TownAndCountry 2008

Removal & Installation

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


CAUTION
The fluid level should be checked with the engine OFF to prevent personal injury from moving parts.


WARNING
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.


WARNING
When servicing power steering components, do not pinch off the power steering hoses in any way to stop the fluid flow. Damage to the hoses may result.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Place the front wheels of the vehicle in a STRAIGHT-AHEAD position.
  4.  
  5. Install a steering wheel holder locking the steering wheel in a STRAIGHT-AHEAD position.
  6.  
  7. Remove the negative (-) battery cable from the battery and isolate the cable.
  8.  
  9. Remove the cap from the power steering fluid reservoir.
  10.  
  11. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the tire and wheel assemblies.
  16.  
  17. Remove the nut securing the control link to the stabilizer bar by holding the stabilizer bar link lower stud stationary (wrench placed on machined flats on stud).
  18.  
  19. If outer the tie rods need to be transferred to the new gear, loosen the tie rod jam nut on both sides of the vehicle.
  20.  
  21. On both sides of vehicle, remove the nut attaching the outer tie rod to the knuckle by holding the rod end stud stationary while loosening and removing the nut with a wrench.
  22.  
  23. Release each outer tie rod end from the knuckle using Remover, Special Tool 9360.
  24.  
  25. Remove the front engine mount thru-bolt.
  26.  
  27. Remove the fore-aft crossmember front mounting bolt.
  28.  
  29. Remove the 4 fore-aft crossmember rear mounting bolts.
  30.  
  31. Remove the fore-aft crossmember.
  32.  
  33. Remove the screws and the push-pins securing the heat shield (1) over the right side of the steering gear (2). Remove the heat shield.

    Click image to see an enlarged view

    Fig. Remove steering gear heat shield

  34.  
  35. Remove the rear engine mount.
  36.  
  37. Remove the screws securing the power steering pressure hose routing clamp(s) to the rear of the crossmember (4.0L engine only).
  38.  
  39. Remove the screws securing the stabilizer bushing retainers to the crossmember.
  40.  
  41. Remove the 2 stabilizer bushing retainers.
  42.  
  43. Utilizing the slit cut into the cushions (bushings), remove the 2 cushions from the stabilizer bar.
  44.  
  45. Slowly rotate the stabilizer bar as necessary and remove it out through the driver side wheel opening.
  46.  
  47. Remove the tube nut fastening the return hose to the power steering gear. Remove the return hose from the gear port.
  48.  
  49. Remove the tube nut fastening the pressure hose to the power steering gear. Remove the pressure hose from the gear port.
  50.  
  51. Remove the bolts (1) securing the steering gear (2) to the crossmember.

    Click image to see an enlarged view

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

  52.  
  53. Slide the dust shield upward exposing the pinch bolt securing the intermediate shaft extension to the steering gear shaft.
  54.  
  55. Remove the pinch bolt securing the intermediate shaft extension to the steering gear shaft
  56.  
  57. Slide the intermediate shaft extension off the steering gear shaft.
  58.  
  59. Rotate the steering gear to the position shown in the graphic, then slide the steering gear out the left wheel opening.
  60.  
  61. If necessary, remove the outer tie rods from the inner tie rod threads. Count how many rotations it takes to remove each outer tie rod for installation reference.

    Click image to see an enlarged view

    Fig. Rotate the steering gear to the position shown in the graphic, then slide the steering gear out the left wheel opening

  62.  

To install:

  1. If necessary, install the outer tie rods onto the inner tie rod threads. As the outer tie rods are installed, count out the same number of rotations as were counted on the tie rod removal. This will get the toe setting somewhat close to specification before the vehicle is aligned at the end of this procedure. Snug the tie rod jam nuts on both ends of the gear. Do not tighten at this time. Tighten the tie rod jam nuts to specification while performing the wheel alignment at the end of this procedure.
  2.  
  3. Carefully install the power steering gear through the left wheel opening using the reverse of how it was removed, then set it up into the mounted position.
  4.  
  5. Find the power steering gear's center of travel, then match the intermediate shaft extension with that on the steering gear shaft. Slide the extension onto the steering gear shaft.
  6.  
  7. Install the pinch bolt securing the intermediate shaft extension to the extension shaft. Tighten the pinch bolt to 31 ft. lbs. (42 Nm).
  8.  
  9. Slide the dust shield down over the pinch bolt and the steering gear shaft.
  10.  
  11. Center the steering gear mounting bosses over the mounting holes in the crossmember and install 2 steering gear mounting bolts. Tighten the mounting bolts to 55 ft. lbs. (75 Nm).
  12.  
  13. Install the return hose into the power steering gear port. Thread the return hose tube nut into the gear and tighten to 23 ft. lbs. (31 Nm).
  14.  
  15. Install the pressure hose into the power steering gear port. Thread the pressure hose tube nut into the gear and tighten to 23 ft. lbs. (31 Nm).
    NOTE
    Before the stabilizer bar installation, inspect the cushions and links for excessive wear, cracks, damage, and distortion. Replace any pieces failing inspection.


    NOTE
    Before installing the stabilizer bar, make sure the bar is not upside-down. The stabilizer bar must be installed so that when in the mounted position, the ends of the bar curve under the steering gear tie rods, up to the links.

  16.  
  17. Install the stabilizer bar through the driver side wheel opening. Rotate the bar, as necessary, until it is centered over the suspension crossmember and the ends curve upward below the steering gear tie rods.
  18.  
  19. Install the 2 cushions (bushings) on the stabilizer bar utilizing the slit cut into the cushion sides.
  20.  
  21. Install the 2 stabilizer bushing retainers over the cushions.
  22.  
  23. Install the 4 screws securing the stabilizer bushing retainers to the crossmember. Tighten the screws to 33 ft. lbs. (45 Nm).
  24.  
  25. Position the power steering pressure hose routing clamp(s) on the rear of the crossmember (4.0L engine only). Install and tighten the screw(s) to 71 inch lbs. (8 Nm).
  26.  
  27. Install the rear engine mount.
  28.  
  29. Position the heat shield over the steering gear. Install the mounting screws and push-pins. Tighten the screws to 71 inch lbs. (8 Nm).
  30.  
  31. Position the fore-aft crossmember in the engine compartment and install the mounting bolts. Tighten the forward mounting bolt to 83 ft. lbs. (113 Nm). Tighten the rearward mounting bolts at the suspension crossmember to 41 ft. lbs. (55 Nm).
  32.  
  33. Install the front engine mount thru-bolt. Tighten the bolt to 42 ft. lbs. (57 Nm).
  34.  
  35. On each side of the vehicle, attach the outer tie rod to the knuckle. Start a NEW nut onto the outer tie rod stud. While holding the stud stationary, tighten the nut using a wrench. Using a crowfoot wrench on a torque wrench, tighten the nut to 55 ft. lbs. (75 Nm). Then, tighten the nut an additional 245° turn after that torque is met.
  36.  
  37. Attach the stabilizer bar link at each end of the stabilizer bar. At each link, install and tighten the nut while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 65 ft. lbs. (88 Nm).
  38.  
  39. On each side of the vehicle, install the tire and wheel assembly. Install and tighten wheel mounting nuts in proper sequence to 100 ft. lbs. (135 Nm).
  40.  
  41. Lower the vehicle.
  42.  
  43. Connect the negative (-) battery cable on the negative battery post. Tighten the nut to 45 inch lbs. (5 Nm).
  44.  
  45. Remove the steering wheel holder.
  46.  
  47. Fill and bleed the power steering system.
  48.  
  49. Inspect for leaks.
  50.  
  51. Perform a wheel alignment, setting the toe to specifications.
  52.  

 
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