Avenger 2008

Removal & Installation

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WARNING
Power steering fluid, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst.


WARNING
Fluid level should be checked with the engine off to prevent personal injury from moving parts.


CAUTION
When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components.

  1. Siphon out as much power steering fluid as possible from the reservoir.
  2.  
  3. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the column.
  4.  
  5. Position the front wheels of vehicle in the STRAIGHT-AHEAD position, then turn the steering wheel to the right until the intermediate shaft coupling bolt (3) at the base of the column can be accessed.

    Click image to see an enlarged view

    Fig. Intermediate shaft coupling bolt (3)

  6.  
  7. Remove the intermediate shaft coupling bolt (3). Do not separate the intermediate shaft (2) from the steering gear pinion shaft (4) at this time.
  8.  
  9. Return the front wheels of vehicle (and steering wheel) to the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.

    Click image to see an enlarged view

    Fig. Lock the steering wheel in place

  10.  
  11. Raise and support the vehicle.
  12.  
  13. Remove front tires and wheels from both sides.
  14.  
  15. On each side of the gear, remove the nut (3) from the out tie rod end (6) at the knuckle (2).

    Click image to see an enlarged view

    Fig. Remove the nut (3) from the out tie rod end (6) at the knuckle (2)

  16.  
  17. On each side of the gear, separate the outer tie rod end (1) from the knuckle (3) using Remover 9360 (2).

    Click image to see an enlarged view

    Fig. Separate the outer tie rod end (1) from the knuckle (3) using Remover 9360 (2)

  18.  
  19. If equipped, remove the engine belly pan.
  20.  
  21. Remove the rear engine mount.
    1. Remove rear mount retaining bolts (3).

      Click image to see an enlarged view

      Fig. Remove rear mount retaining bolts (3)

    2.  
    3. Remove rear mount through bolt (1).
    4.  
    5. Remove oxygen sensor (1).

      Click image to see an enlarged view

      Fig. Remove oxygen sensor (1)

    6.  
    7. Remove rear mount retaining bolts (2).
    8.  
    9. Remove rear mount (1) towards the rear of the vehicle.

      Click image to see an enlarged view

      Fig. Remove rear mount (1) towards the rear of the vehicle

    10.  

  22.  
  23. Remove the front engine mount through-bolt.

    Click image to see an enlarged view

    Fig. Remove the front engine mount through-bolt

  24.  
  25. Remove the two bolts (5) fastening the fore/aft crossmember (4) to the lower radiator support (3).

    Click image to see an enlarged view

    Fig. Remove the two bolts (5) fastening the fore/aft crossmember (4) to the lower radiator support (3)

  26.  
  27. Remove the four bolts (1) fastening the fore/aft crossmember to the front crossmember. Remove the fore/aft crossmember.

    Click image to see an enlarged view

    Fig. Remove the four bolts (1) fastening the fore/aft crossmember to the front crossmember

  28.  
  29. Remove the screws (1) securing the power steering hose routing clamps (2) to the rear of the crossmember.

    Click image to see an enlarged view

    Fig. Remove the screws (1) securing the power steering hose routing clamps (2) to the rear of the crossmember

  30.  
  31. Unscrew the tube nut (2), then remove the return hose (1) at the steering gear.

    Click image to see an enlarged view

    Fig. Unscrew the tube nut (2), then remove the return hose (1) at the steering gear

  32.  
  33. Unscrew the tube nut (3), then remove the pressure hose (4) at the steering gear.
  34.  
  35. Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2). Remove the shield.
    NOTE
    Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost.



    Click image to see an enlarged view

    Fig. Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2)

  36.  
  37. Mark the location of the front crossmember (9) on the body near each mounting bolt.

    Click image to see an enlarged view

    Fig. Mark the location of the front crossmember (9) on the body near each mounting bolt

  38.  
  39. Support the crossmember (9) with a transmission jack.
  40.  
  41. Remove the four mounting bolts (6) securing the front crossmember (9) to the body.
  42.  
  43. If equipped, remove the mounting screws (8) securing the front crossmember reinforcement brackets (7) (one each side of vehicle) to the body (1). Remove the brackets.
  44.  
  45. If equipped, remove the mounting screws (1) securing the front cross-brace/reinforcement bracket (2) to the body (1). Remove the bracket.

    Click image to see an enlarged view

    Fig. Remove the mounting screws (1) securing the front cross-brace/reinforcement bracket (2) to the body (1)

  46.  
  47. Using the jack, slowly lower the crossmember enough to access the intermediate shaft coupling (1) at the steering gear pinion shaft (4). Slide the coupling off the pinion shaft.

    Click image to see an enlarged view

    Fig. Access the intermediate shaft coupling (1) at the steering gear pinion shaft (4)

  48.  
  49. Remove the dash seals (3, 5) as necessary.
  50.  
  51. Remove the two bolts (1) securing the steering gear (2) to the crossmember.

    Click image to see an enlarged view

    Fig. Remove the two bolts (1) securing the steering gear (2) to the crossmember

  52.  
  53. Remove the steering gear from the crossmember.
  54.  

To install:

  1. Install the steering gear on the crossmember.
  2.  
  3. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the gear mounting bolts to 74 ft. lbs. (100 Nm).
  4.  
  5. Install the dash seals (3, 5) as necessary.
  6.  
  7. Center the power steering gear rack in its travel as necessary.
    NOTE
    When installing the front suspension crossmember (1) back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost making wheel alignment more difficult.


    NOTE
    While raising the steering gear into place, it is not necessary to install the intermediate shaft coupling on the steering gear pinion shaft at this time. It can be installed once the vehicle is lowered. Make sure the coupling does not interfere with steering gear/dash seals at this time.

  8.  
  9. Slowly raise the crossmember (9) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal.
  10.  
  11. Check the positioning of the seals at the dash panel and adjust as necessary.
  12.  
  13. If equipped, position the front crossmember reinforcement brackets (7) (one each side of vehicle) over the crossmember rear mounting bushings and install the mounting screws (8), but do not tighten at this time.
  14.  
  15. If equipped, position the front cross-brace/reinforcement bracket (2) over the crossmember rear mounting bushings and body, then install the mounting screws (1). Do not tighten screws at this time.
  16.  
  17. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 100 ft. lbs. (135 Nm).
  18.  
  19. If equipped, tighten the crossmember reinforcement bracket mounting screws (8) to 37 ft. lbs. (50 Nm).
  20.  
  21. If equipped, tighten the cross-brace/reinforcement bracket mounting screws (1) to 37 ft. lbs. (50 Nm).
  22.  
  23. Remove the transmission jack.
  24.  
  25. Install the heat shield (1) over the steering gear (2). Install the mounting screws and push-pins.
  26.  
  27. Install the pressure hose tube (4) at the gear. Tighten the tube nut (3) to 24 ft. lbs. (32 Nm).
  28.  
  29. Install the return hose tube (1) at the gear. Tighten the tube nut (2) to 24 ft. lbs. (32 Nm).
  30.  
  31. Position the power steering hose routing clamps (2) on the crossmember. Install and tighten the screws to 71 inch lbs. (8 Nm).
  32.  
  33. Install the fore/aft crossmember (4) and front engine mount through-bolt.
  34.  
  35. Install the rear engine mount.
  36.  
  37. If equipped, install the engine belly pan.
    NOTE
    Prior to attaching the outer tie rod end to the knuckle, inspect the tie rod seal boot. If the seal boot is damaged, replace the outer tie rod end.

  38.  
  39. On each side of the gear, install the outer tie rod end (6) into the hole in the knuckle (2) arm. Start a NEW tie rod mounting nut (3) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 63 ft. lbs. (85 Nm).
  40.  
  41. On each side of the vehicle, install the tire and wheel assembly.
  42.  
  43. Lower the vehicle.
  44.  
  45. Remove the steering wheel holder.
  46.  
  47. Verify the front wheels of vehicle are in the STRAIGHT-AHEAD position.
  48.  
  49. Center the intermediate shaft (2) over the steering gear pinion shaft (4), lining up the ends, then slide the intermediate shaft onto the steering gear pinion shaft.
  50.  
  51. From center, rotate the steering wheel to the right until the intermediate shaft coupling bolt (3) can be easily installed.
  52.  
  53. Install the intermediate shaft coupling bolt (3). Tighten the bolt to 31 ft. lbs. (42 Nm).
  54.  
  55. Reposition the floor carpet (1) in place.
  56.  
  57. Straighten the steering wheel to STRAIGHT-AHEAD position.
  58.  
  59. Fill and bleed the power steering system.
  60.  
  61. Check for fluid leaks.
  62.  
  63. Perform wheel alignment as necessary.
  64.  

 
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