Steering System: Removal & Installation RAM Pickup 2500

REMOVAL

Note. 1500 series shown in illustration, others similar.

Scheme 28

1. Position the front wheels straight ahead .
2. Disconnect the negative battery cable from the battery.
3. Remove the airbag. Refer to «AIR BAG, Driver , Removal»(ref-457806-S16368975362012030200000) .
4. Partially remove the steering wheel bolt (1) and leave the bolt in the column.
5. Install Steering Wheel Puller (special tool #C-3894-A, Puller, Tie Rod) or equivalent using the top of the bolt to push on, and loosen the steering wheel (2).
6. Remove the tool and steering wheel bolt (1), and discard the steering wheel bolt (1). NOTE: Route the harness through the steering wheel during removal.
7. Remove the steering wheel (2).
8. Remove the clock spring. Refer to «CLOCKSPRING , Removal»(ref-457806-S38289035872012030200000) .
9. Remove the upper and lower column shrouds. Refer to «SHROUD, Steering Column , Removal»(ref-457772-S38136478312012030200000) .
10. Disconnect the wiring harness routing retainers and connectors to the various components of the steering column.
11. If equipped with a floor shift, remove the shift cable from the routing clip (1).
12. If equipped with a column shift, disconnect the shift cable from the shift assembly lever and remove the cable from the bracket.
13. Remove the brake light switch (3).
14. Remove the upper steering shaft coupler bolt (4) and discard. Separate the shaft from the coupler.
15. Remove the forward steering column mounting nuts (5).
16. Support the steering wheel and remove the forward steering column mounting nuts (2).
17. Remove the steering column assembly from the vehicle.
18. Remove and transfer any necessary components.

INSTALLATION

Note. 1500 series shown in illustration, others similar.

1. Position the steering column on the dash panel support and loosely install the mounting nuts (2, 5). NOTE: A new bolt must be used for reinstallation.
2. Install the steering shaft coupler on the steering shaft and loosely install a new bolt (4).
3. Center steering column in dash opening and tighten mounting nuts (2, 5) to 27 N.m (20 ft. lbs.).
4. Tighten the coupler bolt (4) to 38 N.m (28 ft. lbs.).
5. Install the brake light switch (3). Refer to «SWITCH, Stop Lamp , Installation»(ref-457789-S29680731472012030200000) .
6. If equipped with a floor shift, install the shift cable in the routing clip (1).
7. If equipped with a column shift, install the shift cable to the shift assembly lever and the bracket. Adjust the shift cable.
8. Install the clockspring. Refer to «CLOCKSPRING , Installation»(ref-457806-S27945379332012030200000) .
9. Connect the wiring harness routing clips and connectors to the column components.
10. Install the upper and lower shrouds. Refer to «SHROUD, Steering Column , Installation»(ref-457772-S40265822092012030200000) .
11. Align the spline on the steering wheel hub to shaft and install the steering wheel (2). NOTE: A new bolt must be used for reinstallation.
12. Install a new steering wheel bolt (1) and tighten the to 61 N.m (45 ft. lbs.).
13. Install the airbag. Refer to «AIR BAG, Driver , Installation»(ref-457806-S21280811742012030200000) .
14. Connect the negative battery cable to the battery.
15. Test the operation of the horn, Electronic PRNDL Indicator, lights and any other functions that are steering column operated.

Scheme 29

Scheme 30

1. Disconnect the negative battery cable.
2. Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
3. Lock the steering wheel with the wheels in the straight position.
4. Remove the left front tire and wheel assembly. NOTE: Mark both lower coupling (5) connections for proper installation.
5. Remove and discard the lower coupling upper pinch bolt (1).
6. Remove and discard the lower coupling lower pinch bolt (1).
7. Remove the lower steering shaft coupling (2).

1. Install the coupling (2) to the steering rack and pinion, and intermediate shaft using the marks made in the removal process. NOTE: New pinch bolts must be used for reinstallation.
2. Install the lower coupling lower pinch bolt (1) and tighten to 57 N.m (42 ft. lbs.).
3. Install the lower coupling upper pinch bolt (1) and tighten to 38 N.m (28 ft. lbs.).
4. Install the left front tire and wheel assembly. Refer to «Specifications»(ref-457774-S37548064892012030200000) .
5. Remove the support and lower the vehicle.
6. Reconnect the negative battery cable.
7. Unlock the steering wheel.

1. Disconnect the negative battery cable.
2. Lock the steering wheel with the wheels in the straight position.
3. Remove and discard the upper coupling pinch bolt (3).
4. Lower the upper steering coupling shaft (4) from the column.
5. Remove the upper steering coupling shaft seal (2) from the cowl panel.
6. Remove and discard the lower coupling upper pinch bolt (1).
7. Remove the upper steering coupling shaft (3) from the vehicle.

1. Install the upper steering coupling shaft (3) to the vehicle inserting the shaft into the lower coupling. NOTE: New steering coupling shaft pinch bolts for the upper and lower shafts must be used.
2. Install a new lower coupling upper pinch bolt (1) and tighten to 38 N.m (28 ft.lbs).
3. Install the upper steering coupling shaft seal (2) to the cowl panel.
4. Install the steering column shaft into the upper coupling.
5. Install a new upper coupling pinch bolt (3) and tighten to 38 N.m (28 ft.lbs).
6. Unlock the steering wheel.
7. Reconnect the negative battery cable.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. Disconnect the negative battery cable.
2. Remove the steering column upper and lower shrouds. Refer to «SHROUD, Steering Column , Removal»(ref-457772-S38136478312012030200000) .
3. Remove the multi-function switch mounting bracket upper retaining screw (2).
4. Disconnect the clockspring connectors (1).
5. If equipped, disconnect the Steering Angle Sensor (SAS) harness routing retainer (2) and connector (3).
6. If equipped, disconnect the adjustable pedals switch connector (5).
7. Remove the multi-function switch mounting bracket lower retaining screw (4).
8. Carefully pull the multi-function switch mounting bracket (2) toward the steering wheel (1) to gain access to the tilt release lever screws (3).
9. Remove the tilt release lever screws (3). NOTE: The release cam linkage (3) is tabbed to lock into the release cam (1) after installation.
10. Remove the tilt release lever/cam linkage from the steering column by rotating the tilt release lever (4) down (clockwise) to align the linkage tabs with the rectangular hole (2) of the cam (1) and pull out. NOTE: A new tilt release lever (1) includes a pre-loaded spring (3) and the linkage.
11. If the tilt release lever (1) is to be reinstalled on the column, reload the spring (3) against the tab (2) as shown in illustration.

Note. A new tilt release lever (1) includes a pre-loaded spring (3) and the linkage. The spring will have tension and should not be released prior to installation.

Scheme 36

1. If the original tilt release lever (1) is to be reinstalled on the column, carefully reload the spring (3) against the tab (2) as shown in illustration. NOTE: The release lever/cam linkage (3) is tabbed to lock into the release cam (1) after installation.
2. Insert the tilt release lever/cam linkage (3) into the slotted cam hole (2) and rotate the tilt release lever (4) into position.
3. Install the tilt release lever screws (3).
4. From the underside the column, push the pre-loaded spring tip (1) up with a small flat blade screwdriver or suitable tool to release the spring from the tab. The spring should snap against the column in the area shown in illustration (3). Verify the tilt release lever for proper operation before proceeding.
5. Position the multi-function switch mounting bracket and install the lower retaining screw (4).
6. If equipped, connect the adjustable pedals switch connector (5), harness routing retainer (2), and SAS connector (3).
7. Connect the clockspring connectors (1).
8. Install the multi-function switch mounting bracket upper retaining screw (2).
9. Install the steering column shrouds. Refer to «SHROUD, Steering Column , Installation»(ref-457772-S40265822092012030200000) .
10. Connect the negative battery cable.

Scheme 37

1. Disconnect the negative battery cable.
2. Remove the upper and lower column shrouds. Refer to «SHROUD, Steering Column , Removal»(ref-457772-S38136478312012030200000) .
3. Disconnect the gearshift harness connector (5).
4. Disconnect the shift cable (3) from the gearshift lever assembly (2).
5. Remove the gearshift lever assembly mounting screws (4).
6. Remove the gearshift lever assembly.

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

1. Install steering wheel to the column 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. Tighten the bolt to 61 N.m (45 ft. lbs.).
3. Install the driver's side air bag. Refer to «AIR BAG, Driver , Installation»(ref-457806-S21280811742012030200000) .

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.

Scheme 38

Scheme 39

1. Lock the steering wheel.
2. Drain and siphon the power steering fluid from the reservoir.
3. Raise and support the vehicle.
4. Remove and discard the steering coupler pinch bolt.
5. Disconnect the power steering hoses from the rack and pinion (2).
6. Remove the front tires and wheels.
7. Remove the outer tie rod nuts and separate outer tie rods (3) from the knuckles (5) using Ball Joint Remover (special tool #8677, Remover, Ball Joint). Refer to «END, Tie Rod , Removal»(ref-457772-S28246462362012030200000) «END, Tie Rod, Link and Coil , Removal»(ref-457772-S41471723292012030200000) . 1 - FRONT AXLE 2 - STEERING GEAR MOUNTING NUTS AND BUSHINGS NOTE: 4wd model shown in illustration. 2wd model similar.
8. If equipped, remove the skid plate. Refer to «PLATE, Skid, Front , Removal»(ref-457829-S37099224772012030200000) and «PLATE, Skid, Transfer Case , Removal»(ref-457829-S06628527422012030200000) .
9. Remove the rack and pinion mounting bolts (2) and remove the rack from the vehicle.

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

Note. In the frame there are two holes for the mounting of the steering gear, one is slotted and one is round. When tightening the gear to specifications make sure to tighten the mounting bolt with the hole first to avoid movement of the steering gear.

Note. 4wd model shown in illustration. 2wd model similar.

1. Position the rack and pinion to the front crossmember.
2. Install the retaining bolts (2). Tighten the bolts (2) to 319 N.m (235 ft. lbs.).
3. Slide the shaft coupler onto the gear and install a new pinch bolt. Tighten the pinch bolt to 49 N.m (36 ft. lbs.).
4. Clean and dry the tie rod end studs (3) and the tapers in the knuckles (5).
5. Install the tie rod ends into the steering knuckles. Install and tighten the retaining nuts to 61 N.m (45 ft. lbs.), then turn an additional 90°. Refer to «END, Tie Rod , Installation»(ref-457772-S36762826272012030200000) «END, Tie Rod, Link and Coil , Installation»(ref-457772-S09348378192012030200000) .
6. Connect the pressure power steering hose to the steering gear and tighten to 32 N.m (23 ft. lbs.). Refer to «HOSE, Power Steering, Independent Front Suspension , Installation»(ref-457772-S32115279222012030200000) «HOSE, Power Steering, Link and Coil , Installation»(ref-457772-S01574676132012030200000) .
7. Connect the return power steering hose to the steering gear and tighten to 50 N.m (37 ft. lbs.). Refer to «HOSE, Power Steering, Independent Front Suspension , Installation»(ref-457772-S32115279222012030200000) «HOSE, Power Steering, Link and Coil , Installation»(ref-457772-S01574676132012030200000) .
8. If equipped, install the front skid plate. Refer to «PLATE, Skid, Front , Installation»(ref-457829-S14162190652012030200000) and «PLATE, Skid, Transfer Case , Installation»(ref-457829-S13100768802012030200000) .
9. Install the front tires and wheels. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
10. Lower the vehicle.
11. Fill the power steering system with fluid. Refer to «Pump , Standard Procedure»(ref-457772-S36960039432012030200000) .
12. Adjust the toe alignment. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .

1. Remove the steering gear. Refer to «Gear, Independent Front Suspension , Removal»(ref-457772-S20075710442012030200000) «Gear, Link and Coil , Removal»(ref-457772-S35733103372012030200000) . CAUTION: Do not overtighten the vise on the gear case.
2. Mount the steering gear in a soft jawed vise. NOTE: If the bushings are seized a brass punch can be used to remove the bushings from the gear using care not to strike the gear.
3. Remove the front mounting bushings.
4. Remove the rear mounting bushings.
5. Remove the steering gear from the vise and place it on the bench.

Note. Coat all bushings with a thin rubber lubricate oil prior to installation.

Note. A rubber mallet can be used to assist in the installation of the bushings once lubricated.

1. Coat the rear bushings with a thin rubber lubricate oil then install the rear bushings using a rubber mallet to seat the bushings in the gear.
2. Coat the front bushings with a thin rubber lubricate oil then install the front bushings using a rubber mallet to seat the bushings in the gear.
3. Install the steering gear. Refer to «Gear, Independent Front Suspension , Installation»(ref-457772-S12875292612012030200000) «Gear, Link and Coil , Installation»(ref-457772-S26733534862012030200000) .
4. Adjust the toe position (if necessary). Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .

Note. Care is to be taken to assure the steering gear does not travel more than 25 degrees off center, at the output shaft in either direction, prior to setting of the poppet valves. This is critical during the installation of the pitman arm. Failure to do this will result in the improper setting of the poppet valves. If set improperly the gear will not go into relief bypass and there is potential for heat build up and damage to the steering system. Once set, the poppet valves can not be reset.

1. Align reference marks and install pitman arm (3).
2. Install the retaining nut (2) on the pitman shaft and tighten nut to 300 N.m (225 ft. lbs.).
3. Install the drag link (6) to the pitman arm (3). Install the nut (1) and tighten to 54 N.m (40 ft. lbs.). Then an additional 90°.
4. Install the track bar (5) and tighten the bolt (4) to 54 N.m (40 ft. lbs.)
5. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .
6. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 N.m (45 ft. lbs.).

Note. All views are typical.

Scheme 40

1. Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
2. Remove the drag link to pitman arm nut (5) or drag link to tie rod nut (10) as necessary.
3. Loosen the nut/bolt on the tie rod adjuster sleeve (3) as necessary. 1 - PITMAN ARM 2 - DRAG LINK 3 - C -3894-A PULLER
4. Remove the drag link (2) from the pitman arm (1), or from the tie rod with (special tool #C-3894-A, Puller, Tie Rod) (3).
5. Remove the drag link from the adjuster sleeve.

Note. All views are typical.

1. Install the drag link end (2 or 4) to the adjustment sleeve (2) and to the pitman arm or to the tie rod (6) as necessary. Install the drag link to pitman arm nut (5) or drag link to tie rod nut (10) as necessary and tighten to specifications. Refer to «Linkage, Link and Coil , Specifications»(ref-457772-S17078917912012030200000) .
2. Remove the supports and lower the vehicle. Center the steering wheel and adjust the toe. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) . NOTE: Position the clamp on the adjustment sleeve so retaining bolt is located on the bottom side of the sleeve.
3. After adjustment tighten tie rod adjustment sleeve clamp bolts to specifications. Refer to «Linkage, Link and Coil , Specifications»(ref-457772-S17078917912012030200000) .

Note. All views are typical.

Scheme 41

1. Raise and support the vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
2. Remove the wheel(s) as necessary.
3. Remove tie rod to knuckle nut(s) (1) as necessary.
4. For the right tie rod (6), remove the drag link to tie rod retaining nut (9).
5. Loosen the nut/bolt on the tie rod adjuster sleeve (7) as necessary.
6. Remove tie rod (3) from the knuckle (2) with (special tool #8677, Remover, Ball Joint) (1).
7. For the right tie rod, also remove the drag link from the tie rod end with (special tool #8677, Remover, Ball Joint) (1).
8. Remove the tie rod end from the adjuster sleeve.

Note. All views typical.

1. Install the tie rod(s) (6) into the adjuster sleeve and into the steering knuckle(s).
2. For the right side only, 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-457772-S17078917912012030200000) .
3. Install the wheels as necessary. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
4. 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-457771-S15548608852012030200000) .
5. After adjustment tighten tie rod adjustment sleeve clamp bolts to specifications. Refer to «Linkage, Link and Coil , Specifications»(ref-457772-S17078917912012030200000) .

Note. Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve.

1. Position the fluid cooler (1) to the vehicle.
2. Install the mounting bracket bolts (2) securing the fluid cooler (1) to the brace.
3. Install and clamp the return and supply hoses to the power steering fluid cooler lines (3).
4. If equipped, position the lower engine splash shield (2) and install the eight retainers (1).
5. Remove the support and lower the vehicle.
6. Refill the power steering fluid. Refer to «Pump , Standard Procedure»(ref-457772-S36960039432012030200000) .

1. Install the reservoir bracket to the pump housing (if equipped). Do not reuse the o-rings (install new o-rings). Tighten bolts to 7 N.m (62 in. lbs.). NOTE: Ensure the reservoir (1) is fully seated onto the pump (3).
2. Install the reservoir (1) to the bracket/pump body (3).
3. Install the reservoir mounting bolts (2). Tighten bolts to 13 N.m (120 in. lbs.).
4. Install the power steering pump (3). Refer to «Pump , Installation»(ref-457772-S27109949282012030200000) .
5. Install the serpentine drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
6. Fill the power steering pump. Refer to «Pump , Standard Procedure»(ref-457772-S36960039432012030200000) .