Dakota, 2001-2005

Removal & Installation

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  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Front wheels
     
    Outer tie rod ends
     
    Steering shaft coupler
     
    Power steering hoses
     
    Steering gear

    Click image to see an enlarged view

    Fig. Rack and pinion steering gear mounting used on the 2001-03 2WD Dakota models

     

  4.  

To install:

  1. Install or connect the following:

    Steering gear. Tighten the bolts to 190 ft. lbs. (258 Nm).
     
    Power steering hoses. Tighten the fittings to 25 ft. lbs. (35 Nm).
     
    Steering shaft coupler. Tighten the bolt to 36 ft. lbs. (49 Nm).
     
    Outer tie rod ends. Tighten the nuts to 65 ft. lbs. (88 Nm).
     
    Front wheels
     

  2.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Siphon out as much power steering fluid as possible from the pump.
  4.  
  5. Lock the steering wheel.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the front tires.
  10.  
  11. Remove the nuts from the tie rod ends.
  12.  
  13. Separate tie rod ends from the knuckles.
  14.  
  15. Remove the steering gear pinch bolt.
  16.  
  17. Remove the lower steering coupling from the steering gear.
  18.  
  19. Turn the steering gear to the full right position.
    NOTE
    Protect the end of hoses to prevent contamination to the system and damage to the O-rings.

  20.  
  21. Remove the power steering lines from the gear.
  22.  
  23. Remove the steering gear mounting bolts and nuts.
  24.  
  25. Tip the gear forward to allow clearance and move to the right then tip the gear downward on the left side to remove from the vehicle.
  26.  

To install:


NOTE
Before installing gear inspect bushings and replace if worn or damaged.

  1. Install gear to the vehicle and tighten mounting nuts and bolts to 190 ft. lbs. (258 Nm).
  2.  
  3. Install power steering lines to steering gear and tighten the pressure hose to 23 ft. lbs. (31 Nm) and tighten the return hose to 27 ft. lbs. (37 Nm).
  4.  
  5. Slide the shaft coupler onto gear. Install new bolt and tighten to 36 ft. lbs. (49 Nm).
  6.  
  7. Clean tie rod end studs and knuckle tapers.
  8.  
  9. Install tie rod ends into the steering knuckles and tighten the nuts to 55 ft. lbs. (75 Nm).
  10.  
  11. Install the front tires.
  12.  
  13. Remove the support and lower the vehicle.
  14.  
  15. Unlock the steering wheel.
  16.  
  17. Fill system with fluid.
  18.  
  19. Adjust the toe position.
  20.  

2-Wheel Drive




NOTE
The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Siphon out as much power steering fluid as possible from the pump.
  4.  
  5. Lock the steering wheel.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the front tires.
  10.  
  11. Remove the nuts from the tie rod ends.
  12.  
  13. Separate tie rod ends from the knuckles with Puller C-3894-A, or equivalent.
  14.  
  15. Remove the power steering lines from the gear.
  16.  
  17. Remove the lower coupler bolt and slide the coupler off the gear.
  18.  
  19. Remove the mounting bolts from the gear to the front crossmember and remove the gear.

    Click image to see an enlarged view

    Fig. Steering gear mounting-2004 2 wheel drive



    Click image to see an enlarged view

    Fig. Steering gear coupler

  20.  

To install:


NOTE
Before installing gear inspect bushings and replace if worn or damaged.

  1. Install gear on front crossmember and tighten mounting bolts to 200 ft. lbs. (271 Nm).
  2.  
  3. Slide shaft coupler onto gear. Install new bolt and tighten to 36 ft. lbs. (49 Nm).
  4.  
  5. Clean tie rod end studs and knuckle tapers.
  6.  
  7. Install tie rod ends into the steering knuckles and tighten the nuts to 60 ft. lbs. (81 Nm).
  8.  
  9. Install power steering lines to steering gear and tighten the hose to 23 ft. lbs. (31 Nm).
  10.  
  11. Install the front tires.
  12.  
  13. Remove support and lower vehicle.
  14.  
  15. Unlock the steering wheel.
  16.  
  17. Fill system with fluid.
  18.  
  19. Adjust the toe position.
  20.  

4-Wheel Drive




NOTE
The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Siphon out as much power steering fluid as possible from the pump.
  4.  
  5. Lock the steering wheel.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the front tires.
  10.  
  11. Remove the nuts from the tie rod ends.
  12.  
  13. Separate tie rod ends from the knuckles with Puller C-3894-A, or equivalent.
  14.  
  15. Remove the splash shield from under the front end to gain access to the gear.
  16.  
  17. Remove the skid plate.
  18.  
  19. Remove the power steering lines from the gear.
  20.  
  21. Remove the lower coupler bolt and slide the coupler off the gear.
  22.  
  23. Remove the mounting bolts from the gear to the front crossmember. Slide the gear to the right side of the vehicle. Then tilt the left end of the gear down and remove the gear.
  24.  
  25. Adjust the toe position.

    Click image to see an enlarged view

    Fig. Steering gear mounting-2004 4 wheel drive

  26.  

To install:


NOTE
Before installing the gear inspect bushings and replace if worn or damaged.

  1. Install the gear on the front crossmember and tighten the mounting bolts to 200 ft. lbs. (271 Nm).
  2.  
  3. Slide the shaft coupler onto gear. Install a new bolt and tighten to 36 ft. lbs. (49 Nm).
  4.  
  5. Clean the tie rod end studs and knuckle tapers.
  6.  
  7. Install the tie rod ends into the steering knuckles and tighten the nuts to 60 ft. lbs. (81 Nm).
  8.  
  9. Install the power steering lines to steering gear and tighten the hose to 23 ft. lbs. (31 Nm).
  10.  
  11. Install the splash shield.
  12.  
  13. Install the skid plate.
  14.  
  15. Install the front tires.
  16.  
  17. Remove the support and lower the vehicle.
  18.  
  19. Unlock the steering wheel.
  20.  
  21. Fill the system with fluid.
  22.  

 
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