Dodge Durango (DN). Manual — part 25
(5) Remove support and lower vehicle.
(6) Adjust the wheel toe position, Refer to Group 2
Suspension.
RACK & PINION STEERING GEAR - 4x2
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the nuts from the tie rod ends.
(3) Separate tie rod ends from the knuckles with
Puller C-3894-A (Fig. 3).
(4) Remove the power steering lines from the gear.
(5) Remove the lower coupler bolt and slide the
coupler off the gear (Fig. 4).
(6) Remove the mounting bolts from the gear to
the front crossmember and remove the gear (Fig. 5).
INSTALLATION
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
(1) Install gear on front crossmember and tighten
mounting bolts to 258 N·m (190 ft. lbs.).
(2) Slide shaft coupler onto gear. Install new bolt
and tighten to 49 N·m (36 ft. lbs.).
(3) Clean tie rod end studs and knuckle tapers.
(4) Install tie rod ends into the steering knuckles
and tighten the nuts to 108 N·m (80 ft. lbs.).
(5) Install power steering lines to steering gear.
(6) Remove support and lower vehicle.
(7) Fill system with fluid and perform Power
Steering Pump Initial Operation.
(8) Adjust the toe position. Refer to Group 2 Sus-
pension.
RACK & PINION STEERING GEAR - 4x4
REMOVAL
(1) Raise and support the vehicle.
Fig. 3 Tie Rod End Puller
1 – TOOL C-3894-A
2 – BALL STUD
3 – SEAL
4 – TIE-ROD END
5 – LOCKNUT
Fig. 4 Gear Coupler
1 – COUPLER
2 – LOWER SHAFT
3 – TOE PLATE
4 – STEERING COLUMN
5 – UPPER SHAFT
6 – RACK AND PINION STEERING GEAR
Fig. 5 Rack & Pinion Steering Gear - 4x2
1 – RACK AND PINION STEERING GEAR
2 – BUSHING
19 - 12
STEERING
DN
REMOVAL AND INSTALLATION (Continued)
(2) Remove the splash shield from under the front
end to gain access to the gear.
(3) Remove the nuts from the tie rod ends.
(4) Separate tie rod ends from the knuckles with
Puller C-3894-A (Fig. 6).
(5) Remove the power steering lines from the gear.
(6) Remove the lower coupler bolt and slide the
coupler off the gear (Fig. 7).
(7) Remove the mounting bolts (Fig. 8) from the
gear to the front crossmember. Slide the gear to the
right side of the vehicle. Then tilt the left end of the
gear down and remove the gear.
INSTALLATION
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
(1) Install gear on front crossmember and tighten
mounting bolts to 230 N·m (170 ft. lbs.).
(2) Slide shaft coupler onto gear. Install new bolt
and tighten to 49 N·m (36 ft. lbs.).
(3) Clean tie rod end studs and knuckle tapers.
(4) Install tie rod ends into the steering knuckles
and tighten the nuts to 88 N·m (65 ft. lbs.).
(5) Install power steering lines to steering gear.
(6) Install the splash shield.
(7) Remove support and lower vehicle.
(8) Fill system with fluid and perform Power
Steering Pump Initial Operation.
(9) Adjust the toe position. Refer to Group 2 Sus-
pension.
Fig. 6 Tie Rod End Puller
1 – TOOL C-3894–A
2 – BALL STUD
3 – SEAL
4 – TIE-ROD END
5 – LOCK NUT
Fig. 7 Gear Coupler
1 – COUPLER
2 – LOWER SHAFT
3 – TOE PLATE
4 – STEERING COLUMN
5 – UPPER SHAFT
6 – RACK AND PINION STEERING GEAR
Fig. 8 Rack & Pinion Steering Gear - 4x4
1 – MOUNTING BOLT
2 – RACK AND PINION STEERING GEAR
DN
STEERING
19 - 13
REMOVAL AND INSTALLATION (Continued)
DISASSEMBLY AND ASSEMBLY
BOOT SEAL
REMOVAL
(1) Remove steering gear.
(2) Loosen the jam nut then remove the tie rod
end and jam nut.
(3) Remove the outer clamp from the rubber boot
(Fig. 9).
(4) Remove the boot inner clamp.
(5) On 4x2 vehicles mark the breather tube loca-
tion on steering gear before removing the rubber boot
(Fig. 9).
INSTALLATION
(1) Lubricate the boot outer groove (tie rod) with
silicone type lubricant. Ensure that the boot is not
twisted.
(2) On 4x2 vehicles align the breather tube with
the reference mark on the steering gear.
(3) Position and align the new boot over the hous-
ing.
(4) Install inner clamp on the rubber boot.
(5) Install the snorkel clamp on 4x2 vehicles.
(6) Install outer clamp on the inner tie rod.
(7) Install the jam nut and the tie rod end.
(8) Install steering gear.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
TORQUE
Rack and Pinion Steering Gear
Gear to Frame Bolts . . . . . . 258 N·m (190 ft. lbs.)
Intermediate Shaft Bolt . . . . . 49 N·m (36 ft. lbs.)
Tie Rod End
Knuckle Nut . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Jam Nut . . . . . . . . . . . . . . . . 75 N·m (55 ft. lbs.)
Lines
Pressure Line . . . . . . . . . . . . . 35 N·m (25 ft. lbs.)
Return Line . . . . . . . . . . . . . . 35 N·m (25 ft. lbs.)
SPECIAL TOOLS
RACK & PINION STEERING GEAR
Fig. 9 Boot Seal - 4x2
1 – CIRCLE “A”
2 – MARK BREATHER TUBE LOCATION
3 – BOOT
4 – SNORKEL CLAMP
5 – BOOT CLAMP (OUTER)
6 – JAM NUT
7 – USE LUBE HERE
8 – BOOT CLAMP (INNER)
9 – BOOT SEAL
10 – BREATHER TUBE
11 – BREATHER TUBE
Puller C-3894-A
19 - 14
STEERING
DN
STEERING COLUMN
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 16
GEAR SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION AND OPERATION
STEERING COLUMN
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
SERVICE PRECAUTIONS
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag,
refer to Group 8M and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG
SYSTEM.
THEY
MUST
NEVER
BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft or shift tube. This may cause damage to the
shaft, shift tube or bearing.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column (Fig. 2) and (Fig. 3).
DIAGNOSIS AND TESTING
IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, refer to Group 21 Transmission And Trans-
fer Case for procedure.
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. Refer
Fig. 1 Steering Column
1 – UPPER SHROUD
2 – LOWER SHROUD
3 – PANEL BRACKET
DN
STEERING
19 - 15
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