assembly to steering knuckle. Finger tighten bolts. Install 2
remaining rotor and hub assembly bolts. Tighten all bolts to
specification.
5) Install rotor and hub nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS. Install cotter pin. On one ton models,
install adapter hub bolts and hub to rotor and hub assembly. Install
brake caliper, and tighten bolts to specification. Install wheels, and
tighten lug nuts to specification.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application (1) Ft. Lbs. (N.m)
ABS Sensor Bolt ............................................ 15 (11)\
Brake Caliper Bolt ......................................... 38 (52)\
Drag Link Nut .............................................. 65 (88)\
Hub-To-Steering Knuckle Bolt ..................... 125-160 (170-217)\
Lower Ball Joint Nut
216 FBI ................................................. 80 (108)\
248 FBI ........................................ 140-160 (190-217)\
Rotor & Hub Nut .................................. 160-200 (217-271)\
Shock Absorber Lower Bolt ................................ 100 (136)\
Stabilizer Bar Bolt ........................................ 27 (37)\
Tie Rod-To-Steering Knuckle Nut ............................ 65 (88)\
Upper Ball Joint Nut
216 FBI ................................................. 75 (102)\
248 FBI .................................................. 70 (94)\
Wheel Lug Nuts .................................... 95-145 (130-195)\
( 1) - Front axles can be identified by differential cover. The 216 FBI
has rounded edges, the 248 FBI has flat angled edges.
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NOTE: Before testing, check fluid level, belt tension, pump pulley,
tire pressure and engine idle speed.
HYDRAULIC SYSTEM PRESSURE TEST
NOTE: Replacement fittings are required on Pressure Test Gauge(C
-3309E) for adapting to "O" ring type hose tube ends.
Idle Pressure Test
1) Remove high pressure hose at steering pump and connect a
spare hose to pump fitting. Connect opposite end of spare hose to
Pressure Test Gauge (C-3309E). Connect pressure hose from valve side
of steering gear to valve side of gauge. Valve must be installed on
outlet side of gauge. See Fig. 2.
2) Fully open shutoff valve on test gauge. With a thermometer
in fluid reservoir, start engine and warm fluid to 150-170
F (66-
77 C). Turning wheels from stop-to-stop will aid in warming fluid. DO
NOT hold wheels against stop.
3) With engine at idle and gauge valve open, check initial
pressure. See POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS table.
If pressure is greater than 125 psi (8.8 kg/cm
), check for restricted
hoses or crimped lines.
Fig. 2: Installing Pressure Gauge
Courtesy of Chrysler Corp.
POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS
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Application psi (kg/cmFD)
Idle Pressure ...................................... 50-80 (3.5-5.6)\
Relief Pressure
Dakota (4WD) ........................................ 1450 (101.9\
)
Ram Pickup .......................................... 1450 (101.9)\
Ram Van/Wagon ........................................ 1400 (98.4)\
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CAUTION: DO NOT leave shutoff valve closed more than 5 seconds, or
pump damage could result.
Relief Pressure Test
1) Close gauge shutoff valve completely 3 times. Record
highest pressure attained each time. All 3 readings must be greater
than specifications and within 50 psi (3.5 kg/cm
) of each other. See
POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS table. If pressures
are not as specified, replace pump. See POWER STEERING PUMP (GASOLINE)\
or VACUUM/POWER STEERING PUMP (DIESEL) under REMOVAL & INSTALLATION.
CAUTION: DO NOT hold steering wheel against stops more than 4 seconds,
or pump damage may result.
2) Open test valve and turn steering wheel to left and right
stops. Record highest pressure attained at each stop. If output
pressures are not equal against each stop, gear is leaking internally
and must be replaced. See STEERING GEAR under REMOVAL & INSTALLATION.
Shut off engine, remove test gauge, and connect pressure hose.
LUBRICATION
CAPACITY
CAPACITY\
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Models Pts. (L)\
Dakota (4WD) ............................................. 2.5 (1.2\
)
Ram Pickup & Ram Van/Wagon ............................... 2.7 (1.3)\
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FLUID TYPE
CAUTION: DO NOT use Automatic Transmission Fluid (ATF).
Use Mopar Power Steering Fluid (4318055).
FLUID LEVEL CHECK
Check fluid level with engine cold and not running. Remove
fluid level dipstick on pump reservoir. Dipstick should indicate FULL
COLD with fluid temperature of 70-80
F (21-27 C). If needed, add fluid
through dipstick opening, and recheck. DO NOT overfill.
HYDRAULIC SYSTEM BLEEDING
Fill power steering pump reservoir to specified level. Start
engine and slowly turn steering wheel to left and right, but DO NOT
contact steering stops in either direction. Stop engine. Inspect
reservoir fluid level and add fluid if necessary. Bleeding process may
have to be repeated several times to completely purge all air from
system.
ADJUSTMENTS
POWER STEERING PUMP BELT
Vehicles are equipped with dynamic tensioner. No adjustment
is required.
POWER STEERING PUMP PULLEY
Removal
1) Place wheels in straight-ahead position. Place drain pan
under steering gear assembly. Disconnect and cap pressure and return
hoses from steering gear. Disconnect steering column shaft coupling
from steering gear stub shaft.
2) Raise and support vehicle. Disconnect steering linkage
(center link) from pitman arm. See Fig. 9. Disconnect stabilizer bar
(if necessary). Place reference mark on pitman arm and sector shaft.
Remove nut and pitman arm from sector shaft. Remove steering gear-to-
frame bolts. Remove steering gear.
Installation
1) Install steering gear with bolts finger tight. Center
steering gear and align stub shaft with steering column. Install
steering column shaft coupling bolt and tighten to specification. See
TORQUE SPECIFICATIONS.
CAUTION: Stake pitman arm nut against pitman arm to ensure proper
retention.
2) Reposition steering gear to eliminate binding, and tighten
bolts to specification. Install pitman arm on sector shaft with
reference marks aligned. Install lock washer and nut. Tighten nut to
specification.
3) To install remaining components, reverse removal
procedure. Fill pump reservoir. Bleed air from hydraulic system. See
HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
SECTOR SHAFT OIL SEAL
Removal
1) Raise and support vehicle. Place wheels in straight-ahead
position. Disconnect steering linkage (center link) from pitman arm.
Disconnect stabilizer bar (if necessary).
2) Place reference mark on pitman arm and sector shaft.
Remove nut and pitman arm from sector shaft. Place drain pan under
steering gear. Remove retaining ring and steel washer. See Fig. 1.
CAUTION: DO NOT hold steering wheel in left-turn position for more
than 2 seconds.
3) Start engine and momentarily hold steering wheel in
extreme left-turn position. When pressure develops, this should force
upper oil seal, steel washer and lower oil seal from steering gear
housing. Stop engine and remove seals.
Installation
1) Ensure seal bore of steering gear is free of burrs and
sector shaft is free of pitting or roughness. Lubricate replacement
seals and steel washers with power steering fluid.
2) Wrap sector shaft with plastic tape or .005" (.13 mm)
thick shim stock. Install upper oil seal (single lip seal) and steel
washer first. Oil seal must be installed only deep enough to allow for
remaining oil seal, steel washer and retaining ring.
CAUTION: DO NOT install upper oil seal against inner bore surface of
steering gear housing. Oil seals must be installed so each
oil seal is separately seated in shaft bore.
3) Install lower oil seal (double lip seal) and steel washer\
.
Oil seal must be installed only deep enough to allow for steel washer
and retaining ring. Remove tape or shim stock and install retaining
ring.
CAUTION: Stake pitman arm nut against pitman arm to ensure proper
retention.
4) Install pitman arm on sector shaft with reference marks
aligned. Install lock washer and nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS.
5) To install remaining components, reverse removal
procedure. Fill pump reservoir. Allow engine to idle for at least 3
minutes. DO NOT turn wheels during this time. Rotate wheels both
directions and check for leaks. Refill pump reservoir.
CENTER LINK
Removal & Installation
Separate tie rods, idler arm, steering and drag link (if
equipped) from center link. Remove center link. To install, reverse
removal procedure. Tighten nuts to specification.
Fig. 9: Exploded View Of Steering Linkage
Courtesy of Chrysler Corp.
DRAG LINK
Removal & Installation
Remove cotter pins and drag link nuts. Using Separator (C-
4150), separate drag link from steering knuckle or center link and
pitman arm. Remove drag link. To install, reverse removal procedure.
Tighten nuts to specification. See TORQUE SPECIFICATIONS. Install
cotter pins.
IDLER ARM
Removal & Installation
Remove cotter pin and nut from idler arm. Separate idler arm
from center link. Remove idler arm bolts. Remove idler arm. To
install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Install NEW cotter pin.
PITMAN ARM
Removal & Installation
1) Remove cotter pin and nut at pitman arm-to-center link or
drag link. Separate pitman arm from center link or drag link. Mark
location of pitman arm on steering gear shaft. Remove pitman arm-to-
steering gear shaft nut. Separate pitman arm from steering gear.
CAUTION: Stake pitman arm nut against steering gear shaft to ensure
proper retention.
2) To install, reverse removal procedure. Ensure reference
marks are aligned. Tighten bolts and nuts to specification. Install
NEW cotter pin.
TIE ROD END
Removal
Remove cotter pin and nut from tie rod end. Using Tie Rod End
Puller (C-3894-A), remove tie rod end from steering knuckle or center
link. Loosen lock nut or clamp bolt. Remove tie rod end. Note number
of turns required for removal.
NOTE: Use Tie Rod End Puller (C-3894-A) to prevent tie rod end seal\
damage.
Installation
1) To install, reverse removal procedure. Ensure tie rod end
is installed at same location. Position clamp sleeve with bolt located
on bottom. Clamp opening should be aligned with slot in sleeve.
2) Tighten the tie rod end nut to specification. Install a
NEW cotter pin. Check and adjust toe-in. See appropriate
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Tighten clamp
bolt to specification. See TORQUE SPECIFICATIONS.
OVERHAUL
POWER STEERING PUMP OVERHAUL
Only fluid reservoirs, caps, pulleys, "O" rings, seals and
flow control valve are replaceable on pump. See Figs. 7 and 8.
Internal components are non-serviceable. If internal components fail,
replace pump. Replace reservoir, or "O" ring and seals if damaged.
NOTE: If expansion plug is deformed or dislodged, DO NOT remove it.
Replace pump housing.
STEERING GEAR OVERHAUL
* S TE ER IN G U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS
TIE ROD ENDS (INNER AND OUTER)
TRACK BARS
TRAILING ARMS
WHEEL BEARINGS, RACES AND SEALS
Wheel Alignment
WHEEL ALIGNMENT
Wheels and Tires
TIRES
VALVE STEMS
WHEEL ATTACHMENT HARDWARE
WHEELS (RIMS)
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
1) a Pledge of Assurance to their Customers and 2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-