Chrysler Full-Size Vans 1967-1988 Repair Guide

Manual Steering Gear

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REMOVAL & INSTALLATION



See Figure 1

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Fig. Fig. 1: Troubleshooting the Manual Steering Gear

1967-69 Models
  1. Remove the steering column as outlined above.
  2.  
  3. Remove the steering wheel.
  4.  
  5. Remove the turn signal lever.
  6.  
  7. Loosen the turn signal switch clamp screw.
  8.  
  9. Tie a long piece of string to the end of the turn signal switch wiring. Pull the switch and wiring from the column, leaving enough of the string in the column to use in pulling the wiring back down inside the column.
  10.  
  11. Remove the snapring from the top of the steering shaft.
  12.  
  13. Slide the gear and shaft out of the column.
  14.  
  15. Installation is the reverse of removal.
  16.  

1970-73 Models
  1. Disconnect the drag link at the pitman arm.
  2.  
  3. Disconnect the battery.
  4.  
  5. Remove the windshield washer reservoir.
  6.  
  7. Remove the steering column.
  8.  
  9. Remove the bolts and nuts retaining the gear to the frame.
  10.  
  11. From under the left wheel well, remove the 2 bolts from the bottom of the splash shield. Force the splash shield away from the frame about 1 / 2 " and lift the gear off the mounting stud.
  12.  
  13. Installation is the reverse of removal. Tighten the mounting bolts and nut to 100 ft. lbs. Before connecting the drag link, make sure that the steering gear shaft is centered.
  14.  

1974-78 Models
  1. Place the wheels in a straight ahead position.
  2.  
  3. Matchmark the wormshaft coupling.
  4.  
  5. Remove the 2 wormshaft coupling bolts.
  6.  
  7. Disconnect the shift linkage at the column.
  8.  
  9. Matchmark the pitman arm and gear shaft.
  10.  
  11. Remove the pitman arm.
  12.  
  13. Remove the 3 gear mounting bolts.
  14.  
  15. Remove the steering column.
  16.  
  17. Remove the gear through the hole in the inboard side of the frame. It may be necessary to remove the 3 bolts from the left idler arm bracket and move the bracket out of the way.
  18.  
  19. Installation is the reverse of removal. Tighten the coupling bolts to 30 ft. lbs.; the pitman arm nut to 175 ft. lbs.; the steering gear mounting bolts to 100 ft. lbs.
  20.  

1979-88 Models
  1. Disconnect the battery ground.
  2.  
  3. Remove the steering column.
  4.  
  5. Disconnect the pitman arm from the gear.
  6.  
  7. Support the gear, remove the nuts and bolts and remove the gear.
  8.  
  9. Installation is the reverse of removal. Tighten the bolts/nuts to 100 ft. lbs. on 1979-83 vans; 150 ft. lbs. on 1984-88 models. Center the gear shaft before connecting the linkage.
  10.  

ADJUSTMENTS



1967-69 Models

The worm bearing preload adjustment is performed with the gear out of the truck. The gear shaft adjustment can be performed with the gear in the truck. The worm bearing adjustment must be performed first, however.

Worm bearing preload can be checked with the gear in the truck as follows:

  1. Place the wheels in a straight ahead position.
  2.  
  3. Matchmark and disconnect the pitman arm from the gear shaft.
  4.  
  5. Remove the horn button and spring.
  6.  
  7. Make sure that there is no binding in the steering column.
  8.  
  9. Place an inch-pound torque wrench on the steering wheel nut.
  10.  
  11. Turn the steering shaft with the torque wrench 2 full turns to wither side of center. and check the torque necessary to turn the shaft back over the center point. If the off-center torque (worm bearing preload) is 2-5 1 / 2 in. lbs. the gear is properly adjusted.
  12.  

WORM BEARING PRELOAD ADJUSTMENT
  1. The pitman arm must be removed.
  2.  
  3. Loosen the cross shaft shaft adjuster locknut and back out the adjuster screw 2 turns.
  4.  
  5. Turn the steering wheel 2 complete turns to either side of center.
  6.  


WARNING
Never turn the steering wheel hard against either stop with the pitman arm disconnected. Damage to the gear will result!

  1. With an inch-pound torque wrench, turn the steering shaft through the center point and note the turning torque. The torque should be 2-5 1 / 2 in. lbs. If not, add or remove shims beneath the wormshaft cover. Shims are available in 0.0025", 0.0055" and 0.010" thicknesses.
  2.  
  3. Tighten the worm cover bolts to 20 ft. lbs.
  4.  
  5. Recheck the preload. If the preload has changed, redo the adjustment.
  6.  

GEAR SHAFT (CROSS SHAFT) ADJUSTMENT
  1. Disconnect the pitman arm.
  2.  
  3. Counting the number of complete turns, turn the steering wheel completely from one lock to the other. Turn it GENTLY!
  4.  
  5. Turn the wheel back from either stop, 1 / 2 the total number of turns.
  6.  
  7. Loosen the cross shaft adjusting screw locknut and turn the adjusting screw in until all lash is removed. Tighten the locknut. 5. Turn the steering wheel 1 turn off of center.
  8.  
  9. Using an inch-pound torque wrench on the steering wheel nut, measure the torque needed to rotate the wheel over center. The torque reading should be 8-10 in. lbs. more than the worm bearing preload. If not, turn the adjusting screw until it is.
  10.  
  11. When the adjustment is complete, hold the adjusting screw and tighten the locknut to 20 ft. lbs.
  12.  
  13. Recheck the adjustment. If the load has changed, redo the adjustment.
  14.  
  15. Install the pitman arm.
  16.  

1970-88 Models
WORM BEARING PRELOAD ADJUSTMENT
  1. The pitman arm must be removed.
  2.  
  3. Loosen the sector shaft adjuster locknut and back out the adjuster screw 2 turns.
  4.  
  5. Remove the horn pad and spring.
  6.  
  7. Turn the steering wheel to the right stop and turn it back 1 / 2 turn.
  8.  


WARNING
Never turn the steering wheel hard against either stop with the pitman arm disconnected. Damage to the gear will result!

  1. With an inch-pound torque wrench, turn the steering shaft at least 1 turn toward center and note the turning torque. The torque should be 1 1 / 2 -4 1 / 2 in. lbs. If not, turn the adjuster screw clockwise to increase or counterclockwise to decrease, the preload.
  2.  
  3. Hold the adjuster screw and torque the locknut to 85 ft. lbs.
  4.  
  5. Recheck the preload. If the preload has changed, redo the adjustment.
  6.  

BALL NUT AND SECTOR GEAR MESH ADJUSTMENT
  1. Complete the worm bearing preload adjustment first.
  2.  
  3. Turn the steering wheel gently from one lock to the other. Count the number of turns. Turn the wheel back exactly to the midpoint of its travel.
  4.  
  5. Loosen the sector shaft adjuster locknut. Turn the sector shaft adjusting screw, which is located on the housing cover, clockwise until there is no lash present between the ball nut and sector teeth. Tighten the locknut to 24 ft. lbs.
  6.  
  7. Using and inch-pound torque wrench on the steering shaft nut, rotate the steering wheel 1 / 4 turn away from the center. Note the torque required to turn the wheel through center. The reading should be 8 1 / 4 -11 1 / 4 in. lbs. Turn the sector shaft adjustment screw, if required, to obtain the correct preload. Hold the adjusting nut and tighten the locknut to 24 ft. lbs.
  8.  
  9. Recheck the torque load. If the load has changed, redo the adjustment.
  10.  
  11. Once the adjustments are completed, straighten the front wheels and install the pitman arm.
  12.  

Not only should the front wheels be straight-ahead, but both the steering gear and the steering wheel should be centered as well.

  1. Tighten the pitman arm securing nut to 180 ft. lbs.
  2.  
  3. Install the horn button, ring, or trim pad on the steering wheel.
  4.  

 
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