Chrysler Caravan/Voyager/Town and Country 1996-1999

Power Steering Gear

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REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Power steering gear assembly



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Fig. Fig. 2: A crowfoot wrench should be used to remove the power steering lines


WARNING
Position the steering column in the locked position to prevent the SRS clockspring from becoming accidentally over-extended, when the steering column is disconnected from the intermediate coupler.

  1. With the ignition key in the locked position, turn the steering wheel to the left until the steering wheel locks itself in position.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the steering column shaft coupler from the steering gear intermediate coupler.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the front wheels.
  10.  
  11. Place a drain pan under the power steering fluid lines and disconnect the fluid hose from the metal tube portion of the power steering fluid return line and allow the steering fluid to drain into the pan.
  12.  
  13. Remove the tie rod ends from the steering knuckles.
  14.  
  15. Remove the 2 bolts and loosen the third, mounting the ABS Hydraulic Control Unit (HCU) to the front suspension cradle. Rotate the HCU rearward to allow access to the cradle plate mounting nut and bolt just ahead of the HCU.
  16.  

See Figures 3 and 4



Click image to see an enlarged view

Fig. Fig. 3: A special tool is required to remove the roll pin from the coupler



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Fig. Fig. 4: The steering gear is mounted to the front suspension cradle by three bolts

  1. Remove the front suspension cradle plate from the front suspension cradle.
  2.  
  3. Remove the retaining bracket attaching the power steering fluid lines to the front suspension cradle.
  4.  
  5. Using an 18mm crowfoot, disconnect the power steering fluid pressure and return lines from the power steering gear.
  6.  
  7. Remove the 3 bolts and nuts mounting the rack and pinion steering gear to the suspension cradle.
  8.  
  9. Lower the steering gear from the suspension cradle enough to allow access to the steering column intermediate coupler roll pin. Remove the roll pin and separate the intermediate coupler from the steering gear shaft.
  10.  
  11. Remove the rack and pinion steering gear assembly from the front suspension cradle.
  12.  

To install:
  1. Install the rack and pinion steering gear assembly into the front suspension cradle, providing enough room to install the intermediate coupler.
  2.  
  3. Connect the steering gear shaft to the intermediate coupler and secure with roll pin.
  4.  
  5. Place the steering gear assembly in correct position on the suspension cradle and install the 3 steering gear mounting bolts and nuts. Torque the bolts and nuts to 100 ft. lbs. (136 Nm).
  6.  
  7. Connect the power steering fluid pressure and return lines to the correct fittings on the steering gear. Torque the power steering fluid line tube fittings to 275 inch lbs. (31 Nm).
  8.  
  9. Install the outer tie rod ends to the steering knuckles. Torque the tie rod end-to-steering knuckle nuts to 40 ft. lbs. (54 Nm).
  10.  
  11. Install the front suspension cradle plate to the front suspension cradle. Torque the 10 mounting bolts and nuts to 123 ft. lbs. (165 Nm).
  12.  
  13. Install the bracket mounting the power steering fluid lines to the suspension cradle. Be sure the protective heat shields cover the entire rubber hose hose-to-tube connection of both power steering fluid hoses.
  14.  
  15. Install the hose onto the metal tube portion of the power steering fluid return line. Install hose clamp on the return hose. Be sure the hose clamp is installed past the upset bead on the tube.
  16.  
  17. Install the front wheels and lug nuts. Torque the lug nuts, in a star sequence, to 95 ft. lbs. (129 Nm).
  18.  
  19. Lower the vehicle just enough to access the interior of the vehicle.
  20.  
  21. Using the intermediate coupler, turn the front wheels to the left until the intermediate coupler shaft is correctly aligned with the steering column coupler. Connect the steering column shaft coupler to the steering gear intermediate coupler. Install the steering column coupler-to-intermediate shaft retaining pinch bolt. Torque the pinch bolt nut to 250 inch lbs. (28 Nm).
  22.  
  23. Reconnect the negative battery cable.
  24.  
  25. Refill power steering reservoir, with the correct amount of clean, fresh MOPAR® Power Steering Fluid or equivalent, and bleed the system.
  26.  
  27. Check the toe setting and adjust, if necessary. Road test the vehicle and check steering operation.
  28.  

 
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