1994 Dodge Intrepid Repair Question
Disable airbag as outlined under "Precautions."
Disconnect battery ground cable.
Raise and support vehicle.
Disconnect gear shift cable from lever on transaxle then remove cable off transaxle.
On models with 3.5L/V6-215 engine, disconnect throttle cable from throttle body and remove from cable bracket.
On all models, remove both wiper arm assemblies from pivots.
Remove cowl closure panel and weatherstrip as an assembly from cowl.
Disconnect air plenum from throttle bodies, PCV make up air tube and idle air control motor.
Remove plenum from right side of vehicle.
Remove wiper module assembly as outlined under "Wiper Motor, Replace" in the "Electrical" section.
Remove vacuum supply hose for power brake booster at intake manifold and position hose out of the way.
Turn front wheels to full left turn position, then turn wheels back until roll pin is steering coupler is accessible. Lock steering column in place using ignition key.
Mark steering coupler and gear shaft for assembly.
Remove steering coupler roll pin using correct pin punch.
Remove pedal travel sensor from brake booster as follows:
Pump brake pedal 20 times to evacuate stored vacuum.
Remove wiring harness connector from sensor.
Using a small screwdriver, lift retaining ring from notch, then remove retaining ring from grommet.
Remove pedal travel sensor from brake booster by carefully pulling it out of its grommet. Do Not Twist.
Remove brake master cylinder with lines connected from brake booster.
Carefully position master cylinder against left shock tower.
Remove power steering pressure and return hoses from power steering gear.
Bend back retaining tabs on bolt attaching tie rods to steering gear then loosen and remove bolts attaching tie rods to steering gear. Lay tie rods, bolts and plate as an assembly on bellhousing of transaxle.
Remove bolts attaching steering gear assembly to crossmember.
Slide steering gear forward in vehicle to disengage steering coupler. After steering gear is disengaged from steering column, do not rotate steering gear shaft.
Remove steering gear through area in cowl wiper module removal provided.
Fig. 23 Tie Rod Attachment To Steering Gear
If a replacement steering gear assembly is being installed, the replacement gear will need to be positioned prior to installation.
Install steering gear assembly in vehicle through opening in cowl.
When reusing original gear, align paint marks on steering coupler and gear shaft then insert gear shaft into coupling.
When using a replacement gear, position gear by carefully grasping shaft of steering gear and rotating until steering gear is in a full left turn position.
On all gears, align steering gear with mounting holes in crossmember then install gear mounting bracket bolts. Ensure brake line routing clip is installed under left steering gear mounting bracket.
Install steering gear coupler retaining roll pin flush with top of steering coupler.
Attach power steering fluid pressure and return lines to proper ports of steering gear.
On models with 3.5L/V6-215 engine, correct orientation of power steering pressure hose at power steering pump must be maintained. Ensure power steering hose is installed in in orientation clip at power steering pump prior to tightening tube fitting.
On all models, align center take off on power steering gear with tie rod assemblies then install tie rod bolts and washers.
After tie rod bolts have been tighten to specification, bend lock tabs against bolt heads.
Install pedal travel sensor retainer ring on sensor grommet with tab on ring located in top notch of mounting grommet.
Sparingly lubricate pedal travel sensor O-ring with fresh brake fluid then install sensor into grommet by pushing it straight into grommet. Ensure sensor is installed into grommet until tab on sensor is past retaining ring on grommet.
Install master cylinder on brake booster.
Install vacuum supply hose for brake booster on intake manifold.
Install windshield wiper module system.
Connect wiring harness from windshield wiper module into wiring harness.
On models with 3.5L/V6-215 engines, connect air intake plenum to throttle bodies, PCV make up air tube and idle air control motor.
On all models, install cowl closer panel and weather strip.
Install washer hoses on wiper arms then both wiper arms on pivots.
On models with 3.5L/V6-215 engines, install throttle cable in throttle cable bracket and on throttle body.
On all models, raise and support vehicle.
Install gear shift cable on shift lever and mounting bracket.
Install tire and wheel assemblies then lower vehicle.
Rearm airbag as outlined under "Precautions."
Connect battery ground cable.
Bleed system as outlined under "Power Steering System Bleed."
Adjust toe as outlined under "Front Wheel Alignment" in the "Wheel Alignment" unit repair section.
23,190 answers provided