Power Steering System: Removal & Installation Dodge Dakota III

REMOVAL

Scheme 24

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Scheme 31

Scheme 32

1. Position the front wheels straight ahead .
2. Disconnect the negative (ground) cable from the battery.
3. Remove the airbag (3), «(Refer to REMOVAL)»(ref-247645-S39386279482007020100000) .
4. Disconnect the electrical connector (2) from the air bag.
5. Remove the steering wheel (1) with special tool CJ98-1 (2) or an appropriate steering wheel puller. CAUTION: Ensure the puller bolts are fully engaged into the steering wheel and not into the clockspring, before attempting to remove the wheel. Failure to do so may damage the steering wheel/clockspring.
6. Remove the steering column opening cover (3) «(Refer to REMOVAL)»(ref-247640-S18899097732007020100000) .
7. Remove the steering column opening cover reinforcement (2).
8. Remove the tilt lever.
9. Remove the column shrouds (1&2).
10. Remove the clock spring, «(Refer to REMOVAL)»(ref-247645-S18454785422007020100000) .
11. Disconnect the wiring harness to the column (1.2&3). 1 - Shift lever 2 - Cable Connection 3 - Overdrive Electrical Wiring 4 - Mounting Screws
12. Remove the shift cable (2) from the column shift lever actuator (1).
13. Release the shift cable from the column bracket and remove it from the bracket.
14. Remove the SKIM module in order to disconnect the electrical connector.
15. Remove the upper steering shaft coupler bolt (2) from the column (1).
16. Separate the shaft from the coupler (7).
17. Remove the brake light switch and discard «(Refer to REMOVAL)»(ref-247634-S35010989392007020100000) .
18. Remove the four steering column mounting nuts (4).
19. Remove the steering column assembly (3) from the vehicle.

INSTALLATION

Scheme 33

Scheme 34

1. Position the steering column (3) on the dash panel support (1) and loosely install the mounting nuts (4).
2. Firmly slide the steering column upward against the studs (2) in dash panel and hand tighten the nuts.
3. Center steering column (3) in dash opening and tighten mounting nuts (4) to 28 N.m (250 in. lbs.). NOTE: Torque the upper left nut first then the lower right nut. Then torque the lower left nut then the upper right nut.
4. Install the steering shaft coupler (7) on the steering shaft (1) and loosely install a new bolt (2). NOTE: A new bolt must be used for reinstallation.
5. Tighten the coupler bolt (2) to 57 N.m (42 ft. lbs.). 1 - Shift lever 2 - Cable Connection 3 - Overdrive Electrical Wiring 4 - Mounting Screws
6. Install a new brake light switch. Refer to «INSTALLATION»(ref-247634-S11857913462007020100000) .
7. Install the shifter cable (2).
8. Connect the wiring harness (1, 2& 3) to the column.
9. Install the SKIM module.
10. Install the clockspring, (refer to «INSTALLATION»(ref-247645-S34689057962007020100000) ).
11. Install the shrouds (1&2).
12. Install the steering column opening cover reinforcement (2) «(Refer to INSTALLATION)»(ref-247640-S07993606832007020100000) .
13. Install the steering column opening cover (3).
14. Align the spline on the wheel hub to shaft.
15. Then install the steering wheel (3) and install a new bolt (4). Tighten the bolt to 61 N.m (45 ft. lbs.).
16. Reconnect the electrical connectors (2) for the air bag (3).
17. Install the airbag (3) «(Refer to INSTALLATION)»(ref-247645-S09956156402007020100000) .
18. Install the tilt lever handle (5).
19. Install the negative battery terminal.
20. Test the operation of the horn, Electronic PRNDL Indicator, lights and any other functions that are steering column operated.

The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before installing ignition switch.

Scheme 35

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Scheme 38

1. Before installing ignition switch, rotate the slot in the switch to the ON position. 1 - Ignition Switch 2 - Ignition Switch Mounting Screws
2. Connect the electrical connector to rear of the ignition switch. Make sure that locking tabs are fully seated into wiring connector.
3. Position switch (1) to column and install the mounting screw (2). Tighten screw to 3 N.m (26 in. lbs.). 1 - IGNITION SWITCH 2 - TILT LEVER MECHANISM
4. Install the tilt lever bracket (2) mounting screws. Tighten screws to 4.5 N.m (40 in. lbs.). 1 - Ignition Switch Mounting Screws 2 - Non-Tilt Mounting Bracket Screws
5. If the column is non-tilt install the bracket (2). Tighten screws to 4.5 N.m (40 in. lbs.). (Scheme 38) 1 - KEY CYLINDER 2 - GEAR SHIFT LEVER 3 - MOUNTING HOLES 4 - STEERING COLUMN 5 - IGNITION SWITCH
6. Position the wire retainer into the tilt lever bracket.
7. Reconnect the lower clockspring connectors.
8. Install the key cylinder (1)
9. Install steering column upper and lower shrouds.
10. Enable the airbag system. «(Refer to INSTALLATION)»(ref-247645-S09956156402007020100000).

Note. Do not reuse the old steering wheel bolt (4) (a new bolt must be used)

Note. Make sure to align the spline on the steering wheel hub to the column shaft.

1. Install steering wheel (3) to the column (6). NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation.
2. Install the new steering wheel bolt (4). Tighten the bolt to 61 N.m (45 ft. lbs.).
3. Install the driver's side air bag (3) to the steering wheel. «(Refer to INSTALLATION)»(ref-247645-S09956156402007020100000) .

Scheme 39

1. Disconnect the negative battery cable.
2. Lock the steering wheel with the tire in the straight position.
3. Remove and discard the upper pinch bolt (2) from the upper coupling at the column (1).
4. Lower the steering coupler shaft (3) from the column (1).
5. Remove the toe plate (6) nuts (5).
6. Remove and discard the lower coupler pinch bolt (4) from the lower steering coupling shaft (3).
7. Remove the steering coupling shaft (3) from the vehicle.

1. Install the upper steering coupling shaft (3) to the vehicle. NOTE: Note: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used.
2. Install the upper coupling (7) to the column (1).
3. Install the upper pinch bolt (2) use a new bolt and tighten to 38 N.m (28 ft. lbs).
4. Install the toe plate (5) nuts (6) and tighten to 12 N.m (105 in. lbs).
5. Install the shaft (1) to the lower coupling (2).
6. Install the lower pinch bolt (4) use new bolt and tighten to 38 N.m (28 ft. lbs).
7. Unlock the steering wheel.
8. Reconnect the negative battery cable.

Scheme 40

1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Lock the steering wheel with the tire in the straight position.
4. Remove and discard the lower coupling (2) upper pinch bolt (4).
5. Remove and discard the lower coupling (2) pinch bolt (1).
6. Remove the lower steering shaft coupling (2) from the steering gear (3).

1. Install the coupling (2) to the steering gear (3).
2. Install the lower pinch bolt (1) and tighten to 38 N.m (28 ft. lbs.).
3. Install the other end of the coupling (2) to the steering shaft (1). NOTE: New pinch bolts must be used for reinstallation.
4. Install the upper pinch bolt (4) and tighten to 38 N.m (28 ft. lbs.).
5. Lower the vehicle.
6. Reconnect the negative battery cable.
7. Unlock the steering wheel.

Scheme 41

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Scheme 43

1. Remove the tilt lever handle.
2. Remove the steering column opening cover «(Refer to REMOVAL)»(ref-247640-S18899097732007020100000).
3. Remove the lower shroud. NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. 1 - TILT LEVER RELEASE KNOB BRACKET 2 - ELECTRICAL HARNESS TAB 3 - MOUNTING SCREWS (2)
4. Remove the two mounting screws (3) from the tilt lever knob release bracket (1). (Scheme 41)
5. Disconnect the electrical harness plastic mounting tab (2) from the bracket (1). (Scheme 41) 1 - TILT LEVER RELEASE KNOB BRACKET 2 - TILT LEVER CABLE REMOVAL/INSTALL
6. Unsnap the cable (2) from the bracket (1). (Scheme 42) 1 - TILT LEVER RELEASE KNOB BRACKET 2 - END OF CABLE REMOVAL/INSTALL
7. Remove the end of the cable (2) from the tilt lever knob release bracket (1). (Scheme 43)

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Scheme 46

1. Route the cable (2) into the tilt lever release knob bracket (1). (Scheme 43) 1 - TILT LEVER RELEASE KNOB BRACKET 2 - TILT LEVER CABLE REMOVAL/INSTALL
2. Snap the cable end (2) into the bracket (1). (Scheme 42) 1 - TILT LEVER RELEASE KNOB BRACKET 2 - ELECTRICAL HARNESS TAB 3 - MOUNTING SCREWS (2) NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. NOTE: New screws should be used when installing the tilt lever release knob bracket to the column.
3. Install the tilt lever release knob bracket (1) to the column and install the two new mounting screws (3) Tighten the two new screws to 4.5 N.m (40 in. lbs.). (Scheme 41)
4. Install the electrical harness plastic mounting tab (2) to the bracket (1). (Scheme 41)
5. Install the lower shroud.
6. Install the steering column opening cover «(Refer to INSTALLATION)»(ref-247640-S07993606832007020100000).
7. Install the tilt lever handle.

Scheme 47

A rack and pinion steering gears is made up of two main components, the pinon shaft and the rack. Other components are the outer tie rod ends (3&5), inner tie rod ends (1&2), Mounting Bushings and the boots (4). The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. The only serviceable component on the steering gear is the outer tie rod ends (3&5).

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

Scheme 48

1. Install gear (6) to the vehicle and tighten mounting nuts (5) and bolts (2) to 258 N.m (190 ft. lbs.).
2. Install power steering lines (2&3) to steering gear (4) and tighten the pressure hose to 31 N.m (23 ft. lbs.) and tighten the return hose to 37 N.m (27 ft. lbs.). «(Refer to INSTALLATION)»(ref-247608-S12462964042007020100000) .
3. Slide the shaft coupler (1) onto gear (4). Install new bolt (1) and tighten to 49 N.m (36 ft. lbs.).
4. Clean tie rod end studs and knuckle tapers (5).
5. Install tie rod ends (2) into the steering knuckles (5) and tighten the nuts (1) to 75 N.m (55 ft. lbs.). «(Refer to INSTALLATION)»(ref-247608-S38464749412007020100000) .
6. Install the front tires.
7. Remove the support and lower the vehicle.
8. Unlock the steering wheel.
9. Fill system with fluid, «(Refer to STANDARD PROCEDURE)»(ref-247608-S27956298952007020100000) .
10. Adjust the toe position. «(Refer to STANDARD PROCEDURE)»(ref-247604-S32795312152007020100000) .

REMOVAL - OUTER TIE ROD END

Note. Do not twist the boot anytime during removal or installation.

1. Loosen the jam nut (3).
2. Remove the outer tie rod end (2) nut (1) from the ball stud.
3. Separate the outer tie rod end (2) from the knuckle with Remover C3894-A (1).
4. Unthread the outer tie rod end (2) from the inner tie rod (3). Count the number of turns when removing the tie rod end, This will give a good starting point when reassembling and toe adjustment.

INSTALLATION - OUTER TIE ROD END

Note. Do not twist the boot at anytime during removal or installation.

1. Thread the outer tie rod end (2) onto the inner tie rod (4), to it's original position.
2. Install the outer tie rod end into the steering knuckle (5).
3. Tighten the ball stud nut (1) on the ball stud to 75 N.m (55 ft. lbs.).
4. Set wheel toe pattern, «(Refer to STANDARD PROCEDURE)»(ref-247604-S32795312152007020100000) .
5. Tighten jam nut (3) to 75 N.m (55 ft. lbs.).

1. Align the pump (4) with the mounting holes on the engine.
2. Install 3 pump mounting bolts through the pulley access holes (1). Tighten the bolts to 28 N.m (21 ft. lbs.).
3. Install the pressure hose (2) to the pump (4). Tighten the pressure hose to 31 N.m (23 ft. lbs.).
4. Install reservoir return hose (3) to the reservoir (1).
5. Install the serpentine drive belt, «(Refer to INSTALLATION)»(ref-247624-S16163766032007020100000) .
6. Fill the power steering pump, «(Refer to STANDARD PROCEDURE)»(ref-247608-S27956298952007020100000) .

1. Install the cooler (2) to the vehicle.
2. Install the cooler mounting nut (1).
3. Reconnect the hoses (1) at the cooler (3).
4. Reconnect the hose clamps (2).
5. Remove the support and lower the vehicle.
6. Refill the power steering system, «(Refer to STANDARD PROCEDURE)»(ref-247608-S27956298952007020100000) .

Scheme 49

1. Siphon the power steering system.
2. Raise and support the vehicle.
3. Disconnect the return hose (6) at the gear (7).
4. Disconnect the return hose (6) at the cooler (1).
5. Remove the return hose from the vehicle.

1. Remove the power steering pump «(Refer to STEERING/PUMP - REMOVAL)»(ref-247608-S33728394522007020100000) .
2. With the pump on the bench drain the rest of the fluid out into a container.
3. Remove the two bolts and separate the reservoir from the pump body.

1. Install a new o-ring on the port of the reservoir.
2. Install the reservoir on the pump body.
3. Install the two bolts securing the reservoir to the body and tighten.
4. Install the power steering pump «(Refer to INSTALLATION)»(ref-247608-S03312465172007020100000) .

Scheme 50

1. Remove the power steering pump assembly, «(Refer to REMOVAL)»(ref-247608-S33728394522007020100000) .
2. Remove the pulley (2) from the pump (1) using (OTC(R) 7185) power steering pulley removal tool (3) or equivalent.

Scheme 51

1. Replace the pulley if it's bent, cracked, or loose.
2. Install the pulley (2) on the pump (1) using (OTC(R) 7771) power steering pulley installation tool (3) or equivalent making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft.
3. Install the power steering pump assembly, «(Refer to INSTALLATION)»(ref-247608-S03312465172007020100000) .
4. Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts.