Rack and Pinion Boots

Replace the rack and pinion boots on a 1994-2007 Dodge Ram 2500 4WD with 5.9L Cummins diesel engine to prevent contamination and restore steering system protection.

Warnings

Tools required

Parts

• Rack and pinion boot kit (inner and outer) × 1 — Use OEM specification or quality aftermarket
• Boot clamps × 4 — Usually included with boot kit
• Cotter pins × 2 — Appropriate size for tie rod ends
• Power steering fluid × 1 — Mopar ATF+4

Fluids

• power_steering — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is still on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheels
6. Clean steering linkage area with degreaser and wire brush to expose all components
7. Inspect steering linkage for wear or damage while accessing boots

Procedure

1. 1

   Remove steering wheel cover and access steering shaft
   Boot replacement on this truck is performed at the steering linkage (tie rod ends, drag link, and center link) under the vehicle. No access to the in-cab steering column coupling is required for this job.
2. 2

   Mark and remove tie rod ends
   Use a marker or paint pen to mark the tie rod end position on the threaded rod for reference during reassembly. Remove the cotter pin from the tie rod end castle nut and discard. Loosen the tie rod end nut but do not remove completely. Use a tie rod separator tool to break the taper joint between the tie rod end and steering knuckle. Remove the nut and separate the tie rod end.
   ⚠The tie rod separator will apply significant force. Wear eye protection and ensure the tool is properly seated to prevent slipping.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)

   Tie Rod End Nut54 Nm (40 lb-ft)
3. 3

   Remove outer tie rod boot
   Locate the outer boot clamps on the tie rod end. Use boot clamp pliers or side cutters to carefully remove the boot clamps without damaging the tie rod threads. Slide the old boot off the tie rod end. Clean the tie rod threads and sealing surfaces with brake cleaner and a rag. Inspect the tie rod ball joint for excessive wear or damage.
4. 4

   Install new outer tie rod boot
   Slide the new boot onto the tie rod, ensuring it is properly seated in the grooves on both the tie rod end and the tie rod body. Install new boot clamps in the designated positions. Use boot clamp pliers to crimp the clamps securely, ensuring the boot is not twisted and has no gaps. The boot should be fully sealed to prevent contamination.
5. 5

   Access inner tie rod or center link boots
   If replacing inner tie rod boots or center link boots, locate the boot clamps at the steering gear or center link end. These may require accessing from under the vehicle. Remove the old clamps and slide the boot toward the outer end to expose the inner joint. Clean all grease and debris from the joint area.
6. 6

   Inspect and repack inner joints
   Inspect the inner tie rod ball socket or center link joint for wear, corrosion, or damage. If serviceable, clean thoroughly with brake cleaner. Apply fresh chassis grease to the joint if the boot kit includes grease or if manufacturer specifications call for it. Some joints are sealed and do not require additional grease.
7. 7

   Install inner boots
   Slide the new inner boot over the joint, ensuring proper orientation with the small end toward the center link or steering gear and the large end toward the tie rod. Position the boot in the correct grooves and install new clamps. Crimp the clamps securely, ensuring no air pockets or twists in the boot material.
8. 8

   Reinstall tie rod ends to steering knuckles
   Thread the tie rod end back onto the tie rod to the previously marked position. Insert the tie rod end stud into the steering knuckle taper. Install the castle nut and tighten to specification. Align the castle nut slots with the cotter pin hole and install a new cotter pin. Bend the cotter pin ends to secure.
   ℹ️If the castle nut slots do not align with the cotter pin hole at the specified torque, tighten further to the next slot. Never loosen the nut to align.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)

   Tie Rod End Nut54 Nm (40 lb-ft)
9. 9

   Check and top off power steering fluid
   Locate the power steering reservoir under the hood. Check the fluid level and top off with Mopar Power Steering Fluid to the proper level mark. If significant fluid was lost during the procedure, add fluid gradually while turning the steering wheel lock-to-lock with the engine off to bleed air from the system.
10. 10

    Reinstall wheels and lower vehicle
    Install the front wheels onto the hubs. Thread the lug nuts on by hand to prevent cross-threading. Tighten lug nuts in a star pattern while the vehicle is still on jack stands to seat the wheel. Lower the vehicle to the ground and torque the lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure all boot clamps are properly crimped and boots are fully seated with no twists or gaps
2. Verify all tie rod end castle nuts have new cotter pins installed and properly bent
3. Double-check power steering fluid level and top off if necessary
4. If steering shaft coupling was disturbed, ensure coupling bolt is torqued to 34 Nm (25 ft-lb)

Verification

• Start the engine and turn the steering wheel slowly lock-to-lock while checking for leaks at all boot locations
• Check power steering fluid level again after running the engine and add if needed
• Verify no unusual noises from steering linkage during operation
• Test drive the vehicle at low speed to confirm steering operates smoothly without binding or noise
• Have a professional alignment performed to verify toe settings are within specification, as tie rod removal may have affected alignment

More procedures for this vehicle