1999 DODGE NEON Service Repair Manual

BINDING STICKING SEIZED
SHAKE SHUDDER VIBRATION
CONDITION POSSIBLE CAUSES CORRECTION
CATCHES, STICKS IN CERTAIN
POSITIONS OR IS DIFFICULT TO
TURN.1. Low power steering fluid level. 1. Fill power steering fluid reservoir
to specified level and perform
leakage diagnosis.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified
pressure.
3. Lack of lubrication in front
suspension control arm ball joints.3. Lubricate ball joints if ball joints
are not a lubricated for life type ball
joint. If ball joint is a lubricated for
life ball joint, replace ball joint or
control arm.
4. Lack of lubrication in front
suspension outer tie rod ends.4. Lubricate tie rod ends if they are
not a lubricated for life type. If tie rod
end is a lubricated for life type,
replace tie rod end.
5. Loose power steering pump drive
belt.5. Tighten the power steering pump
drive belt to the specified tension.
See accessory drive in service
manual.
6. Faulty power steering pump flow
control. (Verify cause using Power
Steering Pump Test Procedure.)6. Replace power steering pump.
7. Excessive friction in steering
column or intermediate shaft.7. Correct condition. (See Steering
Column Service Procedure)
8. Steering column coupler binding. 8. Realign the steering column to
eliminate the binding condition.
9. Binding upper strut bearing. 9. Correct binding condition in strut
bearing.
10 Excessive friction in steering
gear.10 Replace steering gear assembly.
CONDITION POSSIBLE CAUSES CORRECTION
VIBRATION OF THE STEERING
WHEEL AND/OR DASH DURING
DRY PARK OR LOW SPEED
STEERING MANEUVERS.1. Air in the fluid of the power
steering system.1. Steering shudder can be expected
in new vehicles and vehicles with
recent steering system repairs.
Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check that the inner to outer tie
rod jam nut for is tight. If required,
tighten the jam nut to the specified
torque.
5.Overcharged air conditioning
system.5.Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis)
19 - 4 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

LOW ASSIST, NO ASSIST, HARD STEERING
CONDITION POSSIBLE CAUSES CORRECTION
STIFF, HARD TO TURN,
SURGES, MOMENTARY
INCREASE IN EFFORT WHEN
TURNING.1. Tires not properly inflated. 1. Inflate tires to specified pressure.
2. Low power steering fluid level. 2. Add power steering fluid as
required to power steering fluid
reservoir to obtain proper level.
Perform leakage diagnosis on power
steering system.
3. Loose power steering pump drive
belt.3. Adjust the power steering pump
drive belt to the specified tension. If
drive belt is defective replace and
correctly tension.
4. Lack of lubrication in control arm
ball joints.4. Lubricate ball joints if ball joints
are not a lubricated for life type ball
joint. If ball joint is a lubricated for
life ball joint, replace ball joint or
control arm.
5. Low power steering pump
pressure. (Verify using Power
Steering System Test Procedure)5. Verify cause using the Power
Steering System Test Procedure.
Replace the power steering pump if
necessary.
6. High internal leak in steering gear
assembly.6. Check steering system using the
Power Steering System Test
Procedure. If steering gear is
defective replace steering gear.
PLSTEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)

POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION.1. Tires not inflated to specified
pressure.1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Lack of lubrication in front
suspension control arm ball joints.3. Lubricate ball joints if ball joints
are not a lubricated for life type of
ball joint. If ball joint is a lubricated
for life ball joint, replace ball joint or
control arm.
4. Steering column U-joints
misaligned.4. Realign steering column U-joints.
5. Mispositioned dash cover. 5. Reposition dash cover.
To evaluate items 6 and 7,
disconnect the intermediate shaft.
Turn the steering wheel and feel or
listen for internal rubbing in steering
column.
6. Steering wheel rubbing. 6. Adjust steering column shrouds to
eliminate rubbing condition.
7. Damaged, mis-positioned or
un-lubricated steering column
coupler to dash seal.7. Determine condition which exists
and correct.
8. Binding upper strut bearing. 8. Correct binding condition in strut
bearing.
9. Tight shaft bearing
in steering column assembly.9. Replace the steering column
assembly.
10. Excessive friction in steering
column coupler.10. Replace steering column coupler.
11. Excessive friction in steering
gear.11. Replace steering gear.
19 - 6 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

LOOSE STEERING
VEHICLE LEADS TO THE SIDE
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE STEERING WHEEL
KICKBACK OR TO MUCH
STEERING WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Fill power steering fluid reservoir
to the specified level. Perform
procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front
suspension crossmember.2. Check steering rear to front
suspension crossmember mounting
bolts. Tighten to specified torque if
found to be loose.
3. Worn, broken or loose steering
column to steering gear coupler.3. Check for worn universal joint,
broken isolator or loose fasteners.
4. Free play in steering column.
4.Check components of the steering
system and repair or replace as required.
5. Loose front suspension control
arm ball joints.5. Check and or replace the ball joint
or control arm as required.
6. Loose steering knuckle to ball
joint stud pinch bolt.6. Check pinch bolts and tighten if
required to specified torque.
7. Front wheel bearings loose or
worn.7. Tighten hub nut to specified
torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10 Defective steering gear rotary
valve.10. Replace steering gear assembly.
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT
WANT RETURN TO CENTER
POSITION.1. Radial tire lead. 1.Rotate tires as recommended in
the Tire And Wheel Group of this
service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
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.4. Replace steering gear.
STEERING WHEEL HAS FORE
AND AFT LOOSENESS.1. Steering wheel to steering column
shaft retaining nut not properly
tightened and torqued.1. Tighten the retaining nut to its
specified torque specification.
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.2. Replace steering column.
PLSTEERING 19 - 7
DIAGNOSIS AND TESTING (Continued)

POWER STEERING FLUID LEAK
FOAMY OR MILKY POWER STEERING FLUID
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH: NO
VISIBLE SIGNS OF A LEAK ON
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.1. Overfilled power steering pump
fluid reservoir.1. Adjust the power steering fluid fill
to the correct level.
LOW FLUID LEVEL WITH:
VISIBLE LEAK ON STEERING
GEAR, POWER STEERING
PUMP, FLOOR OR ANYWHERE
ELSE.2. Power steering hose connections
at the power steering pump or
steering gear.2. Check for loose fittings and if
found, tighten the fitting to its
specified torque. If fittings are tight
examine the fittings for damaged or
missing O-ring seals and replace as
required.
3. Power steering pump or power
steering gear leaking.3. Identify the location of the leak
and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.
CONDITION POSSIBLE CAUSES CORRECTION
AERATION AND OVERFLOW OF
FLUID.1. Air leaks. 1. Check for an air leak into the
power steering system as described
under Sucking Air Diagnosis and
correct condition.
2. Low fluid level. 2. Extremely cold temperatures may
cause power steering fluid aeration if
the power steering fluid is low. Add
power steering fluid as required to
bring level up to specification.
3. Cracked power steering pump
housing.3. Remove power steering pump
from vehicle and inspect the power
steering pump housing for cracks. If
a defect in the housing is found,
replace the power steering pump.
4. Water contamination. 4. Drain the power steering fluid
from the system if there is evidence
of contamination. Then refill the
system with fresh clean power
steering fluid.
19 - 8 STEERINGPL
DIAGNOSIS AND TESTING (Continued)

POWER STEERING PUMP
INDEX
page page
DESCRIPTION AND OPERATION
POWER STEERING PUMP................. 9
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM TEST
PROCEDURE......................... 10
SERVICE PROCEDURES
POWER STEERING PUMP
FLOW CONTROL VALVE SEAL............ 11
POWER STEERING PUMP
INITIAL OPERATION.................... 11
POWER STEERING PUMP
SUCTION PORT SEAL.................. 12
POWER STEERING SYSTEM
FLUID LEVEL CHECK................... 11
REMOVAL AND INSTALLATION
POWER STEERING FLUID PRESSURE HOSE . . 13
POWER STEERING FLUID RESERVOIR...... 21POWER STEERING FLUID RETURN HOSE.... 15
POWER STEERING FLUID SUPPLY HOSE
RESERVOIR TO POWER STEERING PUMP . . 17
POWER STEERING PRESSURE SWITCH..... 12
POWER STEERING PUMP (ALL ENGINES).... 18
DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP DRIVE PULLEY.... 22
POWER STEERING PUMP MOUNTING
BRACKET............................ 23
SPECIFICATIONS
POWER STEERING PUMP FASTENER
TORQUE SPECIFICATIONS.............. 25
POWER STEERING PUMP FLOW
SPECIFICATIONS...................... 25
SPECIAL TOOLS
POWER STEERING PUMP................. 25
DESCRIPTION AND OPERATION
POWER STEERING PUMP
On all vehicles equipped with power steering, the
hydraulic pressure for operation of the power steer-
ing gear is provided by a belt driven power steering
pump (Fig. 1). The TTA power steering pump is a
constant flow rate and displacement, vane type pump
.
In the event of a power steering pump drive belt
failure, manual steering control of the vehicle can
still be maintained. However, under these conditions,
steering effort will be significantly increased.All vehicles equipped with power steering use a
remote mounted reservoir for the power steering
fluid. The power steering fluid remote reservoir is
mounted to the rear of the cylinder head on the pas-
senger side of the vehicle.
The service procedures for the TTA power steering
pump are limited to the areas and components listed
below.No repair procedures are to be done on
internal components of the TTA power steering
pumps.
²Repair of power steering fluid leaks from areas
of the power steering pump sealed by O-rings is
allowed (See Pump Leak Diagnosis). However power
steering pump shaft seal leakage will require
replacement of the pump.
²Power steering fluid reservoirs, related compo-
nents and attaching hardware.
²Power steering fluid reservoir filler cap/dipstick
assemblies.
Because of unique shaft bearings, flow control lev-
els or pump displacements, power steering pumps
may be used only on specific vehicle applications. Be
sure that all power steering pumps are only replaced
with a pump that is the correct replacement for that
specific application.
Hydraulic pressure is provided for operation of the
power steering gear by the belt driven power steering
pump id (Fig. 1). It is a constant displacement, vane
type pump. The power steering pump is connected to
the steering gear by a power steering fluid pressure
hose and return hose.
Fig. 1 TTA Power Steering Pump Assembly
PLSTEERING 19 - 9

Rectangular pumping vanes in the shaft driven
rotor, move power steering fluid from the intake to
the cam ring pressure cavities of the power steering
pump. As the rotor begins to turn, centrifugal force
throws the vanes against the inside surface of the
cam ring to pickup residual oil. This oil is then forced
into the high pressure area. As more oil is picked up
by the vanes, the additional oil is forced into the cav-
ities of the thrust plate through two crossover holes
in the cam ring and pressure plate. The crossover
holes empty into the high pressure area between the
pressure plate and the housing end cover.
As the high pressure area is filled, oil flows under
the vanes in the rotor slots, forcing the vanes to fol-
low the inside surface of the cam ring. As the vanes
reach the restricted area of the cam ring, oil is forced
out from between the vanes. When excess oil flow is
generated during high-speed operation, a regulated
amount of oil returns to the pump intake side
through a flow control valve. The flow control valve
reduces the power required to drive the pump and
holds down temperature build-up.
When steering conditions exceed maximum pres-
sure requirements, such as when the wheels are
turned against the stops. The pressure built up in
the steering gear exerts pressure on the spring end of
the flow control valve. The high pressure lifts the
relief valve ball from its seat and allows oil to flow
through a trigger orifice located in the outlet fitting.
This reduces pressure on the spring end of the flow
control valve which then opens and allows the oil to
return to the intake side of the pump. This action
limits maximum pressure output of the pump to a
safe level.
Under normal power steering pump operating con-
ditions, pressure requirements of the pump are below
maximum, causing the pressure relief valve to
remain closed.
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM TEST PROCEDURE
The following procedure can be used to test the
operation of the power steering system on the vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-
sure. This test is to be performed any time a power
steering system problem is present to determine if
the power steering pump or power steering gear is
not functioning properly. The following pressure and
flow test is performed using Pressure/Flow Tester,
Special Tool 6815 (Fig. 2).
POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE
(1) Check power steering pump drive belt tension
and adjust as necessary.
(2) Disconnect power steering fluid pressure hose,
at power steering pump. Use a container for dripping
fluid.
(3) Connect Pressure Gauge, Special Tool from kit
6815 (Fig. 3) to both hoses using adapter fittings.
Connect spare pressure hose, to power steering pump
pressure hose banjo fitting.
(4) Completely open valve on Special Tool 6815
(Fig. 3).
(5) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test
and get air out of fluid. Then shut off engine.
(6) Check power steering fluid level, and add fluid
as necessary. Start engine again and let idle.
(7) Pressure gauge should read below 862 kPa
(125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure reading
Fig. 2 Power Steering Pump Flow/Pressure Tester
Fig. 3 Power Steering Pump Flow/Pressure Tester
Connected To Power Steering Pump
19 - 10 STEERINGPL
DESCRIPTION AND OPERATION (Continued)

should be in the range of 345-552 kPa (50-80 psi).
The flow meter should read between 1.3 and 1.4
GPM
CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.
(8) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pres-
sure is 8240 to 8920 kPa (1195 to 1293 psi.).
²If power steering pump pressures above specifi-
cations but not within 345 kPa (50 psi) of each other,
then replace power steering pump.
²If pressures within 345 kPa (50 psi) of each
other but below specifications, then replace power
steering pump.
CAUTION: Do not force the pump to operate
against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test valve. Turn steering wheel to the
extreme left and right positions until against the
stops, recording the highest indicated pressure at
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL CHECK
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TO PREVENT INJURY FROM
MOVING PARTS. DO NOT USE AUTOMATIC TRANS-
MISSION FLUID IN THE POWER STEERING SYS-
TEM. DO NOT OVERFILL THE POWER STEERING
SYSTEM.
Wipe reservoir filler cap free of dirt. Then check
fluid level. The dipstick should indicate COLD when
fluid is at normal ambient temperature, approxi-
mately 21ÉC to 27ÉC (70ÉF to 80ÉF). In all pumps add
fluid as necessary, use onlyMopar Power Steering
Fluid, or equivalent. DO NOT USE ANY TYPE
OF AUTOMATIC TRANSMISSION FLUID.
POWER STEERING PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only MoparTPower Steering Fluid. Do
not use automatic transmission fluid. Do not over-
fill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateFULL COLDwhen the
fluid is at normal temperature of approximately 21ÉC
to 27ÉC (70ÉF to 80ÉF).
(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.
Then 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.
(5) Start the engine. Slowly turn the steering
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.
POWER STEERING PUMP FLOW CONTROL VALVE
SEAL
The power steering pump does not require removal
from the engine for removal and replacement of the
flow control valve fitting O-Ring.
REMOVE
(1) Remove the power steering fluid pressure hose
from the power steering pump pressure fitting (Fig.
4).
(2) Remove the flow control valve fitting from the
power steering pump housing (Fig. 5).Prevent flow
control valve and spring from sliding out of
housing bore.
(3) Remove and discard O-ring seal from fitting.
INSTALL
(1) If necessary, clean and install flow control
valve and spring in pump housing bore.
(2) Install new O-ring seal on fitting.
(3) Install fitting in pump housing and tighten to
75 N´m (55 ft. lbs.)
(4) Install power steering fluid pressure hose on
flow control valve fitting.
PLSTEERING 19 - 11
DIAGNOSIS AND TESTING (Continued)