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Section 38 (Steering System (Service Information)): Gear: Removal: AWD

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Disconnecting/Connecting Battery Cables
GC0012970Courtesy of DAIMLERCHRYSLER CORP.
  1. Disconnect and isolate battery negative cable (2) from battery post.
  2. Siphon power steering fluid from pump reservoir.
  3. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
    Fig 2: Tire And Wheel Mounting
    GC0012971Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove wheel mounting nuts (3), then both front tire and wheel assemblies (1).
    Fig 3: Removing/Installing Tie Rods (AWD)
    GC0013292Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When loosening jam nut and rotating inner tie rod, use care not to twist bellows at inner tie rod. Remove clamp (2) at inner tie rod and make sure bellows moves freely before rotating inner tie rod.
  5. Loosen tie rod jam nut (1) at each outer tie rod (4).
    Fig 4: Tie Rod Attachment at Knuckle
    GC0013294Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove outer tie rod (2) end nut (1) at each knuckle (3).
    Fig 5: Using Puller on Outer Tie Rod
    GC0013293Courtesy of DAIMLERCHRYSLER CORP.
  7. Using Remover (2), Special Tool 9360, separate outer tie rod (1) from each knuckle.
  8. Remove steering coupling pinch bolt at steering gear. (Refer to STEERING/COLUMN/STEERING COUPLING - REMOVAL) 
    Fig 6: Hoses at AWD Gear
    GC0013290Courtesy of DAIMLERCHRYSLER CORP.
  9. Unthread return hose tube nut (1) from steering gear (2). Remove return hose from steering gear.
  10. Unthread pressure hose tube nut (3) from steering gear (2). Remove pressure hose from steering gear.
    Fig 7: Rack Assembly And Inner Tie Rod Bellows Heat Shields
    GC0013295Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove mounting screws, then heat shield (3) above each inner tie rod bellows (2).
    Fig 8: Steering Gear Mounting Bolts
    GC0013291Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove steering gear upper mounting bolt (4) and nut.
  13. Remove steering gear lower mounting bolts (2 and 3).
  14. Remove steering gear (1).
  15. If necessary, remove outer tie rods from gear. Count number of revolutions off for each tie rod for reference upon installation to replacement gear.
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