1996 CHRYSLER VOYAGER torque

(6) Remove the pressure fitting/flow control valve
from the power steering pump and remove and dis-
card the O-Ring seal.
ASSEMBLE
(1) Install a new O-Ring seal on the pressure fit-
ting/flow control valve, and wet the O-Ring with
clean fresh power steering fluid.
(2) Install the pressure fitting/flow control valve in
the power steering pump. Tighten the pressure fit-
ting/flow control valve to a torque of 75 N´m (55 ft.
lbs.).
CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the hose
should be rotated against the fluid return hose fit-
ting on the pump.(3) Install the power steering fluid pressure hose
in the pressure fitting/flow control valve (Fig. 37).
Tighten the tube nut to a torque of 34 N´m (25 ft.
lbs.)
(4) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
36).
(5) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 36). This is required
to keep the power steering hoses from becoming
overheated.
(6) When used, properly position the protective
heat sleeves (Fig. 36) on the power steering hoses.
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(7) Fill the power steering system with fluid, bleed
air from system and check that power steering fluid
is at correct level.
SPECIFICATIONS
POWER STEERING SYSTEM SPECIFICATIONS
Flow At 1500 RPM And Minimum Pressure.5.0 to 7.0
Liters/Min (1.3 to 1.9 GPM)
Control Valve Pressure Relief. 9653 to 10342 kPa (1400
to 1500psi)
POWER STEERING PUMP FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
POWER STEERING PUMP:
Flow Control Valve Fitting. . . .75 N´m (55 ft. lbs.)
Mounting Bolts.............54N´m(40ft.lbs.)
Rear Bracket To Engine
Mounting Bolts.............54N´m(40ft.lbs.)
POWER STEERING FLUID HOSES:
Hose Tube Nuts.............34N´m(25ft.lbs.)
Routing Bracket To
Suspension Cradle..........28N´m(21ft.lbs.)
Fig. 36 Return Hose At Steel Tube
Fig. 37 Pressure Hose Connection To Power
Steering Pump
19 - 24 STEERINGNS
DISASSEMBLY AND ASSEMBLY (Continued)

POWER STEERING GEAR
INDEX
page page
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION . 26
DIAGNOSIS AND TESTING
POWER STEERING GEAR................. 27
REMOVAL AND INSTALLATION
STEERING GEAR....................... 27
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD END................... 33STEERING GEAR INNER TIE ROD BOOT..... 31
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS...................... 34
SPECIAL TOOLS
POWER STEERING GEAR................. 35
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION
NOTE: 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
Steering 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 move-
ment directs oil behind the integral rack piston,
which, in turn, builds up hydraulic pressure and
assists in the turning effort.
Fig. 1 Power Steering Gear Assembly
19 - 26 STEERINGNS

NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(15) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 12). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 12). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(16) Separate the intermediate coupler from the
shaft of the steering gear.
(17) Remove the steering gear assembly from the
front suspension cradle.
INSTALL
(1) Install the steering gear up in the front sus-
pension cradle, leaving room to install intermediate
coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 13). Hold threaded rod station-
ary while turning nut, this will pull the roll pin into
the intermediate coupler.
(4) Install steering gear assembly on the front sus-
pension cradle. Install the 3 steering gear to front
suspension cradle mounting bolts and nuts (Fig. 11).CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Tighten the 3 steering gear to suspension cra-
dle mounting bolts to a torque of 183 N´m (135 ft.
lbs.).
(6) Attach the power steering fluid pressure and
return lines (Fig. 10) to the proper fittings on the
steering gear. Tighten the power steering fluid line
tube nuts to a torque of 31 N´m (275 in. lbs.).
(7) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod end
stationary using a 11/32 socket, (Fig. 5) tighten tie
rod end to steering knuckle attaching nut. Then
using a crowfoot and 11/32 socket (Fig. 14), tighten
the tie rod end attaching nut to a torque of 54 N´m
(40 ft. lbs.).
Fig. 12 Removing Roll Pin From Intermediate
Coupler
Fig. 13 Installing Roll Pin In Intermediate Coupler
Fig. 14 Torquing Tie Rod End Attaching Nut
19 - 30 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Proper torque on the cradle plate to
suspension cradle mounting bolts is very impor-
tant.
(8) Install cradle plate on front suspension cradle
and install the 10 cradle plate to cradle attaching
bolts and nuts (Fig. 8). Tighten all attaching bolts to
a torque of 165 N´m (123 ft. lbs.).
(9) Install the bracket (Fig. 9) attaching the power
steering fluid tubes to the front suspension cradle.
CAUTION:
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 4).
(11) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamp is installed on return tube past the upset
bead on the tube.Tighten the screw clamp to a
torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 4). This is required
to prevent the power steering hoses from being
overheated.
(12) When used, properly position the protective
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(13) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 129
N´m (95 ft. lbs.).
(14) Lower the vehicle to a level were the interior
of vehicle is accessible.
(15) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering column
shaft coupler (Fig. 3) onto the steering gear interme-
diate coupler. Install steering column coupler to
intermediate shaft retaining pinch bolt (Fig. 3).
Tighten the pinch bolt nut to a torque of 28 N´m (250
in. lbs.).
CAUTION: Do not use automatic transmission fluid
in the power steering system. Only use Mopar,
Power Steering Fluid or an exact equivalent prod-
uct.
(16) Fill power steering pump fluid reservoir to the
proper level.
(17) Start the engine and let run for a few seconds.
Then turn the engine off.(18) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(19) Raise front wheels of vehicle off the ground.
(20) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops. Then turn the engine off.
(21) Add power steering fluid if necessary.
(22) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(23) Stop the engine. Check the fluid level and
refill as required.
(24) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(25) Fill power steering reservoir to correct level
with Mopart, Power Steering Fluid, or equivalent.
(26) Adjust toe (Refer to Group 2 Suspension).
DISASSEMBLY AND ASSEMBLY
STEERING GEAR INNER TIE ROD BOOT
DISASSEMBLE
NOTE: The removal and installation of the inner tie
rod boot must be performed with the steering gear
assembly removed from the vehicle.
(1) Loosen the inner to outer tie rod jam nut (Fig.
15). Remove the outer tie rod from the inner tie rod.
(2) Remove nut attaching the outer tie rod end to
the steering knuckle (Fig. 16).Nut is to be
removed from tie rod end using the following
procedure, hold tie rod end stud with an 11/32
socket, while loosening and removing nut with
wrench.
Fig. 15 Inner To Outer Tie Rod Jam Nut
NSSTEERING 19 - 31
REMOVAL AND INSTALLATION (Continued)

end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 17). Then using a crow-
foot and 11/32 socket (Fig. 21), torque tie rod end
attaching nut to 54 N´m (40 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).
(9) Make toe adjustment by turning inner tie rod.
(10) Tighten the inner to outer tie rod jam nut to
75 N´m (55 ft. lbs.) torque. Lubricate tie rod boot
groove with silicone type lubricant, before installing
outer boot clamp, making sure boot is not twisted.
OUTER TIE ROD END
DISASSEMBLE
(1) Loosen inner tie rod to outer tie rod jam nut
(Fig. 22).
(2) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 23).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(3) Remove the tie rod end stud from steering
knuckle arm, using Remover, Special Tool,
MB-991113 (Fig. 24) or MB-990635.
(4) Remove outer tie rod end from inner tie rod by
un-threading it from the inner tie rod.
Fig. 20 Installing Tie Rod Boot To Steering Gear
Clamp
Fig. 21 Torquing Tie Rod End Attaching Nut
Fig. 22 Inner To Outer Tie Rod Jam Nut
Fig. 23 Tie Rod End Attaching Nut
NSSTEERING 19 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLE
(1) Install outer tie rod onto inner tie rod.Make
sure jam nut (Fig. 22) is on inner tie rod.
(2) Do not tighten jam nut.
(3) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 23). Then using a crow-
foot and 11/32 socket (Fig. 25), torque tie rod end
attaching nut to 54 N´m (40 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) Adjust the front Toe setting on the vehicle.
Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
manual. Refer to the Specifications Section at the
end of this group for the desired front Toe specifica-
tion.
(5) Tighten tie rod jam nut (Fig. 22) to 55 N´m (75
ft. lbs.) torque.(6) Adjust the steering gear to inner tie rod boots
at inner tie rod if they became twisted during Toe
adjustment.
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS
DESCRIPTION TORQUE
STEERING GEAR:
To Suspension Cradle Bolts. . . .183 N´m (135 ft. lbs.)
Tie Rod To Steering
Knuckle Nut...............54N´m(40ft.lbs.)
Outer To Inner Tie Rod
JamNut..................75N´m(55ft.lbs.)
Power Steering Hose
Tube Nuts...............31N´m(275 in. lbs.)
Coupler Pinch Bolt...........28N´m(250 in. lbs.)
SUSPENSION CRADLE:
Cradle Plate To Cradle
Attaching Bolts...........165 N´m (123 ft. lbs.)
Fig. 24 Tie Rod End Removal From Steering
KnuckleFig. 25 Torquing Tie Rod End Attaching Nut
19 - 34 STEERINGNS
DISASSEMBLY AND ASSEMBLY (Continued)

STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION......... 36
DIAGNOSIS AND TESTING
STEERING COLUMN..................... 38
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS........................... 38REMOVAL AND INSTALLATION
STEERING COLUMN ASSEMBLY............ 38
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS...................... 45
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION
The steering column (Fig. 1) has been designed to
be serviced only as a complete assembly, if a compo-
nent of the steering column is defective. The only
replaceable components of the steering columnassembly are the key cylinder, ignition switch, multi-
function switch, clockspring, halo lamp, speed control
switches, driver airbag, trim shrouds and steering
wheel. These replaceable components of the steering
column can be serviced without requiring removal of
the steering column from the vehicle.
Fig. 1 Steering Column Assembly Components
19 - 36 STEERINGNS

(28) Remove steering column assembly from vehi-
cle. Use care to avoid damage to paint or interior
trim.
INSTALL
(1) Ensure the plastic mounting capsules (Fig. 22)
are installed in the upper mounting bracket of the
steering column. Mounting capsules must be
installed as shown in (Fig. 22) with the thicker edge
of the capsule facing the top of the steering column.
(2) Install steering column assembly into its open-
ing in instrument panel. Install the steering column
lower bracket so the bracket is squarely installed on
its mounting studs (Fig. 21). Then align and install
steering column upper bracket on its mounting studs
(Fig. 21). Tighten the 4 steering column assembly
mounting nut/washer assemblies to a torque of 12
N´m (105 in. lbs.).
(3) Assemble the steering column shaft coupler
(Fig. 20) onto the steering gear intermediate coupler.
Install steering column coupler to intermediate shaft
retaining pinch bolt (Fig. 20). Tighten the pinch bolt
nut to a torque of 28 N´m (250 in. lbs.). Install safety
pin (Fig. 20) in steering column shaft coupler pinch
bolt.
(4) Install the gear slector cable and its mounting
bracket on the upper mounting bracket of the steer-
ing column (Fig. 17). Install and securely tighten the
mounting bracket attaching bolt.
(5) Install the gear selector cable on the pin of the
gear shifter (Fig. 16).
(6) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the PRNDL actuating
cable on the gear shifter pin after the gear selector
cable is installing (Fig. 15).
(7) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the attaching clip
(Fig. 15) for the PRNDL actuating cable on the steer-ing column/shift cable bracket. Cable guide tube will
bow toward passenger side of vehicle. Verify that
actuating cable is operating correctly, then slip the
loop on the end of the cable over end of pin on shift
lever and install in groove (Fig. 15).
(8) Install the steering column fixed shroud on the
steering column assembly (Fig. 19). Shroud is
mounted to steering column using 2 attaching screws
accessed from top of fixed shroud.
(9) Install the instrument cluster trim bezel (Fig.
18) on the instrument panel. The trim bezel is
mounted to the instrument panel using 2 attaching
screws (Fig. 18) and retaining clips.
(10) Install the 3 wiring harness connectors on the
ignition switch (Fig. 14).
(11) Install the vehicle wiring harness connector
into the key cylinder halo light (Fig. 13).
(12) Install the multi-function switch (Fig. 12) on
the tilt head of the steering column assembly. Then
install screw (Fig. 12) attaching multi-function
switch to tilt head of steering column.
(13) Install the vehicle wiring harness connector
on the multi-function switch (Fig. 11). Be sure latch
on connector is fully engaged with tab on switch.
(14) Install the clock spring on the multi-function
switch.
(15) Install the vehicle wiring harness connector
(Fig. 10) on the clock spring assembly.
(16) Install the lower steering column shroud on
the tilt head of the steering column (Fig. 23). Install
and securely tighten the screw attaching the lower
shroud to the tilt head.
(17) Install the upper steering column shroud on
the tilt head of the steering column (Fig. 24). Install
and securely tighten the 2 screws attaching the
upper shroud to the lower shroud.
Fig. 22 Mounting Capsules Correctly Installed On
Steering Column
Fig. 23 Lower Steering Column Shroud Installed
NSSTEERING 19 - 43
REMOVAL AND INSTALLATION (Continued)