Pacifica, 2003-2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn the front wheels to the straight-ahead position.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Cap from the power steering fluid reservoir and siphon out as much fluid as possible
     
    Front wheels
     

  6.  
  7. If transferring tie rod ends to a new gear, loosen the jam nuts.

    Nut attaching tie rod end to the knuckle on both sides
     
    Tie rod ends from the knuckle using tool C-3894-A
     

  8.  
  9. Remove the roll pin fastening intermediate shaft extension-to-power steering gear shaft as follows:
    1. Insert removal tool 631A through the roll pin attaching the intermediate shaft extension to the steering gear.
    2.  
    3. Thread the knurled nut all the way onto the remover.
    4.  
    5. Hold the remove head steady and turn the hex nut to pull the pin from the shafts and remove the tool.
    6.  

  10.  
  11. Remove or disconnect the following:

    Intermediate shaft extension off the gear shaft
     
    Tube nut attaching return hose to the gear
     
    Return hose from the gear port
     
    Two gear mounting bolts and the gear.
     

  12.  
  13. If necessary, remove the tie rod ends counting how many turns it takes as this will aid during installation.

    Click image to see an enlarged view

    Fig. Use tool C-3894-A to separate the tie rod ends from the knuckle

    Use tool C-3894-A to separate the tie rod ends from the knuckle

    Click image to see an enlarged view

    Fig. Insert removal tool 631A through the roll pin attaching the intermediate shaft extension to the steering gear

    Insert removal tool 631A through the roll pin attaching the intermediate shaft extension to the steering gear
  14.  

To install:

  1. If removed, install the tie rod ends.
  2.  
  3. Install or connect the following:
    NOTE
    The drivers side gear mounting bolt is longer than the passenger side bolt.



    Gear through the left wheel well being careful of the tie rod end shields
     



    Gear bolts after centering the gear over the mounting bosses over the holes in the cradle and tighten to 120 ft. lbs. (163 Nm)
     

  4.  
  5. Wipe the power steering hoses on the gear, the connections with a lint free cloth and replace the O-rings coated with clean power steering fluid.

    Pressure and return hoses to the gear and tighten the tube nut to 275 inch lbs. (31 Nm)
     

  6.  
  7. Find the gear's center of travel and match the splines inside the intermediate shaft extension with those on the gear shaft, then slide the extension onto the shaft.
  8.  
  9. Install the roll pin as follows:
    1. Position installer 6381-A onto the extension and gear shaft.
    2.  
    3. Slide the roll pin onto the remover shaft.
    4.  
    5. Thread the knurled nut all the way onto the end of the installer.
    6.  
    7. While holding the install head, turn the hex nut to pull the pin into the shafts. Once the pin is centered in the intermediate shaft extension, remove the tool.
    8.  

  10.  
  11. Install or connect the following:

    Shaft cover over the top of the gear
     
    Outer tie rod ends to the knuckle using new nuts and tighten to 35 ft. lbs. (47 Nm), then an additional 180 degree ( 1 / 2 ) turn
     
    Snug the jam nuts
     
    Wheels
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the power steering system.
  14.  
  15. Perform a wheel alignment and tighten the tie rod jam nuts to 55 ft. lbs. (75 Nm).
  16.  

 
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