Dodge Sprinter. Manual — part 256
torque to 45 N·m (33 ft. lbs.) and a final additional
90° turn for final torque.
(3) Install the universal joint to the steering gear
(Fig. 2). Tighten to 24 N·m (18 ft. lbs.).
(4) Install both the power steering hoses to the
steering gear (Fig. 2). Tighten the high pressure hose
to 37 N·m (27 ft. lbs.).
(5) Install the spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).
(6) Install the left outer tie rod end to the steering
gear.
(7) Install both the outer tie rod ends to the steer-
ing knuckle (Fig. 2). Tighten to 130 N·m (96 ft. lbs.).
(8) Install the upper stabilizer bar link to the sta-
bilizer bar.
(9) Install the front wheels.
(10) Fill and bleed the power steering system
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE).
(11) Reset toe adjustment.
(12) Check steering system for leaks.
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
U-Joint To Steering Gear
24
18
212
High Pressure Hose To
Steering Gear
37
27
328
Return Line To Steering
Gear
37
27
328
Steering Gear To Frame
Initial Torque
25
18
221
Steering Gear To Frame
Second Torque
Then additional 90° turn
45
33
398
19 - 8
GEAR
VA
LINKAGE
TABLE OF CONTENTS
page
page
LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . 10
TIE ROD END
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 10
LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD
END
NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.
(2) Remove the front tires.
(3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.
(4) Position indicator plunger on the topside of the
outer tie rod end.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the outer tie rod
end.
(5) Position a pry bar in order to pry downwards
on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Outer Tie Rod End Nut
130
96
—
Outer Tie Rod End Lock-
ing Nut
50
37
—
Steering Gear Boot
Clamp
7
—
62
VA
LINKAGE
19 - 9
SPECIAL TOOLS
FRONT SUSPENSION
TIE ROD END
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Loosen the lock nut (Fig. 1).
(4) Remove the tie rod end retaining nut (Fig. 1).
(5) Separate the tie rod end from the steering
knuckle (Fig. 1) using special tool C-3894–A.
(6) Remove the outer tie rod end from the inner tie
rod end by unscrewing (Fig. 1).
INSTALLATION
(1) Install the outer tie rod end by screwing it onto
thew inner tie rod end (Fig. 1).
(2) Install the outer tie rod end into the steering
knuckle (Fig. 1).
(3) Tighten the outer tie rod end nut
(Fig. 1).
Tighten to 130 N·m (96 ft. lbs.).
(4) Install the front wheels.
(5) Lower the vehicle.
(6) Perform toe adjustment.
(7) Tighten the lock nut after toe adjustment (Fig.
1). Tighten to 50 N·m (37 ft. lbs.).
Puller Tie Rod C-3894-A
Fig. 1 OUTER TIE ROD END
1 - OUTER TIE ROD END RETAINING NUT
2 - TIE ROD SEPERATOR TOOL
3 - OUTER TIE ROD END
4 - LOCKING NUT
5 - INNER TIE ROD END
19 - 10
LINKAGE
VA
PUMP
TABLE OF CONTENTS
page
page
PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - PUMP LEAKAGE
STEERING PUMP - INITIAL OPERATION . . . . 11
POWER STEERING SYSTEM . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . 12
FLUID
POWER STEERING PUMP FILL AND BLEED
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 13
FLUID COOLER TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 13
HOSES
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE . . . . . . . . . . . . . . . 14
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE . . . . . . . . . . . . . . . 14
PUMP
DESCRIPTION
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.
DIAGNOSIS AND TESTING - 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:
• Pump shaft seal behind the pulley
• Pump to reservoir O-ring
• Reservoir cap
• Pressure and return lines
• Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING:
THE
FLUID
LEVEL
SHOULD
BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicate COLD when the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
VA
PUMP
19 - 11
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