I have a caravan with a 3.8 v6 and it cranks but won't start.When I remove the fuel pump relay and jump across from point 87 to 30 with a jumper the van starts and idles but wants to die when in gear.Installed a new fuel pump relay and it still cranks but no start.What is going on please can you help?Also anyone can leave me a email at bobandannie@***.net any time please.

 

what is your fuel pressure?

 

SLIDING DOOR ADJUSTMENTS
NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section.

PRELIMINARY CHECKS
Close the sliding door, visually checking C-post striker alignment entry into latch. Striker at this point must not affect alignment. Striker should go straight into the latching mechanism.
On vehicles with left sliding doors, check the fuel door blocker striker entry into latch. Striker at this point must not affect alignment.
Check C-post and B-post for door to aperture gaps and door to door gaps. All gaps should be 5 mm ± 1 mm.
Check door for height using character lines as a reference. Also check roof contour as a controlling factor.
Using the procedures noted below, adjust the side door in the order the individual steps are called out.

DOOR FLUSHNESS ADJUSTMENT
Check sliding door flushness at the C-pillar striker.
Adjust the C-pillar striker in or out until the door is flush.
Check upper B-pillar flushness to A-pillar cover.
Loosen one nut on upper hinge and adjust door in or out until the door is flush.
Check flushness at upper C-pillar.
If upper C-pillar flushness is out of specification use a heavy rubber mallet on the door assembly until door is in specifications.
DOOR GAP ADJUSTMENT - UP/DOWN
Visually inspect the sliding door for fitting low at the top of the door by checking the alignment of the top contour of the door to the quarter panel.
Fully open the sliding door.
Verify that all center hinge bolts are tight.
Adjust the rear of the sliding door up by turning the center hinge bolt clockwise (SLIDING DOOR CENTER HINGE).
Close the door and check the sliding door alignment.
Adjust the front of the sliding door up by adjusting lower hinge bolts.
Open door half way and remove lower hinge bolt access plug.
Loosen bolts as necessary to move the front of door up or down.
Check the upper hinge for possible bind, adjust as necessary.
Close the door and check the sliding door alignment.
Fully open door and apply thread lock nut onto the center hinge bolt. Tighten nut until till it butts up against the welded nut on the center hinge. Tighten nut to 15 N·m (130 in. lbs.). It may be necessary to hold the center hinge bolt to prevent it from turning while tightening nut.
Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
Check height of sliding door at the B-post and C-post to determine which area is contributing the greatest to the incorrect gaps.
If the sliding door is high at the C-post;
Open the door to mid-point of travel.
Mark outline of center hinge on sliding door to assist in making adjustments.
Loosen center hinge bolts (SLIDING DOOR CENTER HINGE).
Move hinge fore or aft to position the sliding door into the correct location.
Tighten center hinge bolts.
Verify alignment, adjust as necessary.
If the sliding door is low at the B-post;
Remove access plug in the sliding door trim panel.
Open the door to mid-point of travel.
Mark outline of lower roller arm bracket on sliding door to assist in making adjustments.
Loosen lower roller arm bracket bolts (SLIDING DOOR LOWER ROLLER ARM).
Move hinge downward to raise the door.
Tighten lower roller arm bracket bolts.
Verify alignment, adjust as necessary.
If the sliding door is low at the C-post;
Open the door to mid-point of travel.
Mark outline of center hinge on sliding door to assist in making adjustments.
Adjust the adjustment bolt up or down to move the door position. (SLIDING DOOR CENTER HINGE).
Move hinge downward to raise the door.
Tighten center hinge bolts.
Verify alignment adjust as necessary.
If the sliding door is high at the B-post;
Remove access plug in the sliding door trim panel.
Open the door to mid-point of travel.
Mark outline of lower roller arm bracket on sliding door to assist in making adjustments.
Loosen lower roller arm bracket bolts (SLIDING DOOR LOWER ROLLER ARM).
Move hinge upward to raise the door.
Tighten lower roller arm bracket bolts.
Verify alignment, adjust as necessary.
DOOR SEAL COMPRESSION
First check Gap & Flush. Check seal compression near the middle of the door even with the latch assembly. Using a piece of paper, place it across door seal and close door. Pull paper out of door opening. If paper tears setting is to tight, if paper slides thought to easily the compression is insufficient and needs to be adjusted.
Adjust seal compression at the top of the B-post seal;
Open door to mid-point of travel.
Mark outline of upper roller arm on door to assist in making adjustments.
Loosen bolts attaching upper roller arm to door (SLIDING DOOR UPPER STOP).
Decrease the length of the upper roller arm to increase seal compression.
Increase the length of the upper roller arm to decrease seal compression.
Tighten all upper roller arm bolts.
Verify door alignment, adjust as necessary.
Adjust seal compression at the bottom of B-post seal.
Open door to mid-point of travel.
Mark outline of lower roller arm on lower roller arm bracket to assist in making adjustments (Sliding Door Lower Roller Arm).
Loosen bolts holding lower roller arm to lower roller arm bracket.
Pivot lower roller arm toward center of vehicle to decrease seal compression.
Pivot lower roller arm outward to increase seal compression.
Tighten lower roller arm bolts.
Verify alignment, adjust as necessary.
NOTE: Adjusting seal compression at the B-post can affect door flushness the C-post.

STABILIZER ADJUSTMENT - UPPER/LOWER
Open sliding door.
Loosen the bolts holding the male stabilizers to the sliding door enough that the stabilizers can move with some effort.
Close and then reopen sliding door.
Tighten all stabilizers bolts.

 

SUBJECT:
Flash: WIN For No Start Or Starts And Immediately Stalls
OVERVIEW:
This bulletin involves flash reprogramming the Wireless Ignition Node (WIN) with new
software.
MODELS:
2010 (RT) Town & Country / Caravan (International
Markets)
2010 (WH) Grand Cherokee (International Markets)
2010 (XH) Commander (International Markets)
SYMPTOM/CONDITION:
The vehicle will not start or start and immediately stalls. The issue is caused by skim lock
out. Dealers may also see Diagnostic Trouble Codes P0513 -Lost Communication with
Column Lock Module and/or B2224 - Column Lock Internal Module.
NOTE: Vehicles must have sales code XGM Tire Pressure Monitor.

 

PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET
1. Raise the vehicle to a comfortable working position and support.


2. Wipe the front parking brake cable strand clean at the intermediate bracket area.

CAUTION: Do use any type of sharp instrument directly on the cable strand to hold it in place. Damage to the cable strand or coating can occur.


3. Clamp an appropriate pair of pliers on the front parking brake cable button only and pull the cable stand rearward until it stops, then grasp the front cable strand and hold it in this position. Remove the pliers from the button.




4. While holding the front cable in this position, install the equalizer (attached to both rear cables) on the front parking brake cable.
5. Release the grasp on the front parking brake cable.
6. Lower the vehicle.
7. Apply and release the parking brake lever one time. This will seat the parking brake cables and allow the auto adjuster in the parking brake lever mechanism to correctly tension the parking brake cables.

 

SUBJECT:
NS Strut Tower Corrosion
OVERVIEW:
This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS:
1996 - 2000 NS Town&Country/Voyager/Caravan
SYMPTOM/CONDITION:
Cosmetic corrosion or perforation at upper strut tower/s usually between the strut
and upper load path beam inner panel (inner fender).
DIAGNOSIS:
Inspect left and right strut towers for condition. If corrosion is present, perform
one of the following repair procedures.
NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE
REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED:
Qty. Part No. Description
1 05080009AA Strut Cap (Left Side)
1 Kit 05086513AA NS Strut Cap Installation Kit
(Left Side).
1 05080008AA Strut Cap (Right Side)
1 Kit 05086512AA NS Strut Cap Installation Kit
(Right Side).
11/2 - 2 Cartridges
Per Side
05083855AA Mopar Structural Adhesive
EQUIPMENT REQUIRED:
W-7804R 90-degree drill motor (PSE)
W-861 High-speed air cutter (die grinder) (PSE)
23-044-02 -2-
05016570AA Adhesive dispenser (MOPAR)
W-AK175 ACH Power set rivet gun (PSE)
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion
resistant materials and/or primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION
SHEET INCLUDED IN THE PARTS KITS.

 

Flash: WIN For No Start Or Starts And Immediately Stalls
OVERVIEW:
This bulletin involves flash reprogramming the Wireless Ignition Node (WIN) with new
software.
MODELS:
2010 (RT) Town & Country / Caravan (International
Markets)
2010 (WH) Grand Cherokee (International Markets)
2010 (XH) Commander (International Markets)
SYMPTOM/CONDITION:
The vehicle will not start or start and immediately stalls. The issue is caused by skim lock
out. Dealers may also see Diagnostic Trouble Codes P0513 -Lost Communication with
Column Lock Module and/or B2224 - Column Lock Internal Module.
NOTE: Vehicles must have sales code XGM Tire Pressure Monitor.

 

This is a TSB that just came out for the 62TE transmission. Check with your dealer on this TSB.
MODELS:
2010 JC Journey
2010 JS Sebring/Avenger
2010 RT Town & Country/Grand Caravan
NOTE: This bulletin applies to select vehicles equipped with a 62TE automatic
transmission (sales code DG2) built from January 1, 2010 (MDH 0101XX)
through July 28, 2010 (MDH 0728XX) and with incorrect bearing preload.
GROUP: Transmission and
Transfer Case
DATE: September 22, 2010
DISCUSSION:
Some vehicles may have been built with transmission transfer gear bearings that were
built with incorrect bearing preload. Incorrect bearing preload may result in transfer gear
bearing noise.
NOTE: Not every vehicle equipped with the 62TE built from January 1, 2010 through
July 28, 2010 is affected by this issue. Only vehicles identified on the VIN list
may have incorrect transfer gear bearing preload.
1. Turn the steering wheel to the far left.
2. Open hood.
3. Raise the vehicle on the hoist.
4. If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the
left front wheel's cap with an appropriate removal tool utilizing the notch located
between the wheel and the outer edge of the cap. Use care not to damage the wheel
coating.
5. Remove the left front wheel's five wheel mounting (lug) nuts from their studs.
6. Remove the left front tire and wheel assembly from hub.
7. Remove the two bolts securing the left disc brake caliper and adapter bracket to the
steering knuckle.
8. Remove the disc brake caliper and adapter bracket from the knuckle and rotor as an
assembly (Fig. 1). Hang the assembly out of the way using wire or a bungee cord. Use
care not to overextend the brake hose when doing this.
NOTE: The front splash shield on some vehicles is a two piece assembly.
9. Remove push pins that secure the left front splash shield.
10. Remove fasteners that secure the left front splash shield.
11. Remove the left front splash shield.
NOTE: Journey/Sebring/Avenger models continue to next step. Town & Country
Models, proceed to Step #21.
12. Journey/Sebring/Avenger models, lower the vehicle.
13. Remove the air cleaner housing. Refer to the information provided in
DealerCONNECT>TechCONNECT>Service Information>09 - Engine>Air intake
System>Body, Air Cleaner>Removal.
14. Support the transaxle with a floor jack.
15. Remove the bolts at the left transmission mount and remove the mount.
16. Remove the floor jack from the transmission.
17. Raise the vehicle on the hoist.
18. Support the engine with a screw jack.
19. Remove the fore aft member mount through bolt.
20. Lower transaxle. Allow the transaxle to rest on the fore aft member
21. Remove transfer gear cover-to-case bolts.
22. Remove transfer gear cover.
23. Remove the oil scavenger by releasing the two lower tabs and sliding the
scavenger away from the gears.
CAUTION: The scavenger is secured to the transmission case by small tabs. These
tabs break easily. Use extreme care when removing the scavenger from
the transmission.
24. Grind the staked tabs from the transfer gear (underdrive compounder side).
25. Install the Gear Holder 9739 onto the transfer gear (underdrive compounder side) and
remove the nut. Hold Transfer Gear In Vehicle
26. Remove the transfer gear.
27. Remove the transfer gear bearing select fit shim.
Fig. 9 Transfer Gear Select Fit Shim
1 - Transfer Gear Bearing Retainer
2 - Transfer Gear Bearing Select Fit Shim
28. Using a micrometer, measure the select shim that was removed.
29. Refer to the following table and install the appropriate select shim onto the transfer
gear shaft.
Original Shim
Measurement
Install New Shim Part
Number
New Shim Thickness
SPACER, TRANSFER
SHAFT BEARING, 4.04 -
4.06 mm (0.1591 - 0.1600
in.)
04800567AA SPACER, TRANSFER
SHAFT BEARING, 4.13 -
4.15 mm (0.1626 - 0.1634
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.07 -
4.09 mm (0.1602 - 0.1610
in.)
04800568AA SPACER, TRANSFER
SHAFT BEARING, 4.16 -
4.18 mm (0.1638 - 0.1646
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.10 -
4.12 mm (0.1614 - 0.1622
in.)
04800569AA SPACER, TRANSFER
SHAFT BEARING, 4.19 -
4.21 mm (0.1649 - 0.1657
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.13 -
4.15 mm (0.1626 - 0.1634
in.)
04800570AA SPACER, TRANSFER
SHAFT BEARING, 4.22 -
4.24 mm (0.1661 - 0.1669
in.)
SPACER, TRANSFER 04800571AA SPACER, TRANSFER
21-005-10 -10-
SHAFT BEARING, 4.16 -
4.18 mm (0.1638 - 0.1646
in.)
SHAFT BEARING, 4.25 -
4.27 mm (0.1673 - 0.1681
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.19 -
4.21 mm (0.1649 - 0.1657
in.)
04800572AA SPACER, TRANSFER
SHAFT BEARING, 4.28 -
4.30 mm (0.1685 - 0.1693
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.22 -
4.24 mm (0.1661 - 0.1669
in.)
04800573AA SPACER, TRANSFER
SHAFT BEARING, 4.31 -
4.33 mm (0.1697 - 0.1705
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.25 -
4.27 mm (0.1673 - 0.1681
in.)
04800574AA SPACER, TRANSFER
SHAFT BEARING, 4.34 -
4.36 mm (0.1709 - 0.1717
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.28 -
4.30 mm (0.1685 - 0.1693
in.)
04800575AA SPACER, TRANSFER
SHAFT BEARING, 4.37 -
4.39 mm (0.1720 - 0.1728
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.31 -
4.33 mm (0.1697 - 0.1705
in.)
04800576AA SPACER, TRANSFER
SHAFT BEARING, 4.40 -
4.42 mm (0.1732 - 0.1740
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.34 -
4.36 mm (0.1709 - 0.1717
in.)
04800577AA SPACER, TRANSFER
SHAFT BEARING, 4.43 -
4.45 mm (0.1744 - 0.1752
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.37 -
4.39 mm (0.1720 - 0.1728
in.)
04800578AA SPACER, TRANSFER
SHAFT BEARING, 4.46 -
4.48 mm (0.1756 - 0.1764
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.40 -
4.42 mm (0.1732 - 0.1740
in.)
04800579AA SPACER, TRANSFER
SHAFT BEARING, 4.49 -
4.51 mm (0.1768 - 0.1776
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.43 -
4.45 mm (0.1744 - 0.1752
in.)
04800580AA SPACER, TRANSFER
SHAFT BEARING, 4.52 -
4.54 mm (0.1780 - 0.1787
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.46 -
4.48 mm (0.1756 - 0.1764
in.)
04800581AA SPACER, TRANSFER
SHAFT BEARING, 4.55 -
4.57 mm (0.1791 - 0.1799
in.)
30. Install Holder 9739 onto the transfer gear.
31. Install a new transfer gear (underdrive compounder side) nut (p/n 6508521AA) and
tighten to 271 N·m (200 ft. lbs.).
-11- 21-005-10
32. Use Staking Tool 9721 and stake the new nut.
33. Clean the transfer gear cover sealing surface and mating surface.
34. Install the oil scavenger.
35. Spread a bead of MOPAR® ATF RTV (p/n 05010884AA) (MS-GF41) onto the transfer
gear cover sealing surface.
36. Install transfer gear cover-to-case bolts and tighten to 12 N·m (105 in. lbs.).

 

HYDRAULIC PRESSURE TESTS
Pressure testing is a very important step in the diagnostic procedure. These tests usually reveal the cause of most transaxle problems.

Before performing pressure tests, be certain that fluid level and condition, and shift cable adjustments have been checked and approved. Fluid must be at operating temperature (150 to 200 degrees F.)

Install an engine tachometer, raise vehicle on hoist which allows front wheels to turn, and position tachometer so it can be read.

Attach 150 psi gauges to ports required for test being conducted. A 300 psi gauge (C-3293) is required for reverse pressure test.

Test port locations are shown in
Pressure Taps

TEST ONE-SELECTOR IN LOW 1st GEAR
Attach pressure gauge to the low/reverse clutch tap.
Move selector lever to the (L) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed to 20 mph.
Low/reverse clutch pressure should read 115 to 145 psi.
This test checks pump output, pressure regulation and condition of the low/reverse clutch hydraulic circuit and shift schedule.
TEST TWO-SELECTOR IN DRIVE 2nd GEAR
Attach gauge to the underdrive clutch tap.
Move selector lever to the (3) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph.
Underdrive clutch pressure should read 110 to 145 psi.
This test checks the underdrive clutch hydraulic circuit as well as the shift schedule.
TEST THREE-OVERDRIVE CLUTCH CHECK
Attach gauge to the overdrive clutch tap.
Move selector lever to the (Circle D) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 20 mph.
Overdrive clutch pressure should read 74 to 95 psi.
Move selector lever to the (3) position and increase indicated vehicle speed to 30 mph.
The vehicle should be in second gear and overdrive clutch pressure should be less than 5 psi.
This test checks the overdrive clutch hydraulic circuit as well as the shift schedule.
TEST FOUR-SELECTOR IN CIRCLE DRIVE, OVERDRIVE GEAR
Attach gauge to the 2/4 clutch tap.
Move selector lever to the (Circle D) position.
Allow vehicle front wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph.
The 2/4 clutch pressure should read 75 to 95 psi.
This test checks the 2/4 clutch hydraulic circuit.
TEST FIVE-SELECTOR IN CIRCLE DRIVE, OVERDRIVE
Attach gauge to the torque converter clutch off pressure tap.
Move selector lever to the (Circle D) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 50 mph.
CAUTION: Both wheels must turn at the same speed.

Torque converter clutch off pressure should be less than 5 psi.
This test checks the torque converter clutch hydraulic circuit.
TEST SIX-SELECTOR IN REVERSE
Attach gauge to the reverse clutch tap.
Move selector lever to the reverse position.
Read reverse clutch pressure with output stationary (foot on brake) and throttle opened to achieve 1500 rpm.
Reverse clutch pressure should read 165 to 235 psi.
This test checks the reverse clutch hydraulic circuit.
TEST RESULT INDICATIONS
If proper line pressure is found in any one test, the pump and pressure regulator are working properly.
Low pressure in all positions indicates a defective pump, a clogged filter, or a stuck pressure regulator valve.
Clutch circuit leaks are indicated if pressures do not fall within the specified pressure range.
If the overdrive clutch pressure is greater than 5 psi in step (6) of Test Three, a worn reaction shaft seal ring is indicated.

 

POWER STEERING GEAR
NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear assembly must be replaced.

NOTE: Before proceeding with this procedure, review the SERVICE WARNINGS AND CAUTIONS at the beginning of the REMOVAL AND INSTALLATION section.

REMOVAL
CAUTION: Positioning the steering column in the locked position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler.

Remove cap from power steering fluid reservoir.
Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.
With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position.
With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler Steering Column Shaft To Intermediate Shaft Attachment
Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this service manual, for the required lifting procedure to be used for this vehicle.
Remove the front tires.
Raise the heat sleeve Power Steering Fluid Return Hose Connection on the power steering return hose to expose the return hose to steel tube connection. Remove the return hose from the metal tube of the power steering fluid return line Power Steering Fluid Return Hose Connection Then allow the remaining power steering fluid to drain from the system through the hose and metal tube.
Remove nut attaching outer tie rod end to steering knuckle Removing/Installing Tie Rod End Attaching Nut Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench.
Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or MB-991113 Tie Rod End Removal From Steering Knuckle
Remove the 2 bolts and loosen the third HCU Bracket Attaching Bolts attaching the antilock brakes hydraulic control unit (HCU) to the front suspension cradle. Then rotate the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU.
Remove the 10 nuts and bolts Front Suspension Cradle Plate And Attaching Bolts attaching the cradle plate to the bottom of the front suspension cradle. Then remove the cradle plate from the cradle.
If the vehicle is equipped with All-Wheel-Drive, remove the power transfer unit. Refer to Group 21 in this service manual.
Remove the bracket Tube Bracket (FWD Shown) attaching the power steering fluid tubes to the front suspension cradle.
Using a 18mm crowfoot, Power Steering Fluid Pressure And Return Hoses At Steering Gear remove the power steering fluid pressure and return lines Power Steering Fluid Pressure And Return Hoses At Steering Gear from the power steering gear.
Remove the 3 bolts and nuts Steering Gear Mounting To Suspension Cradle mounting the steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear.

Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin Removing Roll Pin From Intermediate Coupler Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing with the knurled nut Removing Roll Pin From Intermediate Coupler Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler.
Separate the intermediate coupler from the shaft of the steering gear.
Remove the steering gear assembly from the front suspension cradle.
INSTALLATION
Install the steering gear up in the front suspension cradle, leaving room to install intermediate coupler.
Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear.
Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut Installing Roll Pin In Intermediate Coupler Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler.
Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front suspension cradle mounting bolts and nuts Steering Gear Mounting To Suspension Cradle
CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important.

Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 N·m (135 ft. lbs.)
Attach the power steering fluid pressure and return lines Power Steering Fluid Pressure And Return Hoses At Steering Gear to the proper fittings on the steering gear. Tighten the power steering fluid line tube nuts to a torque of 31 N·m (275 in. lbs.)
Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, Removing/Installing Tie Rod End Attaching Nut tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket Torquing Tie Rod End Attaching Nut , tighten the tie rod end attaching nut to a torque of 54 N·m (40 ft. lbs.)
If the vehicle is equipped with All-Wheel-Drive, install the power transfer unit. Refer to Group 21 in this service manual
CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important.

Install cradle plate on front suspension cradle and install the 10 cradle plate to cradle attaching bolts and nuts Front Suspension Cradle Plate And Attaching Bolts Tighten all attaching bolts to a torque of 165 N·m (123 ft. lbs.)
Install the bracket Tube Bracket (FWD Shown) attaching the power steering fluid tubes to the front suspension cradle.
Install the power steering fluid return hose on the steel tube at the front suspension cradle Power Steering Fluid Return Hose Connection
Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamp is installed on return tube past the upset bead on the tube. Tighten the screw clamp to a torque of 2 N·m (18 in. lbs.)
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses Power Steering Fluid Return Hose Connection This is required to prevent the power steering hoses from being overheated.

When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position.
Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 129 N·m (95 ft. lbs.)
Lower the vehicle to a level were the interior of vehicle is accessible.
Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate coupler shaft is properly aligned with the steering column coupler. Assemble the steering column shaft coupler Steering Column Shaft To Intermediate Shaft Attachment onto the steering gear intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt Steering Column Shaft To Intermediate Shaft Attachment Tighten the pinch bolt nut to a torque of 28 N·m (250 in. lbs.)
Perform the POWER STEERING PUMP INITIAL OPERATION service procedure listed in the POWER STEERING PUMP section of this group to properly fill and bleed the power steering system.
Inspect for leaks.
Adjust front toe.