Steering System: Other RAM Cab & Chassis 3500 HD

POWER STEERING FLOW AND PRESSURE

The following procedure is used to test the operation of the power steering system on the vehicle. This test will provide the gallons per minute (GPM) or flow rate of the power steering pump along with the maximum relief pressure. Perform test any time a power steering system problem is present. This test will determine if the power steering pump or power steering gear is not functioning properly. The following pressure and flow test is performed using Power Steering Kit (special tool #6815, Kit, Power Steering) and Power Steering Kit (special tool #6893A, Kit, Power Steering).

Scheme 56

1. Connect Hose Assembly (special tool #6959, Assembly, Hose) (1) to the valve side of Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3), and connect Adapter (special tool #6826, Adapter, LH P/S Tester) (2) to the hose assembly.
2. Connect Power Steering Hose (special tool #6713, Hose, Power Steering) (6) to the gauge side of Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3), and connect P/S Adapter (special tool #6825A, Adapter, Power Steering) or (special tool #6865, Adapter, Power Steering (Jeep)) (as necessary for clearance) to the hose assembly.
3. disconnect the P/S pump pressure line at the P/S pump.
4. Connect the hose from the valve side of the Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3) to the pressure line at the P/S pump.
5. Connect the hose from the gauge side of the Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3) to the P/S pump.
6. Proceed with the Flow and Pressure Test. Refer to «TEST PROCEDURE»(ref-476492-S03240266142012060400000) .

DIESEL ENGINE TOOL CONNECTIONS

1. Connect Hose Assembly (special tool #6959, Assembly, Hose) (1) to the valve side of Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3), and connect Adapter (special tool #8185-2, Adapter, Power Steering Tester) (2) to the hose assembly.
2. Connect Power Steering Hose (special tool #6713, Hose, Power Steering) (6) to the gauge side of Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3), and connect P/S Adapter (special tool #8630-1, Adapter Power Steering) (5) to the hose assembly.
3. Disconnect the P/S pump pressure line at the hydro-boost connection.
4. Connect the hose from the valve side of the Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3) to the hydro-boost line.
5. Connect the hose from the gauge side of the Power Steering Analyzer (special tool #6800, Analyzer, Power Steering) (3) to the P/S pump pressure line at the hydro-boost connection.
6. Proceed with the Flow and Pressure Test. Refer to «TEST PROCEDURE»(ref-476492-S03240266142012060400000) .

LEVER ONLY

1. Disconnect the negative battery cable.
2. Remove the upper and lower column shrouds. Refer to «SHROUD, STEERING COLUMN, REMOVAL»(ref-476492-S05235613012012060400000) .
3. Disconnect the gearshift harness connector (5).
4. Disconnect the gearshift harness retainers (6).
5. Remove the gearshift lever pinch bolt (7) from the gearshift lever assembly (2).
6. Remove the gearshift lever (1) from the gearshift lever assembly (2).

1. Install the gearshift lever (1) in the gearshift lever assembly (2).
2. Install the gearshift lever pinch bolt (7) and tighten to 12 N.m (105 in. lbs.).
3. Connect the gearshift harness retainers (6).
4. Connect the gearshift harness connector (5).
5. Install the upper and lower column shrouds, steering column opening cover, and reinforcement. Refer to «SHROUD, STEERING COLUMN, INSTALLATION»(ref-476492-S35053097302012060400000) .
6. Connect the negative battery cable.

Scheme 57

1. From below the steering column, remove the two outboard screws within the recess areas (2) that secure the upper shroud (1) to the lower shroud (4). NOTE: There are snap connections near the instrument cluster and between the shroud and the steering wheel that secure the upper and lower shroud.
2. Remove the upper shroud (1) by pushing gently inward and upward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other.

Scheme 58

1. From below the steering column, remove the two outboard screws within the recess areas (2) that secure the upper shroud (1) to the lower shroud (4). NOTE: There are snap connections near the instrument cluster and between the shroud and the steering wheel that secure the upper and lower shroud.
2. Remove the upper shroud (1) by pushing gently inward and upward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other.
3. Remove the steering column opening cover from the instrument panel. Refer to «COVER, STEERING COLUMN OPENING, REMOVAL»(ref-476497-S24155983532012060400000) .
4. Remove the lower shroud to column retaining screw (2) and carefully move the lower shroud over the steering column tilt lever and off the steering column.

UPPER

Note. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever boot into the opening in both shroud halves.

1. Position the upper shroud (1) onto the steering column over the lower shroud (4).
2. Align the snaps features on the upper and lower shroud halves and apply hand pressure to snap together.
3. From below the steering column, install the two outboard screws within the recess areas (2) that secure the upper shroud (1) to the lower shroud (4).

LOWER

1. Position the lower shroud (4) over the steering column tilt lever and align on the steering column. NOTE: If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever boot into the opening in both shroud halves.
2. Position the upper shroud (1) onto the steering column over the lower shroud (4).
3. Align the snap features on the upper and lower shroud halves (1, 4) and apply hand pressure to snap together.
4. From below the steering column, install the two outboard screws within the recess areas (2) that secure the upper shroud (1) to the lower shroud (4).
5. Install the lower shroud to column retaining screw (3).
6. Install the steering column opening cover. Refer to «COVER, STEERING COLUMN OPENING, INSTALLATION»(ref-476497-S13936471872012060400000) .

Scheme 59

1. Disable and remove the driver's side airbag. Refer to «AIR BAG, DRIVER, REMOVAL»(ref-476529-S33304881012012060400000) .
2. Remove the steering wheel bolt and discard. NOTE: The jaws should point outward from the center of the steering wheel for removal.
3. Install Gear Puller (special tool #L-4407A, Puller, Gear) (1) and OTC® 7929A jaws (3) or equivalent and loosen the steering wheel (2).
4. Remove the tools (1, 3) and then remove the steering wheel (2).

OUTER TIE ROD END

Note. All views are typical.

Scheme 60

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

1. Thread the outer tie rod end (3) onto the inner tie rod (2), to it's original position. NOTE: If a new tie rod end is to be installed, make sure the boot (2) is properly lubricated.
2. Clean all old grease and debris from the boot (2) with a clean cloth.
3. Apply outer tie rod grease P/N 68088623AA (1) to the tie rod end boot (2).
4. Install the outer tie rod end (3) into the steering knuckle.
5. Tighten the ball stud nut on the ball stud to 61 N.m (45 ft. lbs.) then an additional 90°.
6. Set wheel toe pattern. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) .
7. Tighten jam nut (1) to 127 N.m (94 ft. lbs.).

Scheme 61

1. Thread the inner tie rod (1) to the rack and pinion (2).
2. Tighten the inner tie rod end using Inner Tie Rod Wrench (special tool #10087-3, Wrench, Inner Tie Rod) (2) and Inner Tie Rod Adapter Wrench (special tool #10087-2A, Adapter Wrench, Inner Tie Rod) (1) to 169 N.m (125 ft.lbs.).
3. Install the inner tie rod end boot (2) and reclamp (1, 3) to the tie rod (4) and rack.
4. Install the jam nut (1) to the inner tie rod end (2).
5. Install the outer tie rod (3) the same number of turns when removed. Refer to «END, TIE ROD, INSTALLATION»(ref-476492-S41584081052012060400000) .
6. Install the front wheels.
7. Lower the vehicle.
8. Perform toe adjustment. Refer to «TOE ADJUSTMENT - RACK AND PINION STEERING SYSTEM»(ref-476491-S39524231722012060400000) .
9. Tighten the jam nut (1) after toe adjustment. Tighten to 50 N.m (37 ft. lbs.).

DAMPER - 2500/3500

Note. All views are typical.

Scheme 62

Scheme 63

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the steering damper mounting nut and bolt (9) at the axle.
3. Remove the steering damper mounting nut (6) at the linkage bracket (3).
4. Remove the steering damper (1).

DAMPER - 4500/5500

Note. All views are typical.

Scheme 64

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the steering damper mounting nut and bolt (4) at the axle.
3. Remove the steering damper mounting nut and bolt (2) at the linkage bracket (5).
4. Remove the steering damper (3).

BRACKET - 2500/3500

Note. All views are typical.

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the steering damper mounting nut (6) at the linkage bracket (3) and position the steering damper (1) off the retaining bolt (7).
3. Remove the four (or two) mounting bracket u-bolt nuts (5) and remove the bracket (3).

BRACKET - 4500/5500

Note. All views are typical.

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the steering damper mounting bolt and nut (2) at the linkage bracket (5) and position the steering damper (3) away from the bracket (5).
3. Remove the mounting bracket bolts and nuts (1) and remove the bracket (5).

Note. All views are typical.

1. Position the steering damper (8) on the axle bracket. Install the bolt and nut (9) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
2. Position the steering damper (1) on the linkage bracket bolt (7), install the nut (6) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
3. Remove the support and lower the vehicle.

Note. All views are typical.

1. Position the steering damper (3) on the axle bracket, install the bolt and nut (4) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
2. Position the steering damper (3) on the linkage bracket (5), install the bolt and nut (2) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
3. Remove the supports and lower the vehicle.

Note. All views are typical.

1. Place the steering damper retaining bolt (7) in the bracket (3) and position the bracket on the flat of the linkage.
2. With the bracket (3) centered on the flat of the linkage, position the u-bolts (2) over the linkage, through the bracket and install the four (or two) u-bolt nuts (5). Do not tighten at this time.
3. Verify the bracket (3) is centered in the flat area of the linkage and tighten the four (or two) u-bolt nuts (5) to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
4. Position the steering damper (1) on the retaining bolt (7).
5. Install the steering damper retaining nut (6) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
6. Remove the support and lower the vehicle.

Note. All views are typical.

1. Position the steering damper bracket (5), install the bolts and nuts (1) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
2. Position the steering damper (3), install the bolt and nut (2) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
3. Remove the support and lower the vehicle.

RH - TO TIE ROD

Note. All views are typical.

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the drag link to tie rod nut (10).
3. Loosen the nut/bolt on the drag link adjuster sleeve (3) as necessary.
4. Remove the drag link (2) from the tie rod (6). (3).
5. Remove the drag link (2) from the adjuster sleeve (3).

TO PITMAN ARM

Note. All views are typical. 2500 shown in illustration, others similar.

Scheme 65

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the drag link to pitman arm nut (5).
3. Loosen the nut/bolt on the tie rod adjuster sleeve (3). 1 - PITMAN ARM 2 - DRAG LINK 3 - C -3894-A PULLER
4. Remove the drag link (2) from the pitman arm (1), with (special tool #C-3894-A, Puller, Tie Rod) (3).
5. Remove the drag link from the adjuster sleeve.

TO KNUCKLE

Note. All views are typical.

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Loosen the nut/bolt (2) on the drag link adjuster sleeve (1) as necessary.
3. Remove the cotter key (1) and the drag link/tie rod to knuckle nut (2). WARNING: Any time the tie rod end has been disconnected from the knuckle, a new boot/seal must be used or damage to the ball stud may result.
4. Remove the tie rod end (3) from the knuckle (1) with (special tool #10390, Separator, Tie Rod) (2).
5. Remove the drag link end (2) from the knuckle (1) with (special tool #C-3894-A, Puller, Tie Rod) (4) and (special tool #10403, Separator, Drag Link) (3).
6. Remove the drag link end (3) from the adjuster sleeve.

Note. All views are typical.

1. Install the drag link end (2) to the adjustment sleeve (3) and to the tie rod (6).
2. Install the drag link to tie rod nut (10) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
3. Remove the supports and lower the vehicle. Center the steering wheel and adjust the toe. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) . NOTE: Position the clamp on the adjustment sleeve so retaining bolt is located on the bottom side of the sleeve.
4. After adjustment, tighten drag link adjustment sleeve clamp bolts to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .

Note. All views are typical. 2500 shown in illustration, others similar.

1. Install the drag link end (4) to the adjustment sleeve (3) and to the pitman arm.
2. Install the drag link to pitman arm nut (5) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
3. Remove the supports and lower the vehicle. Center the steering wheel and adjust the toe. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) . NOTE: Position the clamp on the adjustment sleeve so retaining bolt is located on the bottom side of the sleeve.
4. After adjustment, tighten the tie rod adjustment sleeve clamp bolts to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .

Note. All views are typical.

1. Install the drag link end to the adjustment sleeve (1). WARNING: Any time the tie rod end has been disconnected from the knuckle, a new boot/seal must be used or damage to the ball stud may result.
2. Install the tie rod end (4) with a new boot/seal, and drag link (3) into the knuckle (5).
3. Install the drag link/tie rod to knuckle nut (2) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
4. Install the cotter key (1).
5. Install the wheel. Refer to «WHEELS, STANDARD PROCEDURE»(ref-476494-S34959638912012060400000) .
6. Remove the supports and lower the vehicle. Center the steering wheel and adjust the toe. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) . NOTE: Position the clamp on the adjustment sleeve (1) so retaining bolt is located on the bottom side of the sleeve.
7. After adjustment tighten tie rod adjustment sleeve clamp bolts (2) to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .

RH - DRAG LINK TO TIE ROD

Note. All views are typical.

Scheme 70

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the wheel.
3. Remove tie rod to knuckle nut (1).
4. Remove the drag link to tie rod retaining nut (10).
5. Loosen the nut/bolt on the tie rod adjuster sleeve (7).
6. Remove tie rod (3) from the knuckle (2) and the drag link from the tie rod with (special tool #8677, Remover, Ball Joint) (1).
7. Remove the tie rod end from the adjuster sleeve.

LH - ALL

Note. All views are typical.

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the wheel.
3. Remove tie rod to knuckle nut (1).
4. Loosen the nut/bolt on the tie rod adjuster sleeve (7) as necessary.
5. Remove tie rod (3) from the knuckle (2) with (special tool #8677, Remover, Ball Joint) (1).
6. Remove the tie rod end from the adjuster sleeve.

RH - WITH DRAG LINK TO KNUCKLE

Note. All views are typical.

Scheme 71

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
2. Remove the wheel.
3. Loosen the nut/bolt (1) on the tie rod adjuster sleeve (2) as necessary.
4. Remove the cotter key (1) and the drag link/tie rod to knuckle nut (2). WARNING: Any time the tie rod end has been disconnected from the knuckle, a new boot/seal must be used or damage to the ball stud may result.
5. Remove the tie rod end (3) from the knuckle (1) with (special tool #10390, Separator, Tie Rod) (2). CAUTION: Do not allow the LH tie rod to hang freely from the knuckle. Damage to the tie rod ball stud may result.
6. Remove the steering damper/mounting bracket bolts and nuts (1) and remove the bracket and shock from the tie rod end.
7. Remove the tie rod end from the adjuster sleeve.

Note. All views typical.

1. Install the tie rod (6) into the adjuster sleeve (7) and into the steering knuckle.
2. Install the drag link (2) to the tie rod (6). Install the nut (10) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
3. Install the wheels as necessary. Refer to «WHEELS, STANDARD PROCEDURE»(ref-476494-S34959638912012060400000) .
4. Remove the supports and lower the vehicle. Center the steering wheel and adjust the toe. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) . NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve.
5. After adjustment tighten tie rod adjustment sleeve clamp bolts to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .

Note. All views typical.

1. Install the tie rod (6) into the adjuster sleeve (7) and into the steering knuckle.
2. Install the wheel. Refer to «WHEELS, STANDARD PROCEDURE»(ref-476494-S34959638912012060400000) .
3. Remove the supports and lower the vehicle to the surface. Center the steering wheel and adjust the toe. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) . NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve.
4. After adjustment tighten tie rod adjustment sleeve clamp bolts to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .

Note. All views typical.

1. Install the tie rod into the adjuster sleeve (2). WARNING: Any time the tie rod end has been disconnected from the knuckle, a new boot/seal must be used or damage to the ball stud may result.
2. Install the tie rod (4) with a new boot/seal to the knuckle (5).
3. Install the nut (2) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
4. Install the cotter pin (1).
5. Install the steering damper/mounting bracket, bolts and nuts (1) and tighten to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .
6. Install the wheel. Refer to «WHEELS, STANDARD PROCEDURE»(ref-476494-S34959638912012060400000) .
7. Remove the supports and lower the vehicle to the surface. Center the steering wheel and adjust the toe. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-476491-S01116482942012060400000) . NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve.
8. After adjustment tighten tie rod adjustment sleeve clamp bolts to specifications. Refer to «LINKAGE, LINK AND COIL, SPECIFICATIONS»(ref-476492-S05358199202012060400000) .

PUMP LEAKAGE

The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir o-rings can be replaced.

Check for leaks in the following areas

1. Pump shaft seal behind the pulley
2. Pump to reservoir O-ring
3. Reservoir cap
4. Pressure and return lines
5. Flow control valve fitting

POWER STEERING PUMP AND HOSES

Note. This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering service information. Refer to DIAGNOSIS AND TESTING .

CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS

1. Place gear selector in PARK (or NEUTRAL) with wheels chalked.
2. With the engine idling, have a helper turn the steering wheel.
3. Using an electronic listening tool, determine if noise is coming from the pump.
4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load?
5. Replace the power steering pump if excessive noise is present. Refer to «PUMP, REMOVAL»(ref-476492-S31177418272012060400000) .

CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE

Check hoses and hose tubes as following

1. Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque. Refer to «PUMP, SPECIFICATIONS»(ref-476492-S40873637122012060400000) . Do not bend tubing to adjust. Replace the hose assembly if damaged.
2. Check fastener torque of hose mounting brackets and tube nuts. Refer to «PUMP, SPECIFICATIONS»(ref-476492-S40873637122012060400000) .
3. Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque. Refer to «PUMP, SPECIFICATIONS»(ref-476492-S40873637122012060400000) . Do not bend tubing to adjust. Replace the hose assembly if damaged.

Scheme 72

Note. Be sure the vacuum tool used in the following procedure is clean and free of any fluids.

1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. Refer to «FLUID, STANDARD PROCEDURE»(ref-476492-S40816308822012060400000) .
2. Tightly insert P/S Cap Adapter (special tool #9688A, Cap Adapter, Power Steering Pump) (4) into the mouth of the reservoir (3). CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump.
3. Attach Hand Vacuum Pump (special tool #C-4207-A, Vacuum Pump, Hand) (2), or equivalent, with reservoir (1) attached, to the P/S Cap Adapter (special tool #9688A, Cap Adapter, Power Steering Pump) (4). CAUTION: Do not run the vehicle while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period.
4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes.
5. Slowly release the vacuum and remove the special tools.
6. Adjust the fluid level as necessary. Refer to 1 .
7. Repeat through until the fluid no longer drops when vacuum is applied. Refer to 1 .
8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops.
9. Stop the engine and check for leaks at all connections.
10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary.

Flushing is required when the power steering/hydraulic booster system fluid has become contaminated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steering gear/booster spool valve operation.

Note. The engine should not be run so that all of the fluid is drained from the system. The pump should never be run without fluid.

1. Raise the front end of the vehicle off the ground until the wheels are free to turn.
2. Remove the return line from the pump.
3. Plug the return line port/ports at the pump.
4. Position the return line/lines into a large container to catch the fluid.
5. While an assistant is filling the pump reservoir start the engine.
6. With the engine running at idle turn the wheel back and forth. NOTE: Do not contact or hold the wheel against the steering stops.
7. Run a quart of fluid through the system then stop the engine and install the return line/lines.
8. Fill the system with fluid and perform Steering Pump Initial Operation. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .
9. Start the engine and run it for fifteen minutes then stop the engine.
10. Remove the return line/lines from the pump and plug the pump port/ports.
11. Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again.
12. Install the return line/lines and perform Steering Pump Initial Operation. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

RETURN HOSE - RESERVOIR TO COOLER

1. Drain and siphon the power steering system.
2. Disconnect the return hose at the reservoir.
3. Raise and support the vehicle.
4. Remove the return hose from the routing clamp at the fan shroud.
5. Disconnect the return hose at the cooler.
6. Remove the hose from the vehicle.

Scheme 73

1. Install the return hose to the vehicle.
2. Reconnect the return hose at the cooler.
3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 N.m (37 ft. lbs.) .
4. Reattach the hose to the routing clip at the fan shroud.
5. Remove the support and lower the vehicle.
6. Refill the power steering system. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

Scheme 74

Note. Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail.

1. Install the pressure hose to the vehicle.
2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 N.m (23 ft. lbs.) .
3. Reconnect the pressure hose at the pump. Tighten the hose to 31 N.m (23 ft. lbs.).
4. Remove the support and lower the vehicle.
5. Refill the power steering system. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

1. Install the return hose to the vehicle.
2. Reconnect the return hose at the cooler.
3. Reattach the hose to the routing clip at the fan shroud.
4. Remove the support and lower the vehicle.
5. Reconnect the return hose at the reservoir.
6. Refill the power steering system. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

Scheme 75

1. Drain and siphon the power steering system.
2. Raise and support the vehicle.
3. Disconnect the return hose at the cooler.
4. Disconnect the return hose (2) at the gear. see scheme 119
5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle.

Scheme 76

1. Drain and siphon the power steering system.
2. Raise and support the vehicle.
3. Disconnect the pressure hose at the pump.
4. Disconnect the pressure hose (2) at the gear (4). (Scheme 72)
5. Remove the pressure hose from the vehicle.

1. Drain and siphon the power steering system.
2. Disconnect the return hose at the reservoir.
3. Raise and support the vehicle.
4. Remove the return hose from the routing clamp at the fan shroud.
5. Disconnect the return hose at the cooler.
6. Remove the hose from the vehicle.

Scheme 77

1. Install the return hose to the vehicle.
2. Reconnect the return hose at the cooler.
3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 N.m (38 ft. lbs.) .
4. Reattach the hose to the routing clip at the fan shroud.
5. Remove the support and lower the vehicle.
6. Refill the power steering system. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

Scheme 78

Note. Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail.

1. Install the pressure hose to the vehicle.
2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 N.m (23 ft. lbs.) .
3. Reconnect the pressure hose at the pump. Tighten the hose to 36 N.m (27 ft. lbs.).
4. Remove the support and lower the vehicle.
5. Refill the power steering system. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

1. Install the return hose to the vehicle.
2. Reconnect the return hose at the cooler.
3. Reattach the hose to the routing clip at the fan shroud.
4. Remove the support and lower the vehicle.
5. Reconnect the return hose at the reservoir.
6. Refill the power steering system. Refer to «PUMP, STANDARD PROCEDURE»(ref-476492-S33933653792012060400000) .

Scheme 79

1. Remove the power steering pump assembly (1). Refer to «PUMP, REMOVAL»(ref-476492-S31177418272012060400000).
2. Remove the pulley (2) from the pump using (OTC® 7185) power steering pulley removal tool or equivalent (3). see scheme 123

Scheme 80

1. Replace the pulley (2) if it's bent, cracked, or loose.
2. Install the pulley (2) on the pump (1) using (OTC® 7771) power steering pulley installation tool or equivalent (3) making sure it is flush with the end of the shaft. see scheme 124 Ensure the tool and pulley remain aligned with the pump shaft.
3. Install the power steering pump assembly. Refer to «PUMP, INSTALLATION»(ref-476492-S40503161912012060400000).
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.

Scheme 81

1. Drain and siphon the power steering fluid from the reservoir.
2. Remove the serpentine belt.
3. Remove the power steering pump. Refer to «PUMP, REMOVAL»(ref-476492-S31177418272012060400000) .
4. Remove the reservoir mounting bolts (2).
5. Remove the reservoir (1).
6. Remove the rear bracket to the pump mounting bolts (if equipped).