2001 CHRYSLER VOYAGER steering

(10) Move the heat sleeve on the power steering
return hose to expose the hose connection at the
pump (Fig. 5). Remove the hose from the power
steering Pump. Allow the remaining power steering
fluid to drain from the power steering pump and res-
ervoir through the removed return hose.
(11) Remove the power steering fluid pressure line
from the power steering pump (Fig. 6). Drain excess
power steering fluid from tube.
(12) Remove the fasteners, then the accessory
drive splash shield.
(13) Remove the adjuster nut attaching rear of
power steering pump to the cast mounting bracket.
(Fig. 7)
(14) Remove the front adjuster nut and the lower
pivot bolt (Fig. 8) attaching power steering pump
bracket to cast bracket.
(15) Remove the drive belt from the power steering
pump pulley.
(16) Remove the power steering pump and the
front bracket from the cast bracket on the engine as
an assembly through the exhaust tunnel.
(17) Remove the 3 bolts attaching the front
bracket to the power steering pump and separate the
power steering pump from the front bracket.
(18) If transferal of the power steering pump pul-
ley is necessary, (Refer to 19 - STEERING/PUMP -
DISASSEMBLY).
REMOVAL - PUMP (3.3L/3.8L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL).(3) Raise the vehicle.
(4) Remove the drive belt splash shield.
Fig. 4 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
Fig. 5 PRESSURE AND RETURN HOSES - 2.4L
1 - PUMP
2 - RETURN HOSE
3 - ROUTING CLAMPS
4 - PRESSURE FITTING AT GEAR
5 - RETURN FITTING AT GEAR
6 - CRADLE CROSSMEMBER
7 - STEERING GEAR
8 - PRESSURE FITTING AT PUMP
19 - 26 PUMPRS
PUMP (Continued)

(5) Loosen (do not remove) the pump bracket thru-
bolt (#3 in figure) (Fig. 9).
(6) Remove the pressure hose routing bracket bolt
(Fig. 10).
(7) lower the vehicle.
(8) Remove cap from power steering fluid reser-
voir.
(9) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(10) Disconnect the fluid supply hose from the
pump (Fig. 11)(11) Disconnect the pressure hose from the pump
(Fig. 11)
(12) Remove the mounting bolt from the rear of
the pump using care not to lose the spacer between
the pump and bracket (Fig. 9).
(13) Remove the three front mounting bolts
through the pulley (Fig. 9)
(14) Remove the pump through the engine com-
partment rocking it over the aluminum bracket.
Fig. 6 Power Steering Fluid Pressure And Return
Hose
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 7 Power Steering Pump Attaching Nut
1 - POWER STEERING PUMP MOUNTING BRACKET
2 - FRONT SUSPENSION CRADLE
3 - POWER STEERING PUMP
4 - NUT
Fig. 8 PUMP FRONT MOUNTING
1 - NUT
2 - BOLT
3 - PUMP
Fig. 9 PUMP MOUNTING
1 - REAR PUMP BOLT
2 - PUMP MOUNTING BOLT
3 - BRACKET THRU BOLT
4 - PUMP BELT PULLEY
5 - POWER STEERING PUMP
6 - BRACKET
RSPUMP19-27
PUMP (Continued)

DISASSEMBLY - PUMP (PULLEY)
The only serviceable part of the power steering
pump is the pulley. The procedure following is for
removal and installation of the pulley from the pump
once the pump is removed from the vehicle.(1) Remove the power steering pump from the
vehicle. Refer to Removal And Installation in this
section of the service manual.
(2) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 or C-4068 (Fig.
12).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump.
(3) Replace pulley if it is found to be bent, cracked,
or loose.
ASSEMBLY - PUMP (PULLEY)
The only serviceable part of the power steering
pump is the pulley. The procedure following is for
removal and installation of the pulley from the pump
once the pump is removed from the vehicle.
(1) Install the pulley with Installer C-4063 (Fig.
13). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.
(3) Install the pulley until it is flush with the end
of the power steering pump shaft (Fig. 14).
(4) Install the power steering pump on the vehicle.
NOTE: Once the pump is installed on the vehicle,
run the engine until it's warm (5 min.) and note any
belt chirp. If chirp exists, move the pulley outward
approximately 0.5 mm (0.020 in.). If noise increases,
press the pulley on 1.0 mm (0.040 in.). Be careful
that the pulley does not contact the pump mounting
bolts.
Fig. 10 PRESSURE HOSE ROUTING CLAMP
1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
3 - CRADLE CROSSMEMBER
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET
Fig. 11 SUPPLY & PRESSURE HOSES AT PUMP
1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
3 - POWER STEERING PUMP
Fig. 12 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
19 - 28 PUMPRS
PUMP (Continued)

INSTALLATION - PUMP (2.4L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its cast
mounting bracket (Fig. 7), then install the nut and
bolt attaching the front bracket to the cast bracket
(Fig. 8).Do not fully tighten at this time..
(3) Install the rear nut (Fig. 7).
(4) Install the power steering pump drive belt on
pulley and adjust (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION).(5) Tighten the two adjustment slot bolts and the
one pivot bolt to 54 N´m (40 ft.lbs.) torque.
(6) Install the accessory drive splash shield.
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(7) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 6). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(8) Install the power steering fluid low pressure
return hose on the power steering pump low pressure
fitting (Fig. 6).Be sure hose clamps are properly
reinstalled.
(9) Install the power steering fluid supply hose on
the power steering pump fluid fitting.Be sure hose
is clear of accessory drive belts all hose clamps
are properly reinstalled.
(10) When used, properly position the protective
heat sleeve on the power steering return hose. Tie
strap the heat sleeve to the power steering hose to
keep in it's proper position.
(11) Install the exhaust system (Fig. 4). Install all
exhaust system isolators/hangers on the exhaust sys-
tem brackets, then the four bolts and flag nuts (Fig.
3).
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness.
(13) Lower vehicle.
(14) Connect the negative battery cable on the
negative battery post.
(15) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(16) Inspect for leaks.
INSTALLATION - PUMP (3.3L/3.8L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
engine compartment of the vehicle.
(2) Install the power steering pump on its mount-
ing bracket.
(3) Install the 3 front and 1 rear power steering
pump mounting bolts (Fig. 9). Remember to place
spacer between pump and rear mounting bracket
when installing rear mounting bolt. Tighten the
power steering pump mounting bolts to a torque of
54 N´m (40 ft. lbs.).
NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
Fig. 13 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL
C-4063±A
Fig. 14 Pulley To Pump Shaft Location
1 - PULLEY
2 - PUMP BODY
3 - PUMP SHAFT
4 - HUB
RSPUMP19-29
PUMP (Continued)

(4) Install the power steering fluid pressure line
into the pressure output fitting of the power steering
pump (Fig. 11). Tighten the pressure line to pump fit-
ting tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid low-pressure
return hose on the power steering pump low pressure
fitting (Fig. 11).Be sure hose clamps are prop-
erly reinstalled.
(6) Raise the vehicle.
(7) Install the routing clip on the engine for the
pressure hose (Fig. 10).
(8) Tighten the pump thru-bolt (Fig. 9). Tighten to
54 N´m (40 ft. lbs.) torque.
(9) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Install the drive belt splash shield.
(11) Lower the vehicle.
(12) Install the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(13) Connect the negative battery cable on the
negative battery post.
(14) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(15) Inspect for leaks.
SPECIAL TOOLS
POWER STEERING PUMP
FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS.
The fluid level can be read on the exterior of the
power steering fluid reservoir. The fluid level should
be within the ªFILL RANGEº when the fluid is at
normal ambient temperature, approximately 21ÉC to
27ÉC (70ÉF to 80ÉF) (Fig. 15).
Before removing the power steering filler cap, wipe
the reservoir filler cap free of dirt and debris. Do not
overfill the power steering system. Use onlyMopart
Power Steering Fluid (MS-5931)or quivalent.
FLUID COOLER
DESCRIPTION
All models of this vehicle are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located on the front suspen-
sion cradle crossmember reinforcement (Fig. 16).
There are two different size coolers offered depending
on options. There is a standard 6-inch and an 8-inch
for vehicles equipped with the heavy duty cooling
package.
OPERATION
The purpose of the power steering fluid cooler is to
keep the temperature of the power steering system
fluid from rising to a level that would affect the per-
formance of the power steering system.
Installer C-4063B
Puller C-4333
Fig. 15 POWER STEERING FLUID RESERVOIR
19 - 30 PUMPRS
PUMP (Continued)

The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in series with
the power steering fluid return line, between the
steering gear and the power steering fluid reservoir.
This lowers the temperature of the power steering
fluid prior to it entering the power steering fluid res-
ervoir where it is resupplied to the power steering
pump.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle using a frame contact type hoist
or supported using jack stands. See Hoisting in
Lubrication And Maintenance.
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
16). Remove the cooler.
INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 16). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering fluid hoses on the cooler.
Be sure hose clamps are installed on hose pastthe upset bead on the power steering cooler
tubes.
(3) Lower the vehicle to a point where front tires
are just off the ground.
(4) Perform Power Steering Pump Initial Opera-
tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)
Fig. 16 POWER STEERING COOLER
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
RSPUMP19-31
FLUID COOLER (Continued)

STEERING
TABLE OF CONTENTS
page page
GEAR..................................1PUMP..................................6
GEAR
TABLE OF CONTENTS
page page
GEAR
REMOVAL...............................1INSTALLATION............................4
GEAR
REMOVAL - RHD GEAR
CAUTION: Positioning the steering column in the
locked position will prevent the clockspring from
being accidentally over-extended when the steering
column is disconnected from the intermediate
steering coupler.
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(3) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 1).
(5) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(6) Remove front wheel and tire assemblies.
(7) If equipped, remove hoses at power steering
cooler and allow fluid to drain.
(8) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 2).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(9) Remove both tie rod ends from steering knuck-
les using Puller, Special Tool C-3894±A (Fig. 3).(10) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
Fig. 1 Steering Column Shaft To Intermediate Shaft
Attachment
1 - STEERING COLUMN SHAFT COUPLER
2 - NUT
3 - SAFETY PIN
4 - INTERMEDIATE SHAFT
5 - PINCH BOLT
RGSTEERING19a-1

(11) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 4). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(12) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(13) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 5).
(14) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 6). Allow the hoses to hang down
out of the way.
(15) Remove the heat shield from the steering gear
(Fig. 5).
Fig. 2 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 3 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 4 CRADLE CROSSMEMBER REINFORCEMENT
ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
19a - 2 GEARRG
GEAR (Continued)