Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Neon 1997.1999.2000.2004 Approved Dodge Neon 1997 EPL_19
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PL STEERING 19 - 1
STEERING
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 35
POWER STEERING PUMP . . . . . . . . . . . . . . . . 10 STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION DIAGNOSIS AND TESTING
STEERING SYSTEM AND COMPONENT STEERING SYSTEM DIAGNOSIS CHARTS . . . . 1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION DIAGNOSIS AND TESTING
STEERING SYSTEM AND COMPONENT STEERING SYSTEM DIAGNOSIS CHARTS
DESCRIPTION
This vehicle comes with power steering as stan- STEERING NOISE
dard equipment and is the only steering system There is some noise in all power steering systems.
available. One of the most common is a hissing sound evident
The power steering system consists of these six at standstill parking. Hiss is a very high frequency
major components. Power Steering Pump, Power noise similar to that experienced while slowly closing
Steering Gear, Power Steering Reservoir, Power a water tap. The noise is present in every valve and
Steering Supply and Pressure Hoses, and Power results in high velocity fluid passing valve orifice
Steering Fluid Return Hose. Turning of the steering edges. There is no relationship between this noise
wheel is converted into linear travel through the and performance of the steering. Hiss may be
meshing of the helical pinion teeth with the rack expected when steering wheel at end of travel or
teeth. Power assist steering is provided by an open slowly turning at standstill.
center, rotary type control valve. It is used to direct
oil from the power steering pump to either side of the
integral steering rack piston.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As steering
effort increases as in a turn, the torsion bar twists,
causing relative rotary motion between the rotary
valve body and valve spool. This movement directs
oil behind the integral rack piston, which in turn,
builds up hydraulic pressure and assists in the turn-
ing effort.
19 - 2 STEERING PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Objectionable Hiss Or Whistle 1. Damaged or mispositioned 1. Check for proper seal between
steering column coupler to dash steering column coupler and dash
panel seal. seal.
2. Noisy valve in power steering 2. Replace steering gear assembly.
gear.
Rattle Or Clunk 1. Steering gear loose on front 1. Check steering gear to front
suspension crossmember. suspension crossmember mounting
bolts. Tighten to the specified torque
if found to be loose.
2. Front suspension crossmember to 2. Tighten the front suspension
frame bolts or studs loose. crossmember attaching bolts or
studs to the specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for
wear. Replace worn/loose parts as
required.
4. Loose lower control arm to front 4. Tighten control arm mounting
suspension crossmember bolts. bolts to the specified torques.
5. Loose strut assembly to body 5. Check upper strut mount to body
attaching bolts or nuts. attaching bolts or nuts for looseness.
If required, tighten to the specified
torques.
6. Power steering fluid pressure 6. Adjust hose to proper position by
hose touching the body of the loosening, repositioning, and
vehicle. tightening fitting to specified torque.
Do not bend tubing.
7. Noise internal to power steering 7. Replace steering gear assembly.
gear.
8. Damaged front suspension 8. Replace front suspension
crossmember. crossmember.
Chirp or squeal (in the area of the 1. Loose power steering pump drive 1. Adjust power steering pump drive
power steering pump). Particularly belt. belt to specified tension.
noticeable at full wheel travel and
during standstill parking.
PL STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should
not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose
touching the vehicle body, can create a noise level that could bring complaints.
Whine Or Growl (Pump Noise) 1. Low fluid level. 1. Fill power steering fluid reservoir
to proper level and perform leakage
diagnosis. (Recheck fluid level after
power steering fluid is free of air.)
2. Power steering hose touching 2. Reposition power steering hose.
vehicle body or frame. Replace hose if tube ends are bent.
3. Extreme wear of power steering 3. Replace power steering pump and
pump internal parts. flush system.
Sucking Air Sound 1. Loose clamp on power steering 1. Tighten or replace hose clamp.
fluid low pressure hose.
2. Missing O-Ring on power steering 2. Inspect connection and replace
hose connection. O-Ring as required.
3. Low power steering fluid level 3. Fill power steering fluid reservoir
to proper level and perform leakage
diagnosis.
4. Air leak between power steering 4. Inspect and or replace power
fluid reservoir and power steering steering fluid reservoir as required.
pump.
SQUEAK OR RUBBING SOUND 1. Sound coming from steering 1.Check for squeak in steering
column. column. Inspect for contact between
shroud, intermediate shaft, column,
and steering wheel. Realign if
necessary.
2. Check for lack or grease on
steering column dash panel to lower
coupler seal.
2. Sound internal to steering gear. 1. Replace steering gear assembly.
SCRUBBING OR KNOCKING 1. Incorrect tire size. 1. Verify that tire size on vehicle is
SOUND the same as originally supplied.
2. Check clearance between tires 2. Correct as necessary.
and other vehicle components,
through the full travel of the
suspension.
3. Check for interference between 3.Correct as necessary.
steering gear and other
components.
4.Incorrect steering gear supplied. 4. Replace steering gear with correct
steering gear for specific vehicle.
19 - 4 STEERING PL
DIAGNOSIS AND TESTING (Continued)
BINDING STICKING SEIZED
CONDITION POSSIBLE CAUSES CORRECTION
CATCHES, STICKS IN CERTAIN 1. Low power steering fluid level. 1. Fill power steering fluid reservoir
POSITIONS OR IS DIFFICULT TO to specified level and perform
TURN. leakage diagnosis.
2. Tires not inflated to specified 2. Inflate tires to the specified
pressure. pressure.
3. Lack of lubrication in front 3. Lubricate ball joints if ball joints
suspension control arm ball joints. are not a lubricated for life type ball
joint. If ball joint is a lubricated for
life ball joint, replace ball joint or
control arm.
4. Lack of lubrication in front 4. Lubricate tie rod ends if they are
suspension outer tie rod ends. not a lubricated for life type. If tie rod
end is a lubricated for life type,
replace tie rod end.
5. Loose power steering pump drive 5. Tighten the power steering pump
belt. drive belt to the specified tension.
See accessory drive in service
manual.
6. Faulty power steering pump flow 6. Replace power steering pump.
control. (Verify cause using Power
Steering Pump Test Procedure.)
7. Excessive friction in steering 7. Correct condition. (See Steering
column or intermediate shaft. Column Service Procedure)
8. Steering column coupler binding. 8. Realign the steering column to
eliminate the binding condition.
9. Binding upper strut bearing. 9. Correct binding condition in strut
bearing.
10 Excessive friction in steering 10 Replace steering gear assembly.
gear.
PL STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
SHAKE SHUDDER VIBRATION
CONDITION POSSIBLE CAUSES CORRECTION
VIBRATION OF THE STEERING 1. Air in the fluid of the power 1. Steering shudder can be expected
WHEEL AND/OR DASH DURING steering system. in new vehicles and vehicles with
DRY PARK OR LOW SPEED recent steering system repairs.
STEERING MANEUVERS. Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check that the inner to outer tie
rod jam nut for is tight. If required,
tighten the jam nut to the specified
torque.
5.Overcharged air conditioning 5.Check air conditioning pump head
system. pressure. (See Air Conditioning
Refrigerant System Diagnosis)
LOW ASSIST, NO ASSIST, HARD STEERING
CONDITION POSSIBLE CAUSES CORRECTION
STIFF, HARD TO TURN, 1. Tires not properly inflated. 1. Inflate tires to specified pressure.
SURGES, MOMENTARY
INCREASE IN EFFORT WHEN
TURNING.
2. Low power steering fluid level. 2. Add power steering fluid as
required to power steering fluid
reservoir to obtain proper level.
Perform leakage diagnosis on power
steering system.
3. Loose power steering pump drive 3. Adjust the power steering pump
belt. drive belt to the specified tension. If
drive belt is defective replace and
correctly tension.
4. Lack of lubrication in control arm 4. Lubricate ball joints if ball joints
ball joints. are not a lubricated for life type ball
joint. If ball joint is a lubricated for
life ball joint, replace ball joint or
control arm.
5. Low power steering pump 5. Verify cause using the Power
pressure. (Verify using Power Steering System Test Procedure.
Steering System Test Procedure) Replace the power steering pump if
necessary.
6. High internal leak in steering gear 6. Check steering system using the
assembly. Power Steering System Test
Procedure. If steering gear is
defective replace steering gear.
19 - 6 STEERING PL
DIAGNOSIS AND TESTING (Continued)
POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT 1. Tires not 1. Inflate tires to specified pressure.
WANT TO RETURN TO CENTER inflated to specified pressure.
POSITION.
2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Lack of lubrication in front 3. Lubricate ball joints if ball joints
suspension control arm ball joints. are not a lubricated for life type of
ball joint. If ball joint is a lubricated
for life ball joint, replace ball joint or
control arm.
4. Steering column U-joints 4. Realign steering column U-joints.
misaligned.
5. 5. Reposition dash cover.
Mispositioned dash cover.
To
evaluate items 6 and 7, disconnect
the intermediate shaft. Turn the
steering wheel and feel or listen for
internal rubbing in steering column.
6. Steering wheel rubbing. 6. Adjust steering column shrouds to
eliminate rubbing condition.
7. Damaged, mis-positioned or 7. Determine condition which exists
un-lubricated steering column and correct.
coupler to dash seal.
8. Binding upper strut bearing. 8. Correct
binding condition in strut bearing.
9. Tight shaft bearing 9. Replace the steering column
in steering column assembly. assembly.
10. Excessive friction in steering 10. Replace steering column coupler.
column coupler.
11. Excessive friction in steering 11. Replace steering gear.
gear.
PL STEERING 19 - 7
DIAGNOSIS AND TESTING (Continued)
LOOSE STEERING
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE STEERING WHEEL 1. Air in the fluid of the power 1. Fill power steering fluid reservoir
KICKBACK OR TO MUCH steering system. to the specified level. Perform
STEERING WHEEL FREE PLAY. procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front 2. Check steering rear to front
suspension crossmember. suspension crossmember mounting
bolts. Tighten to specified torque if
found to be loose.
3. Worn, broken or loose steering 3. Check for worn universal joint,
column to steering gear coupler. broken isolator or loose fasteners.
4. Free play in steering column. 4.Check components of the steering
system and repair or replace as
required.
5. Loose front suspension control 5. Check and or replace the ball joint
arm ball joints. or control arm as required.
6. Loose steering knuckle to ball 6. Check pinch bolts and tighten if
joint stud pinch bolt. required to specified torque.
7. Front wheel bearings loose or 7. Tighten hub nut to specified
worn. torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10 Defective steering gear rotary 10. Replace steering gear assembly.
valve.
19 - 8 STEERING PL
DIAGNOSIS AND TESTING (Continued)
VEHICLE LEADS TO THE SIDE
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT 1. Radial tire lead. 1.Rotate tires as recommended in
WANT RETURN TO CENTER the Tire And Wheel Group of this
POSITION. service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
4. Unbalanced steering gear valve. 4. Replace steering gear.
(If this is the cause, the steering
efforts will be very light in direction
of lead and heavier in the opposite
direction.
STEERING WHEEL HAS FORE 1. Steering wheel to steering column 1. Tighten the retaining nut to its
AND AFT LOOSENESS. shaft retaining nut not properly specified torque specification.
tightened and torqued.
2. Steering column lower bearing 2. Replace steering column.
spring retainer slipped on steering
column shaft.
PL STEERING 19 - 9
DIAGNOSIS AND TESTING (Continued)
POWER STEERING FLUID LEAK
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH: NO 1. Overfilled power steering pump 1. Adjust the power steering fluid fill
VISIBLE SIGNS OF A LEAK ON fluid reservoir. to the correct level.
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.
LOW FLUID LEVEL WITH: 2. Power steering hose connections 2. Check for loose fittings and if
VISIBLE LEAK ON STEERING at the power steering pump or found, tighten the fitting to its
GEAR, POWER STEERING steering gear. specified torque. If fittings are tight
PUMP, FLOOR OR ANYWHERE examine the fittings for damaged or
ELSE. missing O-ring seals and replace as
required.
3. Power steering pump or power 3. Identify the location of the leak
steering gear leaking. and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.
FOAMY OR MILKY POWER STEERING FLUID
CONDITION POSSIBLE CAUSES CORRECTION
AERATION AND OVERFLOW OF 1. Air leaks. 1. Check for an air leak into the
FLUID. power steering system as described
under Sucking Air Diagnosis and
correct condition.
2. Low fluid level. 2. Extremely cold temperatures may
cause power steering fluid aeration if
the power steering fluid is low. Add
power steering fluid as required to
bring level up to specification.
3. Cracked power steering pump 3. Remove power steering pump
housing. from vehicle and inspect the power
steering pump housing for cracks. If
a defect in the housing is found,
replace the power steering pump.
4. Water contamination. 4. Drain the power steering fluid
from the system if there is evidence
of contamination. Then refill the
system with fresh clean power
steering fluid.
POWER STEERING SHAFT
POWERPUMP PUMP
STEERING
HOUSING
POWER STEERING PUMP FLUID SUP-
POWER STEERING
PUMP DISCHARGE PLY FITTING
FITTING
19 - 10 STEERING PL
POWER STEERING PUMP
INDEX
page page
DESCRIPTION AND OPERATION POWER STEERING FLUID RESERVOIR . . . . . 22
POWER STEERING PUMP . . . . . . . . . . . . . . . 10 POWER STEERING FLUID RETURN HOSE . . . 16
DIAGNOSIS AND TESTING POWER STEERING FLUID SUPPLY HOSE
POWER STEERING SYSTEM TEST RESERVOIR TO POWER STEERING PUMP . 18
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 11 POWER STEERING PRESSURE SWITCH . . . . 13
SERVICE PROCEDURES POWER STEERING PUMP (ALL ENGINES) . . . 19
POWER STEERING PUMP FLOW CONTROL DISASSEMBLY AND ASSEMBLY
VALVE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 12 POWER STEERING PUMP DRIVE PULLEY . . . 23
POWER STEERING PUMP INITIAL OPERATION POWER STEERING PUMP MOUNTING
...................................... 12 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
POWER STEERING PUMP SUCTION PORT SPECIFICATIONS
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 POWER STEERING PUMP FASTENER
POWER STEERING SYSTEM FLUID LEVEL TORQUE SPECIFICATIONS . . . . . . . . . . . . . 26
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 POWER STEERING PUMP FLOW
REMOVAL AND INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 25
POWER STEERING FLUID PRESSURE SPECIAL TOOLS
HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER STEERING PUMP . . . . . . . . . . . . . . . 26
DESCRIPTION AND OPERATION All vehicles equipped with power steering use a
remote mounted reservoir for the power steering
POWER STEERING PUMP fluid. The power steering fluid remote reservoir is
On all vehicles equipped with power steering, the mounted to the rear of the cylinder head on the pas-
hydraulic pressure for operation of the power steer- senger side of the vehicle.
ing gear is provided by a belt driven power steering The service procedures for the TTA power steering
pump (Fig. 1). The TTA power steering pump is a pump are limited to the areas and components listed
constant flow rate and displacement, vane type below. No repair procedures are to be done on
pump. internal components of the TTA power steering
pumps.
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