1996 Dodge Intrepid Rack and Pinion

Steering problem
1996 Dodge Intrepid 6 cyl Front Wheel Drive Automatic

I need to know how to remove the rack and pinion?
I have it all apart but it is to big to fit through the hole in the fender wall. So I need to know if I need to take something else off the rack and pinion to be able to get it off.
Do you
have the same problem?
Sunday, January 25th, 2009 AT 4:21 PM

1 Reply


Below are the replacement procedures for your rack and pinion. Read over it and ensure you have performed all operations correctly.

NOTE: The power steering gear should not be disassembled in an attempt to service or adjust. If a malfunction or oil leak should occur, the complete rack and pinion steering gear assembly should be replaced.

Disconnect negative battery cable. Disarm the air bag system.
Raise and safely support the vehicle.
Remove the gear shift cable from the shifter lever on the transaxle.
Loosen the bolt at the gear shift cable to transaxle mount. Remove the cable from the transaxle.
Lower the vehicle.
If necessary, disconnect the throttle cable from the throttle body and remove throttle cable bracket.
Remove both wiper arm assemblies from the wiper arm pivots. Remove the cowl closure panel and weatherstrip as an assembly from the cowl.
Disconnect the wiper module wiring harness from the vehicle wiring harness. Remove the wiper module assembly from the vehicle cowl panel.
Disconnect the air plenum from the throttle body, PCV make up air tube and the idle air control motor. Remove he plenum from the right side of the vehicle through the wiper module area.
Remove the vacuum connector from the power brake booster at the intake manifold.
Turn the front wheels to the full left position. Then turn the wheels back in the other direction until the roll pin in the lower steering coupler is accessible. Turn the ignition key switch to the LOCK position to keep the steering column from rotating after the coupler is removed from the steering gear. If the steering column shaft rotates beyond the normal number of turns in either direction, the air bag clock spring will be damaged.
Using paint, mark the steering coupling and steering gear shaft for orientation. Using the correct size punch, remove the roll pin from the steering coupling.
If equipped with a brake pedal travel sensor, remove the pedal travel sensor from the brake booster as follows:
Pump the brake pedal approximately 20 times. This will bleed the vacuum stored in the booster.
Remove the wiring harness connector from the sensor.
Using a small flat tipped tool, lift the retainer ring from the notch. Then remove the retaining ring from the grommet.
Remove the pedal travel sensor from the brake booster by carefully pulling it straight out of its mounting grommet. Do not twist the sensor.
Loosen and remove the two nuts attaching the master cylinder to the brake booster. Remove the master cylinder with the brake lines connected, and position aside.
Remove the power steering pressure hose and return hose from the power steering gear.
Bend back the retaining tabs on bolt attaching the tie rods to the steering gear and remove the bolts.
Lay the tie rods, bolts and plate as an assembly on the bellhousing of the transaxle.
If the rack and pinion steering gear unit being removed is a speed proportional steering gear, disconnect the vehicle wiring harness from the solenoid control module.
Remove the four bolts attaching the steering gear assembly to the crossmember. Slide the steering gear forward in the vehicle to disengage steering coupler from the steering gear shaft. After gear is disengaged, do not rotate the steering gear shaft.
Remove the steering gear assembly from the vehicle through the area in the cowl from which the windshield wiper module was previously removed.

If a replacement rack is being installed, grasp the shaft of the steering gear and rotate until steering gear center take off is in a full left turn position. Install the steering gear into the vehicle through the wiper module opening in cowl.
If the original gear is being installed, align the paint mark on the steering coupler with the mark on the steering gear shaft and install the steering gear shaft into the steering gear coupler.
If a replacement rack is being installed, the steering gear shaft and steering coupler must be aligned. Rotate the steering gear shaft back from the full left turn position until the master spline on the steering gear shaft is aligned with the master spline on the steering coupler. At this point, install the steering gear into the coupler.
Align the steering gear with the mounting holes in the crossmember and install bolts. Be sure the brake line routing clip is installed under the left steering gear mounting bracket. Tighten the mounting bolts to 50 ft. Lbs. (68 Nm).
Install the steering coupler to steering gear shaft retaining roll pin until it is flush with the top edge of the steering coupler.
If equipped with 3.5L engine, correct orientation of the power steering pressure hose at the power steering pump must be maintained. Be sure the power steering hose is installed in orientation clip at the power steering pump prior to tightening tube fitting. Attach the power steering pressure and return lines onto the proper ports of the power steering gear. Tighten both fittings to 23 ft. Lbs. (31 Nm).
Align the center take off on the steering gear with the tie rod assemblies. Install the tie rod attaching bolts and washers into the steering gear assembly. Be sure the washers are installed between the tie rods and the steering gear. Tighten the tie rod to steering gear attaching bolts to 55 ft. Lbs. (75 Nm). Bend the retaining tabs against the heads of the bolts.
Install the pedal travel sensor retainer ring on the travel sensor grommet in the vacuum booster. The tab on the retaining ring should be located in top notch of the mounting grommet.
Sparingly lubricate pedal travel sensor O-ring with fresh brake fluid. Install the pedal travel O-ring into the pedal travel sensor mounting grommet. Coat the end of the sensor with fresh brake fluid and install by pushing straight into the mounting grommet on the brake booster until the tab on the sensor is past the retaining ring on grommet.
Install the wire harness connector to the pedal travel sensor.
Install the master cylinder and tighten nuts to 250 inch lbs. (28 Nm).
Install the power booster vacuum hose to the intake manifold. Install the windshield wiper module to the cowl panel. Reconnect the electrical harness to the module.
If removed, install the air intake plenum and reconnect to the idle air control motor, PCV make up air tube and throttle body.
Install the windshield wiper module assembly into the vehicle cowl area and reconnect the wiring harness from the wiper module to the vehicle wiring harness.
Install the cowl closure panel and tighten the six mounting screws. Install the weather strip on shock towers.
Install the windshield washer hoses on the wiper arms, then install arms on the windshield wiper pivots.
If removed, install the throttle cable to the bracket and install to the throttle body.
Reconnect the wiring harness from the solenoid control valve onto the solenoid control module. Be sure that the harness connector seal is in good condition before installation.
Raise and safely support the vehicle.
Install the gear shift cable onto the shift lever on transaxle. Install gear shift cable on cable mounting bracket of transaxle and securely tighten bolt.
Lower the vehicle. Connect the negative battery cable.
Refill the pump reservoir to the correct lever with Mopar Power Steering Fluid or equivalent. Do not use any type of automatic transmission fluid. Start the engine and turn the steering wheel several times from stop to stop to bleed the air from the fluid in the system. Check and add fluid as required.
Adjust the front suspension toe setting.

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Sunday, January 25th, 2009 AT 4:26 PM

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