Service Procedure
NOTE:
The initial steering linkage inspection process (Step 1 of the service procedure) can be done by write up personnel in the write up area. Vehicles found with the steering linkage shown in Figure 1 can be immediately returned to the customer. See the "Completion Reporting and Reimbursement" section of this recall for special claims processing information.
1. Look under the front of the vehicle and inspect the steering linkage at the steering damper mounting point:
> If the steering damper mounts to the tie rod tube as shown in Figure 1, the steering linkage is good. Return the vehicle to the customer. No further action is required.
> If the steering damper mounts to the tie rod tube as shown in Figure 2, the vehicle will require further inspection and/or repair by a technician. The vehicle should be assigned to a technician and the technician should continue with Step 2 of this procedure.
2. Lift the vehicle on a hoist and inspect the steering linkage drag link for a white part number tag (Figure 3):
> If the steering linkage drag link does not have a white part number tag, continue with Step 3 of this procedure.
^ If the steering linkage drag link has a white part number tag:
> For 2009 model year trucks, continue with Step 9 of this procedure.
> For 2003 through 2008 model year trucks, continue with Step 5 of this procedure.
3. Inspect the steering damper bracket to tie rod tube mounting u-bolt nuts by putting a 13 mm box-end wrench onto the nut (Figure 4):
> If a 13 mm wrench fits the steering damper bracket mounting u-bolt nuts, the bracket and fasteners must be replaced. Continue with Step 4 of this procedure.
> If a 13 mm wrench does not fit the steering damper bracket mounting u-bolt nuts, the bracket does not require replacement. Continue with Step 5 of this procedure.
4. Replace the steering damper bracket and fasteners using the following procedure:
a. Remove and save the steering damper-to-damper bracket mounting nut (Figure 5).
b. Disconnect the steering damper eyelet from the steering damper bracket.
c. Remove and discard the four steering damper bracket nuts, two u-bolts and the steering damper bracket (Figure 5).
d. Place the new steering damper carriage bolt through the square hole in the new steering damper bracket.
e. Place the new steering damper bracket assembly onto the tie rod tube at the flat spot area on the tube and install the new u-bolts and nuts. Lightly snug the nuts to hold the steering damper bracket in position.
f. Center the new steering damper bracket on the flattened area of the tie rod tube.
g. Evenly tighten the four steering damper bracket u-bolt nuts to 25 ft. lbs. (34 N.m). Then tighten the four u-bolt nuts to 45 ft. lbs. (61 N.m).
h. Connect the steering damper to the steering damper carriage bolt.
i. Install the steering damper-to-damper bracket mounting nut and tighten to 75 ft. lbs. (100 N.m).
j. Continue with Step 5 of this procedure.
5. For 2009 model year trucks, continue with Step 6 of this procedure. For 2003 through 2008 model year trucks, inspect the pitman arm part number (Figure 6):
> If the part number cast into the bottom side of the pitman arm is 68039930AA the pitman arm does not require replacement.
> Steering linkage with a white part number tag, continue with Step 9 of this procedure.
> Linkage without a white part number tag, replace the inner drag link joint. Continue with Step 6 of this procedure.
> If the part number cast into the bottom side of the pitman arm is 52106836AB, or is not legible:
> Steering linkage without a white part number tag, replace the inner drag link joint and pitman arm. Continue with Step 7 of this procedure.
> Steering linkage with a white part number tag, replace the pitman arm. Continue with Step 8 of this procedure.
6. Replace the inner drag link joint using the following procedure:
a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7).
b. Remove and discard the inner drag link joint to pitman arm nut (Figure 7).
c. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 8).
d. While counting the number of turns, unscrew the steering inner drag link joint from the drag link adjuster sleeve (right handed threads) and discard the drag link inner joint.
CAUTION:
Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint.
e. Screw in the new inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 6d. of this procedure.
f. Connect the steering inner drag link joint to the pitman arm.
g. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m).
h. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 9).
CAUTION:
Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure.
i. With the adjuster sleeve clamps rotated 45 degrees forward, tighten both drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).
CAUTION:
The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down.
j. Lower the vehicle from the hoist.
k. Drive the vehicle to verify that the steering wheel is straight.
> If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link.
> If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link.
l. Repeat Step 6k. until steering wheel is straight.
m. Continue with Step 9 of this procedure.
7. Replace the inner drag link joint and pitman arm using the following procedure:
a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7).
b. Remove and save the pitman arm retaining nut located on the steering gear output shaft.
c. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 11).
CAUTION:
Failure to use the correct pitman arm puller could cause damage to the steering gear.
d. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 11).
e. While counting the number of turns, unscrew the steering inner drag link joint (with pitman arm still attached) from the drag link adjuster sleeve (right handed threads) and discard the pitman arm and inner drag link joint.
CAUTION:
Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint.
f. Screw in the new steering inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 7e. of this procedure.
g. Install the new pitman arm and retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m).
h. Connect the steering inner drag link joint to the pitman arm.
i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m).
j. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 12).
CAUTION:
Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure.
k. With the adjuster sleeve clamps rotated 45 degrees forward, tighten the drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).lbs.
CAUTION:
The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down.
l. Lower the vehicle from the hoist.
m. Drive the vehicle to verify that the steering wheel is straight.
> If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link.
> If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link.
n. Repeat Step 7m. until steering wheel is straight.
o. Continue with Step 9 of this procedure.
8. Replace the pitman arm using the following procedure:
a. Remove and discard the inner drag link joint nut (Figure 13).
b. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 14).
CAUTION:
Use extreme care not to tear, nick or damage the inner drag link joint rubber boot.
d. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 15).
CAUTION:
Failure to use the correct pitman arm puller could cause damage to the steering gear.
e. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 15).
f. Install the new pitman arm.
g. Install the pitman arm retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m).
h. Connect the steering inner drag link joint to the pitman arm.
i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m).
j. Lower the vehicle from the hoist.
k. Drive the vehicle to verify that the steering wheel is straight.
> If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link.
^ If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link.
l. Repeat Step 8k. until steering wheel is straight.
m. Continue with Step 9 of this procedure.
9. Verify the lower surface of the left outer tie rod socket is parallel to the upper surface of the left knuckle attaching arm using the following procedure:
a. Loosen the tie rod tube adjuster sleeve clamps.
b. Rotate the left tie rod until the bottom of the tie rod socket is parallel to the top of the left steering knuckle arm (Figure 16).
c. Tighten the tie rod adjuster sleeve clamp nuts to 45 ft.lbs. (61 N.m).
CAUTION:
Failure to align the left tie rod end parallel to the steering knuckle could cause tie rod end damage.
d. Return the vehicle to the customer.