1993 DODGE TRUCK Service Repair Manual

19
- 16
STEERING

•

EXPANSION PLUG
-
DO NOT
REMOVE; IF DEFORMED
OR
DISLODGED,
REPLACE
HOUSING
RESERVOIR

HOUSING
CAP
SEAL FITTING

75 N-m

(55
FT.
LBS.)
9119-9

(5)
Start the engine. Slowly turn
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock. (8) Stop the engine. Check the fluid level and refill
as required. (9) If the fluid is extremely foamy, allow the vehi­
cle to stand a few minutes and repeat the above pro­ cedure.
Fig.
14
Pump
and Reservoir
the steering
VALVE
AND

SPRING

J8919-101

Fig.
15 Flow Control Valve/Spring
Installation

•

STEERING
19 - 17
STEERING
LINKAGE

SERVICE
INFORMATION
The tie-rod end ball stud seals should be inspected
during all oil changes. A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, re­
place the tie-rod. A replacement seal can be installed if lubricant is in good condition. Otherwise, a com­
plete replacement tie-rod end should be installed. Lu­
bricate the tie-rod end with MOPAR® Multi-Mileage Lubricant, or equivalent. Use Puller C-3894-A for tie rod removal. Fail­
ure to use this tool could damage the tie rod and seal (Fig. 1).

Fig.
1
Ball
Stud
Removal

STEERING
LINKAGE—2WD

REMOWAL (1) Remove the cotter pin and nut from the tie-rod.
(2) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2),
Use care to avoid damaging the seals. (2) Remove inner tie-rod ends (Fig. 1 and 2) from
center link. (3) Remove idler arm ball stud from center link
(Fig. 2). Remove idler arm bolts from frame side rail
(Fig. 2). (4) Remove pitman arm ball stud from center link.
(5) Mark the pitman arm and shaft positions for
reference. Remove pitman arm with Puller C-4150 (Fig. 3).

INSTALLATION
Replace all damaged or worn steering linkage com­
ponents.
(1) Position idler arm on the frame side rail. In­
stall bolts/nuts and tighten to 88 N-m (65 ft. lbs.)
torque.
IDLER

ARM

DUTY

TIE
ROD
J9119-66

Fig.
2 Steering
Linkage—2WD
Vehicles
Fig.
3 Pitman Arm
Removal

(2) Center steering gear to alignment marks and
install pitman arm.
(3) Install the washer and retaining nut on the pit­
man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque. (4) Install center link to ball studs (Fig. 2). Install
and tighten retaining nuts to 88 N-m (65 ft. lbs.)
torque. Install new cotter pins.

19
- 18
STEERING

•
CAUTION:
It is
possible
to install the
center
link
re­

versed
position.
This
will
result
in
incorrect
geome­

try and interferences during vehicle jounce. Viewed
from the
front
of the vehicle, the
center
link
ends
should
turn
upward. Viewed
from
the side of the ve­
hicle,
the
ends
should
turn
toward
the
front
of the
vehicle. The
tie-rod
ball
studs
enter
the
center
link
bores
from
the
rear.

(5) Install tie-rod ends into center link (Fig. 2).
Tighten the nuts to 54 N»m (40 ft. lbs.) torque. In­ stall new cotter pins.
(6) Insert tie-rod ends into steering knuckle arm
(Fig. 2). Tighten the nuts to 54 N-m (40 ft. lbs.)
torque. Install new cotter pins. (7) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to
the Alignment Specifications chart within Group 2,
Front Suspension).
Position the clamp on the sleeve so retaining
bolt is located on the bottom side of the sleeve.
(8) After adjustment, tighten the tie-rod adjust­
ment sleeve clamp bolt;
• Standard Duty— 25.4 N-m (225 in. lbs.) torque
• Heavy Duty- 34 N-m (25 ft. lbs.) torque

STEERING
LINKAGE—4WD
VEHICLES
Use Puller C-4150 to remove a drag link or pit­
man arm. Failure to use this tool could cause damage to the seals (Fig. 4).

TOOL
C-4150
RH404

Fig.
4
Drag-Link
Removal

REMOVAL (1) Remove drag link tie-rod end ball studs from
steering arm and pitman arm (Fig. 4 and 5).
Use care to avoid damaging the seals. (2) Remove the steering arm nuts and washers
(Fig. 6). Tap the steering arm to loosen it from the
knuckle. Pry the steering arm upward and remove.
STEERING
NUT

LINK
FITTING
J9119-12

Fig.
5
Drag
Link
Fig.
6 Steering Arm
Removal—
Model
44 Axle
(3) Mark the pitman arm and shaft positions for
reference. Remove the nut and washer from the pit­
man arm. Remove the pitman arm with Puller C-4150 (Fig. 7). (4) Remove the cotter pin and nut from the tie-rod.
(5) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2).
Use care to avoid damaging the seals.

INSTALLATION
Replace all damaged or worn steering linkage com­
ponents. (1) Center steering gear to alignment marks and
install pitman arm.
(2) Install the washer and retaining nut on the pit­
man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque. (3) Position the steering arm on the knuckle. In­
stall the washers and attaching nuts. Tighten the
nuts to 122 N-m (90 ft. lbs.).

•

STEERING
19 - 19

Fig.
7 Pitman Arm
Removal
(4) Connect the drag-link ball studs to the steering
knuckle arm and pitman arm (Fig. 8). Install the re­
taining nuts and tighten to 81 N»m (60 ft. lbs.)
torque. Install new cotter pins.
POINT
J9102-62

Fig.
8 Correct
Drag
Link
installation
(5) Insert tie-rod ends into steering knuckle arm
(Fig. 2). Tighten the nuts to 61 N-m (45 ft. lbs.)
torque. Install new cotter pins.
(6) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to the Alignment Specifications chart within Group 2, Front Suspension). Position the clamp on the sleeve so retaining
bolt is located on the bottom side of the sleeve. (7) After adjustment, tighten the tie-rod adjust­
ment sleeve clamp bolt to 34-41 N-m (25-30 ft. lbs.)
torque.

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