300, 300C & Magnum 2006-2008, Charger 2006-2008

Removal & Installation

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All Wheel Drive Vehicles



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate negative battery cable from battery post.
  4.  
  5. Siphon power steering fluid from pump reservoir.
  6.  
  7. Raise and support vehicle.
  8.  
  9. Remove wheel mounting nuts, then both front tire and wheel assemblies.
    WARNING
    When loosening jam nut and rotating inner tie rod, use care not to twist bellows at inner tie rod.



    Click image to see an enlarged view

    Fig. Inner-to-outer tie rod connection-AWD models

  10.  
  11. Remove clamp (2) at inner tie rod (3) and make sure bellows moves freely before rotating inner tie rod.
  12.  
  13. Loosen tie rod jam nut (1) at each outer tie rod (4).
  14.  
  15. Remove outer tie rod end nut at each knuckle.

    Click image to see an enlarged view

    Fig. Outer tie rod end (2) to knuckle (3) connection-AWD models

  16.  
  17. Using Remover, Special Tool 9630, separate outer tie rod from each knuckle.
  18.  
  19. Remove steering coupling pinch bolt at steering gear.
  20.  
  21. Unthread return hose tube nut from steering gear. Remove return hose from steering gear.
  22.  
  23. Unthread pressure hose tube nut from steering gear. Remove pressure hose from steering gear.

    Click image to see an enlarged view

    Fig. Steering gear (3) heat shields, (2) boots, (1) crossmember-AWD models

  24.  
  25. Remove mounting screws, then heat shield above each inner tie rod bellows.

    Click image to see an enlarged view

    Fig. Steering gear mounting (1) gear, (2, 3) lower mounting bolts, (4) upper mounting bolt-AWD models

  26.  
  27. Remove steering gear upper mounting bolt and nut.
  28.  
  29. Remove steering gear lower mounting bolts.
  30.  
  31. Remove steering gear.
  32.  
  33. If necessary, remove outer tie rods from gear. Count number of revolutions off for each tie rod for reference upon installation to replacement gear.
  34.  

To install:

  1. If necessary, install outer tie rods from original gear to replacement inner tie rods. Install each outer tie rod same amount of threads as it was installed on original gear. This will get toe setting close, saving some time when toe is set later in this procedure.
  2.  
  3. Lift steering gear into mounted position and install steering gear lower mounting bolts. Install upper mounting bolt and nut. Tighten all bolts to 75 ft. lbs. (102 Nm).
  4.  
  5. Install heat shield above each inner tie rod bellows. Tighten screws to 89 inch lbs. (10 Nm).
    NOTE
    Always use a NEW O-ring on the ends of the steering hoses.

  6.  
  7. Lubricate NEW O-ring on end of pressure hose with clean power steering fluid.
  8.  
  9. Install pressure hose to steering gear. Tighten tube nut to 35 ft. lbs. (47 Nm).
  10.  
  11. Lubricate NEW O-ring on end of return hose with clean power steering fluid.
  12.  
  13. Install return hose to steering gear. Tighten tube nut to 35 ft. lbs. (47 Nm).
  14.  
  15. Align splines and install steering coupling to steering gear shaft. Install NEW pinch bolt. Tighten bolt to 40 ft. lbs. (54 Nm).
  16.  
  17. Install each outer tie rod end to its knuckle. Install nut and tighten to 63 ft. lbs. (85 Nm).
  18.  
  19. Install tire and wheel assemblies. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm).
  20.  
  21. Lower vehicle.
  22.  

RWD Models



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate negative battery cable from battery post.
  4.  
  5. Siphon power steering fluid from pump reservoir.
  6.  
  7. Raise and support vehicle.
  8.  
  9. Remove wheel mounting nuts, then both front tire and wheel assemblies.
    WARNING
    When loosening jam nut and rotating inner tie rod, use care not to twist bellows at inner tie rod. Remove clamp at inner tie rod and make sure bellows moves freely before rotating inner tie rod.



    Click image to see an enlarged view

    Fig. Outer tie rod end and knuckle-RWD models

  10.  
  11. Loosen tie rod jam nut (3) at each outer tie rod (5).

    Click image to see an enlarged view

    Fig. Removing outer tie rod end from the knuckle with tool 9630

  12.  
  13. Remove outer tie rod nut (1) at each knuckle (2).
  14.  
  15. Using Remover (2), Special Tool 9630, separate outer tie rod (1) from each knuckle.

    Click image to see an enlarged view

    Fig. Remove the steering coupling from the gear-RWD models

  16.  
  17. Remove steering coupling (2) pinch bolt (1) at steering gear (3).
  18.  
  19. Unthread pressure hose tube nut from steering gear. Remove pressure hose from steering gear.
  20.  
  21. Unthread return hose tube nut from steering gear. Remove return hose from steering gear.

    Click image to see an enlarged view

    Fig. Steering gear (2) mounting bolts (1)-RWD models

  22.  
  23. Remove steering gear mounting bolts.
  24.  
  25. If necessary, remove outer tie rods from gear. Count number of revolutions off for each tie rod for reference upon installation to replacement gear.
  26.  

To install:

  1. If necessary, install outer tie rods from original gear to replacement inner tie rods. Install each outer tie rod same amount of threads as it was installed on original gear. This will get toe setting close, saving some time when toe is set later in this procedure.
  2.  
  3. Lift steering gear into mounted position and install steering gear mounting bolts. Tighten bolts to 70 ft. lbs. (95 Nm).
    NOTE
    Always use a new O-ring on the ends of the steering hoses.

  4.  
  5. Lubricate new O-ring on end of return hose with clean power steering fluid.
  6.  
  7. Install return hose to steering gear. Tighten tube nut to 35 ft. lbs. (47 Nm).
  8.  
  9. Lubricate new O-ring on end of pressure hose with clean power steering fluid.
  10.  
  11. Install pressure hose to steering gear. Tighten tube nut to 35 ft. lbs. (47 Nm).
    WARNING
    Prior to coupling installation, make sure gear is centered in its travel to match clockspring centering in steering column.

  12.  
  13. Align coupling with input shaft and install steering coupling. Install new pinch bolt. Tighten bolt to 40 ft. lbs. (54 Nm).
  14.  
  15. Install each outer tie rod end to its knuckle. Install nuts and tighten to 63 ft. lbs. (85 Nm).
  16.  
  17. Install tire and wheel assemblies. Tighten the wheel mounting nuts to 110 ft. lbs. (150 Nm).
  18.  
  19. Lower vehicle.
  20.  
  21. Connect negative battery cable to battery post. It is important that this is performed properly.
  22.  
  23. Fill pump reservoir with fluid and perform pump initial operation procedure.
  24.  
  25. Perform wheel alignment setting toe to specifications.
  26.  

 
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