1993 DODGE TRUCK Service Repair Manual

19
- 8
STEERING

POWER
STEERING
SYSTEM
DIAGNOSIS

LOOSE
STEERING

CONDITION
POSSIBLE
CAUSE
CORRECTION

EXCESSIVE
WHEEL

KICKBACK
OR
TOO

MUCH
STEERING
WHEEL
PLAY
1.
Air in system
2.
Gear
loose
on
crossmember

3.
Worn/broken intermediate shaft
4.
Free
play in steering column
5.
Loose
ball
joints

6. Front wheel bearings
loose
or worn
7.
Loose
outer tie rod
ends

8.
Loose
inner
tie
rod
ends

9.
Defective steering gear
rotary
valve
1.
Add
fluid.

2.
Check
gear
to
crossmember
mounting bolts. Tighten
to
specification,

3.
Check
for worn universal
joint
ond
broken isolator.
Replace
intermediate shaft
if

worn.

4.
Check
and replace
as
required. 5.
Check
and replace
as
required.

6.
Tighten hub nut or replace
with
new parts
as
necessary.

7.
Check
and replace
as
required.
8.
Replace
gear.

9.
Replace
gear.

VEHICLE
LEADS
TO THE
SIDE

CONDITION
POSSIBLE
CAUSE
CORRECTION

WHEEL
DOES
NOT

WANT
TO
RETURN
TO
CENTER
POSITION
1. Radial
tire
lead
2. Front
end
misaligned

3.
Wheel braking
4.
Unbalanced
steering
gear
valve.
(If this is the
cause,
the steering
efforts
will
be very
light
in

direction
of
lead and heavier in the opposite
direction)
1.
Rotate
tires
as
recommended in Tire

Service.

2. Align
front
end
as
recommended
in
Wheel
Alignment
Service
Procedure.

3.
Check
for
dragging
brakes
as
directed
in
Brake
Service
Procedure.

4.
Checking
for
pull
with
outer
tie
rod end
disconnected.
If verified, replace gear.

9119-6

•

STEERING
19-9 POWER STEERING SYSTEM DIAGNOSIS

FLUID
LEAK

CONDITION POSSIBLE CAUSE
CORRECTION
LOW
FLUID LEVEL
WITH: •NO
VISIBLE
SIGNS
OF
LEAKS ON THE
STEERING GEAR,
PUMP,
ON
FLOOR,
OR

ANYWHERE ELSE
LOW FLUID LEVEL WITH: • VISIBLE LEAK ON STEERING GEAR, PUMP, FLOOR, OR
ANYWHERE ELSE
1.
Overfilled reservoir

2.
Hose connections at pump or gear

3.
Pump or gear leak
1.
Adjust fill level.

2.
Check for loose fittings and tighten to specifications. If fittings are tight, examine
for damaged or missing
O-ring
and replace as required.

3.
Identify location of leak and repair or replace as indicated in Power Steering
Pump and/or Gear sections of this
service manual.
FOAMY OR MILKY FLUID
CONDITION POSSIBLE CAUSE CORRECTION
AERATION AND
OVERFLOW OF FLUID
1.
Air leaks

2.
Low
fluid level

3.
Cracked pump housing

4.
Water contamination
1.
Check for air leak as described under
sucking air and correct.

2.
Extremely cold temperatures may cause system aeration if the oil level is low.
Add fluid as required.

3.
Remove pump from vehicle and separate reservoir from housing. Check expansion
plug and housing for
cracks.
Replace
pump as required.

4.
Drain and refill fluid if there is evidence of contamination.
9119-7

19
- 10
STEERING

• GEAR LEAKAGE DIAGNOSIS

1.
SIDE COVER LEAK
-
TORQUE SIDE COVER BOLTS
TO 60
NTTI
(45 FT.
LBS.). REPLACE
THE
SIDE COVER
SEAL
IF THE
LEAKAGE PERSISTS.

2.
ADJUSTER PLUG SEAL
-
REPLACE
THE
ADJUSTER PLUG SEALS.
3.
PRESSURE
LINE
FITTING - TOR­

QUE THE
HOSE
FITTING NUT TO

27
N.m
(20
FT. LBS.).
IF
LEAKAGE
PERSISTS,
REPLACE
THE
SEAL.

4.
PITMAN
SHAFT
SEALS
-
REPLACE
THE SEALS.

5. TOP
COVER SEAL
-
REPLACE
THE
SEAL. J9219-29

•

STEERING
19 - 11
POWER STEERING PUMP
INDEX

page

Power
Steering
Hose
11

Power
Steering Pump—Initial Operation
15

Pump
Pulley
15

Pump
Replacement—Diesel Engine
12

SERVICE
INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an inter­
nal fluid leak occurs, the complete unit must be re­
placed.

POWER
STEERING HOSE
Max. cool, vehicles are equipped with a power
steering auxiliary fin oil cooler. The oil cooler is
mounted to the engine block under the steering
pump (Fig. 2). Cap hose open ends and pump/steering gear fit­
tings to prevent entry of foreign material.

WARNING; POWER STEERING
FLUID
(AND
PUMP
COMPONENTS)
AND THE
EXHAUST SYSTEM
CAN
BE EXTREMELY
HOT IF THE
ENGINE
HAS
BEEN
RECENTLY OPERATING.
DO NOT
START
THE EN­
GINE WITH
ANY
LOOSE
OR
DISCONNECTED
HOSES.
DO
NOT
ALLOW
THE
HOSES
TO
TOUCH
A

HOT EXHAUST
MANIFOLD
OR THE
CATALYTIC

CONVERTER.

REMOWAL (1) Remove fasteners from hose retaining brackets
at all locations. (2) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser­
voir (Fig. 1, 2).
(3) If applicable, remove cooler bracket fasteners
from block. (4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2).

INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks. The
hose must be kept away from exhaust system components. Do not distort hose tube ends by bend­
ing, kinking or over tightening.
(3) Tighten cooler bracket fasteners to 41 N»m (30
ft. lbs.) torque (Fig. 1, 2). (4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing. page

Pump
Replacement—Gasoline Engine
......... 14

Pump
Reservoir
15

Service
Information
....................... 11

Fig.
1
Power
Steering
Hose Diesel Engine
SCREW
Fig.
2
Power
Steering
Hose
V/6, V/8

19
- 12
STEERING

• (5) Tighten fittings at pump and gear to 35 Nnn
(25 ft. lbs.) torque.
(6)
Install clamps on return hose on gear and
pump.
(7)
After installation, inspect and test for fluid

leaks.

PUMP REPLACEMENT—DIESEL ENGINE

REMOVAL
(1) Place a drain pan under the power steering
pump.
(2) Disconnect and cap the vacuum and steering
pump hoses.
(3) Disconnect the electrical connector on the oil
pressure sender unit (Fig. 3). Remove sender unit
from engine block and plug hole in block.

PUMP ENGINE BLOCK Fig.
3 Oil
Pressure
Sending
Unit
(4) Disconnect and cap the oil feed line from the
bottom of the vacuum pump (Fig. 4). (5) Remove the lower bolt that attaches the vacu­
um/steering pump assembly to the engine block. Re­
move the nut from the steering pump attaching
bracket (Fig. 4).

(6)
Remove upper bolt from the pump assembly
(Fig. 5). Remove the assembly from the engine (Fig.

6).

(7) Remove the gasket from the mounting surfaces
on engine block and pump assembly.
(8) Drain the fluid from the steering pump.
(9) Remove the steering pump to vacuum pump
bracket attaching nuts (Fig. 7).
(10) Slide the steering pump from the bracket. Use
care not to damage the internal oil seal in the vac­ uum pump (Fig. 8).
Fig.
4 Oil
Feed
Line
Removal/Installation

Fig.
5
Pump
Assembly
Upper
Bolt

(11) Remove the two pump body spacers (Fig. 8),
for pump installation.
INSTALLATION (1) Install the two pump body spacers (Fig. 8).
(2) Rotate the drive gear until the steering pump
and vacuum pump drive dogs align. Install the steer­
ing pump onto the vacuum pump bracket. Use care
to avoid damaging the oil seal in the vacuum pump during installation. The steering pump housing

•

STEERING
19 - 13

Fig.
6 Pump Assembly Removal/Installation
PUMP
Jf
119-78

Fig. 7 Bracket Nut Removal/Installation
and spacers must mate completely with the vac­
uum pump bracket (Fig. 9).
(3) Install the three (3) vacuum pump bracket to
steering pump nuts. Tighten to 24 N«m (18 Ft. lbs.)
torque.
(4) Position a new gasket on the vacuum pump as­
sembly, use sealer if necessary to retain the gasket.
(5) Align and install the pump assembly on the en­

gine.
Ensure the steering pump stud is inserted into
PUMP
BRACKET

SPACERS
J9119-69

Fig.
8 Steering
Pump
Removal/Installation

Fig.
9 Steering/Vacuum
Pump Assembly
the block bracket. Tighten the pump-to-engine block
attaching bolts to 77 N*m (57 ft. lbs.) torque.
(6) Install the steering pump to attaching bracket
nut and tighten to 24 N*m (18 ft. lbs.) torque.
(7) Remove plug and install the oil pressure send­
ing unit and electrical connector. (8) Install the oil feed line to the vacuum pump.
Tighten the oil line connection to 7 N»m (60 in. lbs./ 5 ft. lbs.) torque.

19
- 14
STEERING

• (9) Install the fluid hoses to the power steering
pump, Tighten the pressure fitting at the pump to 30
N*m (22 ft. lbs.) torque.
(10) Install and clamp the hose on the vacuum
pump. (11) Fill the reservoir with power steering fluid
only. If necessary, refer to Pump Initial Operation
for detailed instructions.
(12) Start and run the engine. Check the operation
of the brakes, if necessary refer to Group 5, Brakes
for additional information.

PUMP REPLACEMENT—GASOLINE ENGINE

REMOVAL

WARNING:
DO NOT
REMOVE
THE
WATER PUMP COOLANT TUBE UNLESS
THE
COOLANT SYSTEM HAS BEEN DEPRESSUR1ZED
AND
DRAINED*
WARNING:
DO NOT
ATTEMPT
TO
REMOVE
THE
PUMP
WITHOUT
REMOVING
THE
BELT FIRST.
THE

AUTOMATIC TENSIONER
IS
UNDER
A
HIGH
SPRING
LOAD.

(1) Remove the serpentine drive belt. Rotate ten­
sioner clock-wise and hold in place, and remove belt
(Fig. 10).

Fig.
10 Serpentine Belt Removal/Installation
(2) Clamp the fluid return hose and disconnect the
hoses from the power steering pump. Cap the fit­

tings.

(3) Remove battery ground cable and nut at stud.
Unthread stud from cylinder head, do not remove
from bracket. Loosen upper bracket bolt. Remove the lower bracket to engine block bolts. Pivot the pump
assembly past the coolant tube. Remove the upper
stud. Remove upper bolt from cylinder head. The
steering pump and mounting bracket will be re­
moved from engine as an assembly.
(4) Remove the pump pulley, refer to the procedure
below. This will allow access to the pump attaching screws.

(5)
Remove the bracket to pump attaching screws
(Fig. 11).

Fig.
11
Pump
Removal/Installation

INSTALLATION
(1) Install the bracket to pump mounting screws
(Fig. 11). Tighten to 54 N-m (40 ft. lbs.). (2) Install the pump pulley, refer to the procedure
below.
(3) Position the steering pump (with pulley) and
mounting bracket on the engine block (Fig. 11). In­ stall the upper stud and bolt in bracket. Pivot the
pump down past the coolant tube. Install the lower
bolts in bracket (Fig. 11). (4) Install the bracket to engine block attaching
bolts (Fig. 11). Tighten the bolts and nut to 41 N*m (30 ft. lbs.).
(5) Connect the fluid hoses to the pump. (6) Install the serpentine drive belt. Rotate ten­
sioner clock-wise and hold in place, slip the belt over
the pulleys. Refer to Group 7, Cooling for belt rout­ ing.

CAUTION:
Do not use
automatic
transmission
fluid
to
fill the
reservoir.

(7) Fill the reservoir with power steering fluid
only. If necessary, refer to Pump Initial Operation
for detailed instructions.

#
_ ,

Fig.
12 Pulley
Removal
(Typical)

Do not hammer on pulley because this will
damage it and the pump. (2) Replace pulley if bent, cracked, or loose.
INSTALLATION (1) Install the pulley with Installer C-4063-A (Fig.

13).
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.
With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If noise is increases, press on 1.0 mm (0.040 in.). Be
careful that pulley does not contact mounting

bolts.

PUMP RESERVOIR

REMOVAL
Discard all O-ring seals during disassembly,
they are not re-usable.
(1) Remove the filler cap and drain the fluid from
reservoir before removing parts. (2) Remove mounting studs and pressure fitting
(Fig. 14). Rock reservoir by hand or use a soft face
mallet to remove. STEERING 19-15

Fig.
13 Pulley
Installation
(Typical)
(3) Remove O-ring seals from housing and reser­
voir (Fig. 14). (4) Remove flow control valve and spring from
housing.
INSTALLATION Clean all parts before installation. Lubricate
new O-ring seals with MOPAR® Power Steering Fluid or an equivalent product.
(1) Install flow control valve and spring (Fig. 15).
(2) Install new O-ring seals in housing (Fig. 15).
Tighten mounting studs to 48 N«m (35 ft. lbs.) torque.
(3) Install fitting in flow control valve bore.
Tighten the fitting to 75 N-m (55 ft. lbs.) torque.
POWER STEERING PUMP-INITIAL OPERATION

CAUTION:
The
fluid
level
should
be
checked
with

engine
off to
prevent
injury
from
moving
compo­
nents.
Use
only
MOPAR®
Power
Steering
Fluid.
Do

not
use
automatic
transmission
fluid.
Do not
over­

fill.

Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the fluid is at normal temperature. (1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes. (2) Start the engine and let run for a few seconds.
The turn the engine off. (3) Add fluid if necessary. Repeat the above proce­
dure until the fluid level remains constant after run­
ning the engine. (4) Raise the front wheels off the ground.
PUMP PULLEY

REMOVAL
(1) Remove the pulley with Puller C-4333 (Fig.

12).