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.

How to Remove a Stuck CV Axle Shaft with a Tie-Down Strap and Pry Bar – It Really Works

Okay, I know this sounds crazy but a 10^th grade student brought a tie-down strap to my automotive class to remove a stuck CV axle shaft on his 2001 Kia. Before trying this weird idea, one student decided to call the local parts store to “get the right tool for the job:” a CV axle puller. Great idea! After spending $31 for this tool, the darn thing did not work. The tool was not thin enough to get behind the axle to attach a slide hammer.

After wasting a whole class period with the "right tool,” I decided to go with a student's weird tie-down strap idea. How do you wrap a tie-down strap around the back of a CV axle shaft?  

First, separate the shaft at the back boot (not required, but it gives you extra room to work).

Second, use the flat surface of the strap to lie along the back of the axle, creating an “L-shaped” layer around the shaft extension. This keeps the strap from slipping off the shaft.

Spool the yellow flat of the tie-strap around the back sides of the shaft extension – creating an "L-shaped" layer that must overlap or cross at least once for pulling…

Third, connect one end of the strap to something solid on the vehicle; and connect the other end so that the strap pulls in the direction of axle removal (creating a 90 degree pull angle).  

Fourth, tighten the ratchet handle on the strap, and apply constant pressure on the joint.

Fifth, tell everybody to get out of the way, because this force can create a projectile if the axle suddenly release.  

Of course, after applying pressure to the strap, nothing happened. Nothing!

That’s when I went underneath the car with a pry bar and gave the axle shaft end an upward jerking pry because the straps was pulling downward at an angle to prevent the strap from slipping off the shaft. After a couple seconds of rocking the shaft – BAM! The shaft “broke free” and automatic transmission fluid poured out. The old tie-strap idea worked without any damage to the transmission and it did not cost us a dime. The only bad thing about this idea was that I was splattered in automatic transmission fluid. So much for being a professional (http://bit.ly/IdEaCZ  click here for a laugh)!

The morale of this story:  listen to your students, their ideas sometime work.

Amazing Students with Weird Ideas That Work!