2005 GRAND CARAVAN Power Steering Rack Replacement 3.3L Engine

http://www.youtube.com/watch?v=reY8cpnKUWA

The video above shows three (3) possible methods for removing a rack and pinion steering gear…

1. Removing the bolts on the rear cradle mounts and dropping the engine downward 3 to 5 inches.
2. Removing the battery, battery box, and speedometer servo to gain access to the pressure and return lines.
3. Removing the lower emission device, undercarriage plate, and charcoal canister to gain access to the rack mount bolts and lines.

The factory manual is always best to follow, however it does not give precise directions to best possible methods for rack and pinion gear removal on this vehicle. My suggestion is to use a combination of all three methods to gain access to the mounting bolts and lines. If you do not feel comfortable about these procedures - do not attempt the repairs and hire a professional.

New or remanufactured steering gears will usually place the pinion shaft and rack in the straight ahead position to facilitate ease of installation. Under no circumstance are you to rotate the steering wheel when the steering shaft is disconnected from the rack. If the steering shaft is rotated, you may damage the clock spring in the steering column (mounted just below the steering wheel).

The clock spring is used to trigger the air bags during a front-end collision. See Chrysler Van Clock Spring video on YouTube by realfixesrealfast –

http://www.youtube.com/watch?v=7ipVKnDNzXM

 Summary of steps... 

1. Remove the tie-rod ends on both sides…
2. Remove the emission device – remove the hoses and electrical wires…
3. Remove the cruise control servo, battery, and battery box…
4. Remove the undercarriage bracket with power steering cooler…
5. Take fluid out of the power steering reservoir…
6. Remove the canister and bracket to get the rack mounting bolts...
7. Remove the rack pressure and return lines – mark a “U” for Upper or “L” for Lower prior to removal. 
8. Do not cross-thread the line fittings into the rack housing. Position the fittings parallel to the housing and shake the lines while you thread the nut into the hole with your fingers. The soft aluminum threads in the rack housing can be easily damaged - so be careful…
9. Remove the roll pin on the universal steering shaft coupler joint with a punch and hammer...
10. Remove the old rack and reverse the procedures…

Caution: When installing the lines, ensure that new o-ring seals are installed. New or remanufactured steering gears will be positioned in the straight ahead position to facilitate ease of installation. Under no circumstance are you allowed to rotate the steering wheel when the steering shaft is disconnected. Failure to follow this procedure will result in clock spring damage.