure fluid return hose from
the power steering pump back on the steel tube on
the steering gear (Fig. 4). Install hose clamp, be sure
the hose clamp is installed past the retaining bead
the steel tube. Install the hose routing clip on the
power steering pump bolt/stud, install clip retaining
nut and tighten. (7) Install the serpentine accessory drive belt (Fig.
18). Be sure the belt is correctly installed and
aligned on all pulleys before starting engine. (8) Install the right front underhood splash shield.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(9) Fill power steering pump reservoir to correct
fluid level. (10) Connect the negative battery cable on the
negative battery post. (11) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING PUMP PULLEY SERVICE
SAGINAW VANE SUBMERGED PUMP
REMOVE
(1) Remove the pulley with Puller C-4333 (C-4068)
(Fig. 1).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump. (2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install the pulley with Installer C-4063 (Fig.2).
Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft. (3) Force pulley flush with the end of the shaft.
Fig. 1 Pulley Removal (Typical)
Fig. 2 Pulley Installation (Typical)
19 - 20 STEERING Ä

POWER STEERING GEAR INDEX
page page
General Information ....................... 25
Outer Tie Rod ........................... 27 Steering Gear Service
..................... 25
GENERAL INFORMATION
The power steering gear (Fig. 1) should NOT be
serviced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced. If a steering gear boot needs to be replaced due to
damage, refer to the power steering gear service sec-
tion in this manual for proper procedure. The power steering system consists of these four
major components. Power Steering Gear, Power Steer-
ing Pump, Pressure Hose, and Return Line. Turning of
the steering wheel is converted into linear travel
through the meshing of the helical pinion teeth with
the rack teeth. Power assist steering is provided by an
open center, rotary type control valve which directs oil
from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn. The torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This movement
directs oil behind the integral rack piston, which, in
turn, builds up hydraulic pressure and assists in the
turning effort. The drive tangs on the pinion of the power steering
pump mate loosely with a stub shaft. This is to permit
manual steering control to be maintained if the drive
belt on the power steering pump should break. How-
ever, under these conditions, steering effort will be
increased.
STEERING GEAR SERVICE
The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced.
REMOVAL
(1) Raise vehicle See Hoisting, Group 0. Put oil drain
pan under vehicle to catch power steering fluid. (2) Remove front road wheels.
(3) Remove both tie rod ends from steering knuckles,
using Puller Special Tool C-3894-A (Fig. 1). (4) Disconnect engine damper strut from crossmem-
ber (if so equipped). (5) Remove the 3 front suspension crossmember at-
taching bolts and the nut (Fig. 2) from the locating
stud. Lower front suspension crossmember, using
Fig. 1 Power Steering Gear Assembly
Ä STEERING 19 - 25

bolts and nut on locating stud (Fig. 2). The right rear
crossmember stud is a pilot that correctly locates
the crossmember. Tighten down this bolt first,
then torque all 4 crossmember fasteners to 122
N Im (90 ft. lbs.).
CAUTION: Proper torque on the crossmember to
frame rail mounting bolts is very important.
(3) Torque the 4 bolts (Fig. 3) attaching the steering
gear assembly to front crossmember, to 68 N Im (50 ft.
lbs.). To ensure proper alignment of the steering
gear tighten left front bolt first. (4) Attach the engine damper strut from the engine
to the crossmember (if so equipped). (5) Attach the fluid tubes (Fig. 3) from the power
steering pump to the fittings on the steering gear.
Torque the fluid pressure line to steering gear tube nut
to 31 N Im (275 in. lbs.).
(6) Mount the outer tie rod ends to the steering
knuckles. Install the tie rod end to steering knuckle
attaching nuts. Torque the tie rod end to steering
knuckle nuts to 52 N Im (38 ft. lbs.). Install cotter pin
in tie rod end. (7) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 129
N Im (95 ft. lbs.).
(8) Lower vehicle.
CAUTION: Do not use automatic transmission fluid. (9) Fill power steering pump fluid reservoir to the
(Full-Cold) proper level. (10) Start the engine and let run for a few seconds.
Then turn the engine off.
(11) Add fluid if necessary.
(12) Raise front wheels of vehicle off the ground.
(13) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in
system. Stop engine, check fluid level, and inspect
system for leaks. Fill pump reservoir to correct
level with Mopar t, Power Steering Fluid, or
equivalent. See Checking Fluid Level.
(14) Lower front wheels of vehicle back on the
ground. (15) Adjust toe (Refer to Group 2 Suspension).
OUTER TIE ROD
REMOVAL
(1) Loosen inner tie rod to outer tie rod jam nut (Fig.
4). (2) Remove outer tie rod to steering knuckle cotter
pin and attaching nut (Fig. 4). (4) Remove the tie rod end from steering knuckles, using Puller Special Tool C-3894-A (Fig. 5).
(5) Remove outer tie rod from inner tie rod.
INSTALLATION
(1) Install outer tie rod onto inner tie rod. Make
sure jam nut is on inner tie rod (Fig. 4). (2) Do not tighten jam nut.
(3) Install outer tie rod onto steering knuckle. In-
stall tie rod to steering knuckle attaching nut and
torque to 52 N Im (38 ft.lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(4) Make toe adjustment by turning inner tie rod.
(5) Tighten the inner to outer tie rod jam nut to 75
N Im (55 ft. lbs.) torque. Lubricate tie rod boot groove
with silicone type lubricant before installing outer
boot clamp, making sure boot is not twisted.
Fig. 4 Outer Tie Rod
Fig. 5 Tie Rod End Removal
Ä STEERING 19 - 27

CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw (Fig. 10).
CAUTION: Proper torque to the crossover cable ad-
justing screw is very important (Fig. 10).
(6) Remove lock pin from gearshift housing and re-
install lock pin (so long end is up) in gear shift hous-
ing. Tighten lock pin to 8 N Im (70 in. lbs.).
(7) Check for shift into first and reverse.
(8) Gearshift mechanism and cables are now func-
tioning properly.
IN-CAR TRANSAXLE DISASSEMBLE/ASSEMBLE
The following items can be serviced without remov-
ing the transaxle from the vehicle:
² Gear shift housing
² Synchronizers
² Intermediate shaft speed gears
² Input shaft
² Reverse idler gear and shaft
² Shift forks and pads
² Shift rails ²
Roller detents
² Speedometer pinion
² All external covers
Observe following procedure:
(1) Disconnect negative cable from battery.
(2) Remove both shift cables from shift cover levers.
(3) Remove left front wheel and tire assembly and
left splash shield. (4) Place drain pan under transaxle and remove
transaxle rear end cover. (5) Push out the fifth fork roll pin and slide the fifth
fork and synchronizer sleeve off the rail/hub. (6) Remove the fifth hub snap ring, hub assembly
and speed gear. (7) Remove fifth gear nut and fifth input gear.
(8) Remove the bearing retainer plate, interlock
plate and shuttles.
CAUTION: Before removing the gearshift housing
assembly, reverse the lock pin (so the long end is
down) and insert lock pin into the same threaded
hole. This procedure will save time when the gear
shift housing assembly is reinstalled. (9) Remove selector shaft housing bolts (note the two
pilot bolts) and remove housing. (10) Remove roller detents and springs, noting that
the rollers align with the shift rails. (11) Push out the 1-2 and 3-4 lug roll pins, remove
the reverse pivot lever and fifth rail C-Clip. If a roll
pin or C-Clip falls, be sure to remove it from the
bottom of the case. (12) Pull out the fifth shift rail and remove the fifth
shift lug and interlock pin. If the pin falls, be sure to
remove it from the bottom of the case. (13) Remove the intermediate shaft ball bearing
snap ring and the bearing support plate. (14) Remove reverse shift rail and lug assembly.
(15) Remove the reverse idler shaft and gear assem-
bly. (16) Rotate the 1-2 shift lug and rail, and 3-4 shift
lug towards the front of the vehicle. (17) Firmly grasp both the input and intermediate
shaft assemblies and pull them out of the transmission
with the 1-2 and 3-4 shift rails, lugs and forks. The differential assembly can only be serviced
by removing the complete transaxle from the
vehicle because bearing preload must be reset. The components listed in the first paragraph can now
be serviced. Refer to the appropriate subassembly
recondition section.
To reassemble the transaxle in the vehicle, reverse
the above procedure using the proper sealants. Fill the
transaxle with SAE 5W-30 engine oil to the bottom of
the fill hole in the end cover.
Fig. 9 Install Cables
Fig. 10 Adjusting Crossover Cable
21 - 4 TRANSAXLE Ä

TRANSAXLE REMOVAL AND INSTALLATION
Transaxle removal does not require engine re-
moval. After installing transaxle, fill transaxle to bottom of
fill plug hole with SAE 5W-30 engine oil before lower-
ing vehicle to floor. (1) Disconnect or connect negativebattery cable.
(2) Install a lifting eyeon battery ground strap bolt
on left side of engine. Then install the engine support
fixture as shown in Figure 1.
(3) Disconnect or connect gearshift cables at tran-
saxle. Disconnect speedometer. Disconnect or connect
gearshift cables bracket at transaxle. (4) Remove or install both front wheel and tire
assemblies. (5) Remove or install left front splash shield.
(6) Remove or install engine left mount from tran-
saxle.
CAUTION:Left engine mounting bolts used in posi-
tion number 1 and number 3 are the same length. The
bolt in the number 2 position is longer. If bolt number
2 is used in position number 3 it can damage the
selector shaft housing when the bolt is seated (Fig.
2).
(7) Remove or install anti-rotational link (or anti-
hop damper) from crossmember bracket. Do not re-
move bracket from transaxle .
(8) Refer to Group 2 Suspension, to remove or
install both drive shafts. When removing or installing the transaxle, it
may be helpful to use locating pins in place of the
top transaxle to engine bolts (Fig. 3).
Make the locating pins from two stock (transaxle
case to engine block) bolts as follows: Using a hacksaw,
remove bolt heads, cut slot in end of bolts for a screw
driver, and remove burrs with a grinding wheel. Install the locating pins into the engine block and
proceed with transaxle installation. After transaxle is
in place, install bolts and remove locating pins before
removing transmission jack.
Fig. 1 Engine Support Fixture
Fig. 2 Left Engine Mount Bolt Location
Fig. 3 Remove or Install Bolts
Ä TRANSAXLE 21 - 5