Dodge Viper SRT-10 (ZB). Manual — part 209

(4) Slide original size toe shims onto mounting

bolts between gear and frame mounts (Fig. 2).
Tighten steering gear mounting bolts to 203 N·m
(150 ft. lbs) torque.

(5) Raise vehicle.
(6) Install outer tie rods onto steering knuckles

(Fig. 3). Install NEW tie rod nuts. Tighten nuts to 75
N·m (55 ft. lbs.) torque.

(7) Install wheels and tires (Refer to 22 - TIRES/

WHEELS - INSTALLATION). Progressively tighten

wheel mounting nuts in proper sequence to 122 N·m
(90 ft. lbs.) torque.

(8) Lower vehicle.
(9) Install power steering pressure hose and return

hose in steering gear fluid ports. Tighten hose tube
nuts to 28 N·m (21 ft. lbs.) torque.

(10) Align intermediate shaft with steering gear

shaft. Slide intermediate shaft coupling onto steering
gear shaft until bolt hole is properly aligned. It may
be necessary to use a soft (brass) drift and hammer
to tap the coupling into place.

(11) Install coupling pinch bolt (Fig. 1). Tighten

pinch bolt to 49 N·m (36 ft. lbs.) torque.

(12) Install air cleaner housing. (Refer to 9 -

ENGINE/AIR

INTAKE

SYSTEM/AIR

CLEANER

HOUSING - INSTALLATION)

(13) Remove steering wheel holder.
(14) Connect battery (-) negative cable to battery

negative post.

CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar

T

Power

Steering Fluid or equivalent.

(15) Fill power steering pump reservoir to correct

fluid level. (Refer to 19 - STEERING/PUMP/FLUID -
STANDARD PROCEDURE)

(16) Perform Power Steering Pump Initial Opera-

tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)

(17) Check for leaks at all hose connections.
(18) Check wheel alignment and adjust toe as nec-

essary. (Refer to 2 - SUSPENSION/WHEEL ALIGN-
MENT - STANDARD PROCEDURE)

TIE ROD - OUTER

REMOVAL

NOTE: Review all Warnings and Cautions. (Refer to
19 - STEERING - WARNING).

(1) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).

(2) Remove front wheel and tire assembly. (Refer

to 22 - TIRES/WHEELS - REMOVAL).

(3) Loosen inner-to-outer tie rod adjuster jam nut

(Fig. 5).

CAUTION: When releasing tie rod from knuckle
using Puller, Special Tool C-4150A, use care not to
pinch and damage tie rod grease seal.

(4) Remove nut from outer tie rod (Fig. 3).

Fig. 3 Knuckle Mounting

1 - UPPER BALL JOINT COTTER PIN
2 - LOWER BALL JOINT COTTER PIN
3 - TIE ROD NUT
4 - LOWER BALL JOINT NUT
5 - KNUCKLE (WITH HUB AND BEARING)
6 - UPPER BALL JOINT NUT

Fig. 4 Puller Positioned To Release Tie Rod

1 - OUTER TIE ROD
2 - PULLER C-4150A
3 - KNUCKLE

19 - 24

GEAR

ZB

GEAR (Continued)

(5) Release outer tie rod from knuckle using

Puller, Special Tool C-4150A (Fig. 4). Remove tool.

(6) Remove outer tie rod by unthreading it from

inner tie rod.

INSTALLATION

NOTE: Before installing outer tie rod end on inner
tie rod, be sure jam nut is on inner tie rod (Fig. 5).

(1) Thread outer tie rod onto inner tie rod. Snug

inner-to-outer tie rod adjuster jam nut (Fig. 5). Do
not torque jam nut until wheel alignment toe has
been set.

(2) Install outer tie rod onto steering knuckle (Fig.

3). Install NEW tie rod nut. Tighten nut to 75 N·m
(55 ft. lbs.) torque.

(3) Install wheels and tire assembly (Refer to 22 -

TIRES/WHEELS - INSTALLATION). Progressively
tighten wheel mounting nuts in proper sequence to
122 N·m (90 ft. lbs.) torque.

(4) Lower vehicle.
(5) Check wheel alignment and adjust toe as nec-

essary. (Refer to 2 - SUSPENSION/WHEEL ALIGN-
MENT - STANDARD PROCEDURE)

Fig. 5 Tie Rod Jam Nut (Typical)

1 - INNER TIE ROD
2 - JAM NUT
3 - OUTER TIE ROD

ZB

GEAR

19 - 25

TIE ROD - OUTER (Continued)

PUMP

TABLE OF CONTENTS

page

page

PUMP

STANDARD PROCEDURE - POWER

STEERING PUMP INITIAL OPERATION

. . . . . 26

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

DISASSEMBLY - PUMP PULLEY

. . . . . . . . . . . . 27

ASSEMBLY - PUMP PULLEY

. . . . . . . . . . . . . . 28

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 28

FLUID

STANDARD PROCEDURE

STANDARD PROCEDURE - POWER

STEERING FLUID LEVEL CHECKING . . . . . . 28

STANDARD PROCEDURE - FLUSHING

POWER STEERING SYSTEM . . . . . . . . . . . . 29

FLUID COOLER

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 29

HOSE - PRESSURE - PUMP TO FAN

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 30

HOSE - PRESSURE - FAN TO GEAR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

HOSE - RETURN - FAN TO PUMP

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

HOSE - RETURN - GEAR TO COOLER

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 34

HOSE - RETURN - COOLER TO PUMP

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 35

RESERVOIR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 35

PUMP

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 only Mopar

T

Power Steering Fluid

(MS-5931) or equivalent when filling power steering
system. Do not use automatic transmission fluid.
Do not overfill.

Wipe filler cap clean, then check the fluid level.

The dipstick should indicate FULL COLD when the
fluid is at normal temperature of approximately 21°C
to 27°C (70°F to 80°F).

(1) Raise the vehicle’s front wheels off the ground.
(2) With the engine off, turn the steering wheel to

the left until it reaches its stop.

(3) Slowly fill the power steering reservoir to the

FULL COLD level. Leave the filler cap off the res-
ervoir.

(4) With the engine off, rotate the steering wheel

back and forth, lock-to-lock at least 20 times. All the
while, fluid level should be maintained at the FULL
COLD level.

(5) If not already performed, apply the parking

brake and place the transmission in neutral.

(6) Start the engine. Allow it to idle for a few sec-

onds, then stop the engine. Check and adjust the
fluid level.

(7) Return the front wheels to the center position.
(8) Lower the vehicle to the ground.
(9) Hook a scan tool to the vehicle.
(10) Start the engine.
(11) Using the scan tool, activate the hydraulic

fan. To do so, navigate through Engine Diagnostics,
choosing System Tests, then Hydraulic Fan Solenoid
Test. Activate the fan at 100% (full fan) operation.

(12) Keep the engine running and slowly rotate

the steering wheel in both directions (lock-to-lock)
several times, then stop the test.

(13) Stop the engine. Check and adjust the fluid

level.

(14) If the fluid is extremely foamy, allow the vehi-

cle to stand a few minutes and repeat the above pro-
cedure.

(15) Start the engine.
(16) Using the scan tool, activate the hydraulic fan

at 100% (full fan) operation and briefly raise the
engine speed to 3000 rpm to fully engage the hydrau-
lic fan. Allow the engine speed to return to idle and
deactivate the scan tool.

(17) Keep the engine running and slowly rotate

the steering wheel in both directions (lock-to-lock).
Verify the following conditions:

19 - 26

PUMP

ZB

• Smooth power assist

• Noiseless operation

• Proper fluid level

• No system leaks

• Proper fluid condition
(18) Stop the engine. If all the proper conditions

exist, the procedure is complete.

REMOVAL

NOTE: Review all Warnings and Cautions. (Refer to
19 - STEERING - WARNING).

CAUTION: Cap all open ends of power steering
hoses, power steering pump fittings and steering
gear ports when disconnected. This will prevent the
entry of foreign material into the components dur-
ing servicing.

(1) Disconnect negative (-) cable from battery and

isolate cable.

(2) Remove air cleaner housing. (Refer to 9 -

ENGINE/AIR

INTAKE

SYSTEM/AIR

CLEANER

HOUSING - REMOVAL)

(3) Siphon power steering fluid from fluid reser-

voir.

(4) Remove accessory drive belt from tensioner

pulley and power steering pump drive pulley. (Refer
to

7

-

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS - REMOVAL)

(5) Unthread quick-connect fitting and remove

power steering pressure hose from power steering
pump pressure fitting (Fig. 7). Drain excess power
steering fluid from line.

(6) Disconnect A/C clutch coil wire connector (Fig.

1).

(7) Remove return hose from radiator fan at power

steering pump reservoir (Fig. 7).

(8) Remove return hose from fluid cooler at power

steering pump reservoir (Fig. 7).

(9) Remove three bolts mounting power steering

pump to engine (Fig. 2).

(10) Remove power steering pump.
(11) If required, transfer necessary parts from

removed power steering pump to replacement power
steering pump. (Refer to 19 - STEERING/PUMP -
DISASSEMBLY)

DISASSEMBLY - PUMP PULLEY

CAUTION: Do not reuse the old power steering
pump pulley; it is not intended for reuse. A new pul-
ley must be installed if removed.

(1) Remove power steering pump assembly. (Refer

to 19 - STEERING/PUMP - REMOVAL)

(2) Remove pulley from pump with an appropriate

power steering pulley removal tool (Fig. 3).

Fig. 1 A/C Wiring Connector Below Pump

1 - POWER STEERING PUMP PULLEY
2 - A/C CLUTCH COIL WIRING CONNECTOR
3 - A/C CLUTCH PULLEY

Fig. 2 Belt Driven Components Mounting

1 - BELT TENSIONER
2 - GENERATOR
3 - SPACER
4 - IDLER PULLEY
5 - POWER STEERING PUMP
6 - BELT

ZB

PUMP

19 - 27

PUMP (Continued)