1993 DODGE TRUCK Service Repair Manual

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.

11-30 STEERING
Fig.
27 Remove and install Rack Piston

J92T9-12

Fig. 28 Remove and Install Seal on Rack Piston (2) Check for scores, nicks or burrs on the rack pis­
ton finished surface. Slight wear is normal on the
worm gear surfaces.

ASSEMBLE

(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid. (2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align worm shaft spiral groove with rack piston ball guide
hole (Fig. 29).
WARNING: MAKE SURE ALL RACK PISTON BALLS ARE REINSTALLED IN THE RACK PISTON. IM­ PROPER INSTALLATION MAY RESULT IN PER­
SONAL INJURY.
There are 24 balls in the rack piston circuit, 12
are Mack and 12 are silver (Chrome). The black w

INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING
WORM COUNTERCLOCKWISE
J9319-39
Fig.
29 Installing
Balls
in
Rack
Piston
rack piston balls are smaller than the silver

balls.
THE BLACK AND SILVEE BALLS MUST
BE INSTALLED ALT1ENATELY INTO THE
RACK PISTON AND BALL GUIDE. This proce­
dure will maintain worm shaft preload. (3) Lubricate and install rack piston balls through
return guide hole while turning worm shaft COUN­
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 30). (5) Install guide onto rack piston and return with

GUIDE
BALLS J9319-40 Fig.
30
Balls
in the Return
Guide

clamp and screws. Tighten screws to 58 N#m (43 in. lbs.) torque. (6) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly against worm shaft while turning
the stub shaft COUNTERCLOCKWISE.

•

STEERING
19 - 31 The rack piston will be forced onto the tool and
hold the rack piston balls in place. (7) Install the races and thrust bearing to worm
shaft (Fig. 31).

WORM
SHAFT
THRUST
RACES

MAKE
SURE
ANGLE
OF
THRUST
RACES
ARE AS
SHOWN
J9319-41

Fig.
31 Worm Shaft and Bearing
(8) Install worm shaft to housing. (9) Install valve. Refer to Valve Replacement in
this section.
(10) Install rack piston to worm shaft from tool,
compress seals. Hold Arbor tightly against worm shaft and turn
stub shaft CLOCKWISE until rack piston is seated
on worm shaft.

WARNING: MAKE
SURE
ALL
RACK PISTON BALLS
ARE
REINSTALLED
IN THE
RACK PISTON.
IM­
PROPER
INSTALLATION
MAY
RESULT
IN
PER­

SONAL INJURY.

(11) Install rack piston plug and tighten to 150
N»m (111 ft. lbs.) torque. (12) Install housing end plug. Refer to Housing
End Plug Replacement in this section. (13) Install pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
(14) Adjust steering gear. Refer to Steering Gear
Adjustments in this section.
PITMAN
SHAFT
SEALS AND
BEARING

REPLACEMENT

REMOVE (1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.

DISASSEMBLE
(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. 32).
RETAINING
RING

BACKUP WASHER

DOUBLE-UP SEAL
BACKUP WASHER
SINGLE-LIP SEAL
NEEDLE
BEARING
J8919-39

Fig.
32 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.
(5) Remove backup washer and single lip seal with
screwdriver. (6) Inspect the housing for burrs and remove if
necessary.
(7) Remove needle bearing from side cover area of
housing (Fig. 33).

ASSEMBLE

(1) Install needle bearing into housing (Fig. 34).
(2) Install single lip seal with Installer or a suit­
able size socket (Fig. 35).
(3) Coat the double lip seal and washer with
grease. (4) Install the backup washer. (5) Install the double lip seal.
(6) Install the backup washer.
INSTALL

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