Power Steering Rack

Complete removal and installation of the power steering rack assembly on a 1992 Dodge Viper, including disconnecting tie rods, hydraulic lines, steering coupling, and rack mounting hardware.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification
• Power steering line O-rings × 4 — Use OEM specification
• Tie rod end cotter pins × 2 — Use OEM specification
• Rack mounting bushings (if worn) × 2 — Use OEM specification

Fluids

• Mopar power steering fluid or ATF+3 — 1.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove both front wheels
5. Center steering wheel and note exact position for reassembly reference
6. Place drain pan under power steering rack area

Procedure

1. 1

   Disconnect tie rod ends from spindles
   Remove cotter pins from both tie rod end castle nuts using pliers. Loosen but do not remove the tie rod end nuts. Use a tie rod end separator or pickle fork to break the taper connection between the tie rod end and steering knuckle. Once loose, remove the castle nuts completely and separate the tie rod ends from the knuckles. Mark the tie rod position on the threads with paint or center punch for approximate reassembly reference.
2. 2

   Access steering coupling in cabin
   From inside the vehicle, locate the steering column coupling at the firewall. This may require removing the lower dash panel or trim for access. Identify the pinch bolt securing the steering shaft coupling to the rack input shaft.
3. 3

   Disconnect steering shaft coupling
   Mark the relationship between the steering shaft and rack input shaft with paint or a center punch for proper alignment during reassembly. Remove the coupling pinch bolt. Carefully slide the coupling upward off the rack input shaft splines. Some wiggling may be required to free the coupling.
4. 4

   Disconnect power steering pressure line
   Position drain pan directly under the pressure line connection at the rack. Using a flare nut wrench to prevent rounding, loosen and remove the pressure line fitting from the rack inlet port. Allow fluid to drain completely. Cap or plug the line and rack port to prevent contamination.
5. 5

   Disconnect power steering return line
   Using a flare nut wrench, loosen and remove the return line fitting from the rack outlet port. Allow remaining fluid to drain into the pan. Cap or plug the line and rack port. Inspect all O-rings on disconnected fittings and discard them; new O-rings must be used during installation.
6. 6

   Remove rack mounting hardware
   Locate the rack mounting bolts securing the rack assembly to the front crossmember or subframe. Locate the rack mounting bolts securing the rack to the crossmember/frame. Verify the exact number of mounting bolts and bracket clamps against the factory service manual for this vehicle before removal. Support the rack with one hand while removing both mounting bolts. Note the position and orientation of any brackets, washers, or bushings for proper reassembly.
7. 7

   Remove rack assembly from vehicle
   Carefully lower the rack assembly away from the mounting location. Maneuver the rack, still attached to the tie rods, out from the driver's side wheel well. The tie rods may need to be angled or rotated to clear frame components during removal. Once clear, remove the rack from under the vehicle.
8. 8

   Transfer tie rods to new rack
   If reusing tie rods, count and record the number of threads exposed beyond the jam nut on each tie rod before removal. Loosen the tie rod jam nuts and unthread the tie rod ends from the old rack. Install tie rod ends onto the new rack to the same thread depth recorded earlier. Tighten jam nuts snugly but do not final-torque yet (final adjustment will be made after alignment).
9. 9

   Install new rack assembly into vehicle
   Maneuver the new rack assembly with attached tie rods into position through the driver's side wheel well. Align the rack mounting brackets with the crossmember or subframe mounting points. Insert both rack mounting bolts with any brackets and bushings in their original positions. Thread bolts by hand initially to ensure proper alignment.
   Torque spec

   Rack Mounting Bolts102 Nm (75 lb-ft)
10. 10

    Torque rack mounting bolts
    Torque both rack mounting bolts to specification in an alternating pattern to ensure even clamping force. Verify the rack is seated properly in the mounting bushings and has no binding or interference with surrounding components.
    Torque spec

    Rack Mounting Bolts102 Nm (75 lb-ft)
11. 11

    Reconnect power steering lines
    Install new O-rings on both the pressure and return line fittings. Lightly lubricate O-rings with clean power steering fluid. Thread the pressure line fitting into the rack inlet port by hand until snug, then torque to specification using a flare nut wrench. Repeat for the return line fitting at the outlet port.
    Torque spec

    Pressure Line Fitting34 Nm (25 lb-ft)

    Power Steering Line Fittings30 Nm (22 lb-ft)
12. 12

    Reconnect steering shaft coupling
    From inside the vehicle, align the steering shaft coupling with the rack input shaft splines, matching the alignment marks made during disassembly. Slide the coupling fully onto the splines. Install the coupling pinch bolt and torque to specification. Verify the steering wheel is still centered.
    Torque spec

    Coupling Bolt28 Nm (21 lb-ft)
13. 13

    Reconnect tie rod ends to spindles
    Insert the tie rod end tapers into the steering knuckle bores on both sides. Install the castle nuts and torque to specification. Align the castle nut slots with the tie rod end cotter pin holes (tighten further if necessary to align; never loosen to align). Install new cotter pins and bend the ends to secure.
    Torque spec

    Tie Rod End Nut54 Nm (40 lb-ft)
14. 14

    Reinstall wheels and lower vehicle
    Install both front wheels and thread lug nuts by hand. Torque lug nuts to specification in a star pattern. Carefully lower the vehicle from jack stands to the ground. Remove jack stands and lower the floor jack completely.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
15. 15

    Fill and bleed power steering system
    Locate the power steering fluid reservoir under the hood. Fill the reservoir with the manufacturer-specified power steering fluid (Mopar ATF Plus / ATF+ or equivalent for this era) to the cold fill mark. Start the engine and allow it to idle. Turn the steering wheel slowly from lock to lock 10-15 times without holding at full lock. Check fluid level frequently and add as needed. Continue until no air bubbles appear in the reservoir and the fluid level stabilizes. Top off to the appropriate mark.

Reassembly

1. If any lower dash panels or trim were removed for coupling access, reinstall them using original fasteners
2. Torque all fasteners to specification as indicated in the procedure steps
3. Use new O-rings on all hydraulic connections and new cotter pins on tie rod ends
4. Ensure no tools or parts are left in the wheel wells or under the vehicle

Verification

• Start engine and verify no power steering fluid leaks at rack connections or line fittings
• Turn steering wheel lock to lock several times and verify smooth operation with no binding or unusual noises
• Check power steering fluid level and top off if necessary
• Verify steering wheel returns to center position when released
• Test drive vehicle in a safe area at low speed to confirm proper steering function
• Schedule professional wheel alignment as tie rod position will have changed

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