Chrysler Pacifica. Manual — part 746
INSTALLATION
(1) Install remote audio control switches on steer-
ing wheel. (Refer to 8 - ELECTRICAL/AUDIO/RE-
MOTE SWITCHES - INSTALLATION)
(2) Install
speed
control
switches
on
steering
wheel. (Refer to 8 - ELECTRICAL/SPEED CON-
TROL/SWITCH - INSTALLATION)
(3) Match splines on steering wheel hub with that
on steering shaft and slide steering wheel onto col-
umn shaft.
(4) Install damper on steering wheel (Fig. 16).
(5) Install steering wheel retaining bolt (Fig. 16).
Tighten bolt to 61 N·m (45 ft. lbs.) torque.
(6) Connect speed control wiring connector at
clockspring (Fig. 15).
(7) Connect two airbag squib connectors and horn
connector to driver airbag (Fig. 14).
(8) Place driver airbag on steering wheel and
install mounting screws (Fig. 14). Tighten screws to
10 N·m (90 in. lbs.) torque.
(9) Connect battery negative (-) cable to battery
post following special Diagnosis And Testing proce-
dure. (Refer to 8 - ELECTRICAL/RESTRAINTS -
DIAGNOSIS AND TESTING)
(10) Check operation of horn, speed control and
remote audio controls.
Fig. 16 Steering Wheel Mounting To Column
1 - STEERING COLUMN
2 - WIRING CONNECTOR
3 - STEERING WHEEL
4 - DAMPER
5 - RETAINING BOLT
6 - WIRING CONNECTOR
7 - AIRBAG SQUIB CONNECTORS
CS
COLUMN
19 - 19
STEERING WHEEL (Continued)
GEAR
TABLE OF CONTENTS
page
page
GEAR
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GEAR
WARNINGS AND CAUTIONS
WARNING:
POWER
STEERING
FLUID,
ENGINE
PARTS
AND
EXHAUST
SYSTEM
MAY
BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: 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 for-
eign material into the components.
CAUTION: When servicing power steering compo-
nents, do not pinch off power steering hoses in an
any way to stop fluid flow. Damage to hoses may
result.
REMOVAL
(1) Place front wheels of vehicle in STRAIGHT-
AHEAD position.
(2) Install steering wheel holder locking steering
wheel in STRAIGHT-AHEAD position (Fig. 1).
(3) Remove negative (-) battery cable from battery
and isolate cable.
(4) Remove cap from power steering fluid reser-
voir.
(5) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(6) Raise and support vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(7) Remove both front tire and wheel assemblies.
(8) If outer tie rods need to be transferred to new
gear, loosen tie rod jam nuts on both sides of vehicle.
(9) On both sides of vehicle, remove nut attaching
outer tie rod to steering knuckle by holding rod end
stud stationary while loosening and removing nut
with a wrench.
(10) Remove each outer tie rod end from steering
knuckle using Remover, Special Tool C-3894-A (Fig.
2).
(11) Remove roll pin fastening intermediate shaft
extension to power steering gear shaft as follows
(Fig. 3):
(a) Insert Remover, Special Tool 6831A, through
roll pin fastening intermediate shaft extension to
power steering gear.
(b) Thread knurled nut all way onto end of
Remover.
(c) While holding Remove head stationary, turn
hex nut pulling roll pin from shafts.
(d) Remove roll pin from tool.
(12) Slide intermediate shaft extension off steering
gear shaft.
(13) Remove tube nut fastening return hose to
power steering gear (Fig. 4). Remove return hose
from gear port.
Fig. 1 Steering Wheel Holder
19 - 20
GEAR
CS
(14) Remove tube nut fastening pressure hose to
power steering gear (Fig. 4). Remove pressure hose
from gear port.
(15) Remove two power steering gear mounting
bolts.
(16) Carefully remove power steering gear. Tip
gear forward at top (Fig. 5), then slide gear out left
wheel opening. Use care not to cut tie rod boots
on shields as gear is removed.
(17) If necessary, remove outer tie rods from inner
tie rod threads. Count how many rotations it takes to
remove each outer tie rod for installation reference.
Fig. 2 Using C-3894-A To Release Tie Rod
1 - PULLER C-3894-A
2 - OUTER TIE ROD
3 - STEERING KNUCKLE
4 - TIE ROD STUD
Fig. 3 Roll Pin Removal
1 - REMOVER 6831A
2 - KNURLED NUT
3 - STEERING GEAR SHAFT
4 - INTERMEDIATE SHAFT EXTENSION
Fig. 4 Hoses At Steering Gear
1 - POWER STEERING GEAR
2 - RETURN HOSE
3 - PRESSURE HOSE
4 - TUBE NUTS
Fig. 5 Gear Tipped Forward For Removal/Installation
CS
GEAR
19 - 21
GEAR (Continued)
INSTALLATION
(1) If necessary, install outer tie rods onto inner tie
rod threads. As outer tie rods are installed, count out
same amount of rotations as were counted on tie rod
removal. This will get toe setting somewhat close to
specifications before vehicle is aligned at end of this
procedure.
(2) Carefully install power steering gear through
left wheel opening using the reverse of how it was
removed. Use care not to cut tie rod boots on
shields as gear is installed.
NOTE: When installing steering gear mounting
bolts, note driver’s side mounting bolt is longer
than passenger’s side bolt.
(3) Center gear mounting bosses over mounting
holes in cradle and install two power steering gear
mounting bolts. Tighten mounting bolts to 163 N·m
(120 ft. lbs.) torque.
NOTE: Before installing power steering hoses on
power steering gear, wipe clean connections with a
lint-free
cloth
and
replace
O-rings.
Lubricate
O-rings using clean power steering fluid.
(4) Install pressure hose into gear port (Fig. 4).
Thread pressure hose tube nut into gear and tighten
to 31 N·m (275 in. lbs.) torque.
(5) Install return hose into gear port (Fig. 4).
Thread return hose tube nut into gear and tighten to
31 N·m (275 in. lbs.) torque.
(6) Find power steering gear’s center of travel,
then match splines inside intermediate shaft exten-
sion with that on steering gear shaft. Slide extension
onto shaft (Fig. 9).
(7) Install roll pin fastening intermediate shaft
extension to power steering gear shaft as follows
(Fig. 6):
(a) Insert Installer, Special Tool 6831A, exten-
sion and steering gear shaft.
(b) Slide roll pin onto Remover shaft.
(c) Thread knurled nut all way onto end of
Installer.
(d) While holding Installer head stationary, turn
hex nut pulling roll pin into shafts. Stop installing
roll pin once it is centered intermediate shaft
extension.
(e) Remove tool.
(8) Slide shaft cover down over top of steering
gear.
(9) Install outer tie rods to steering knuckles.
Start NEW nut onto stud of each outer tie rod. While
holding stud stationary using a socket, tighten nut.
Using a crowfoot wrench on a torque wrench, tighten
nut to 47 N·m (35 ft. lbs.) torque. Then, tighten nut
an additional 1/2 (180°) turn after that torque is met.
(10) Snug tie rod jam nuts on both sides of vehicle.
Do not torque at this time. Tighten tie rod jam
nuts to 75 N·m (55 ft. lbs.) torque while per-
forming wheel alignment at end of this proce-
dure.
(11) Install tire and wheel assemblies (Refer to 22
- TIRES/WHEELS - INSTALLATION). Tighten wheel
mounting nuts to 135 N·m (100 ft. lbs.) torque.
(12) Lower vehicle.
(13) Connect negative (-) battery cable on negative
battery post.
(14) Remove steering wheel holder.
(15) Fill and bleed power steering system using
Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)
(16) Inspect for leaks.
(17) Perform wheel alignment setting toe to speci-
fications.
(Refer
to
2
-
SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE)
Fig. 6 Roll Pin Installation
1 - INSTALLER 6831A
2 - KNURLED NUT
3 - ROLL PIN
4 - STEERING GEAR SHAFT
5 - INTERMEDIATE SHAFT EXTENSION
19 - 22
GEAR
CS
GEAR (Continued)
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