http://www.dodgeintrepidchat.net/02lhe/02lhe.pdf
REMOVAL - INNER TIE ROD
(1) Remove the battery ground cable from the
ground stud on the shock tower and isolate the
ground cable by installing the cable isolator on the
ground stud (Fig. 33).
(2) Remove caps from both wiper arms at the
attachment to the pivots to expose the wiper arm
attaching nut. Remove the nut attaching each wiper
arm to its pivot (Fig. 34).
(3) Remove the wiper arms from the pivots. Wiper
arms are removed from the pivots by rocking them
back and force on the pivots until they can be pulled
off the pivots.
(4) Remove the wiper module cover and cowl cover
from the vehicle (Fig. 35).
(5) Remove the 8 bolts attaching the reinforcement
to the strut towers and the 1 bolt attaching the wiper
module to the reinforcement (Fig. 36). Remove the
reinforcement from the vehicle.
(6) Remove the in-line resonator and inlet hose
from the throttle body and air let hose coming from
the lid of the air cleaner housing (Fig. 37).
(7) Raise the vehicle on a frame contact hoist until
the front tires of the vehicle are just off the floor. See
Hoisting in Lubrication And Maintenance.
(8) Remove front wheel and tire assembly from
side requiring repair.
(9) Remove the nut attaching the outer tie rod end
to the steering arm on the strut.
10) Remove the tie rod end from the steering arm
of the strut using Puller, Special Tool C-3894–A (Fig.
39).
(11) Turn the steering wheel all the way to the full
right position.
(12) Bend back the retaining tabs on the mounting
plate for the tie rod to steering gear mounting bolts
(13) Remove the bolt fastening the inner tie rod
requiring service to the steering gear (Fig. 41). Be
careful not to loose the washer behind the tie rod.
(14) Loosen the bolt fastening the opposite inner
tie rod to the gear, but do not fully remove it.
(15) Rotate the loose end of the mounting plate out
of the way.
(16) Remove the tie rod assembly from the vehicle
through the wheel opening.
(17) Loosen the pinch bolt at the outer to inner tie
rod adjustment sleeve.
(18) Remove outer tie rod from adjustment sleeve
and inner tie rod.
INSTALLATION - INNER TIE ROD
(1) Install the outer tie rod into the adjustment
sleeve on the inner tie rod. Screw the tie rod in until
the exposed thread length on the outer tie rod is
equal to the exposed threads on the adjuster. Make
sure no more than 20 mm thread length is exposed
on either the tie rod or the adjuster sleeve (Fig. 42).
Do not tighten the adjustment pinch bolt at this
time.
CAUTION: When setting the front Toe on the vehicle,
the maximum dimension of exposed threads
allowed on the adjuster and outer tie rod cannot
exceed the distance shown in (Fig. 42). If the maximum
distance is exceeded, inadequate retention of
either the adjuster or the outer tie rod can result.
This condition can cause separation of the outer tie
rod end from the inner tie rod. Ensure that adjustment
sleeve pinch bolts are torqued to the required
specification when Toe setting procedure is completed.
(2) Install the tie rod assembly through the tie rod
hole in the wheel opening inner fender.
(3) Install the outer tie rod on the steering arm of
the strut. Install the tie rod steering arm nut.
Do not tighten the nut at this time.
(4) Align the inner tie rod with the mounting hole
in the center take off on steering gear. Rotate the
mounting plate into position over the tie rod. Install
tie rod attaching bolt through tie rod and washer
into steering gear.
(5) Bend retaining tabs against heads of tie rod
attaching bolts (Fig. 40).
(6) Place the front wheels in the straight-ahead
position.
(7) Tighten the outer tie rod steering arm nut to a
torque of 37 N·m (27 ft. lbs.).
(8) Install the wheel and tire assembly. Install and
tighten wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then
repeat the tightening sequence to the full specified
torque of 135 N·m (100 ft. lbs.).
(9) Lower the vehicle.
(10) Install the in-line resonator and inlet hose on
the throttle body and air inlet hose coming from the
lid of the air cleaner housing (Fig. 37).
(11) Install the reinforcement on the vehicle (Fig.
36). Install the 8 bolts attaching the reinforcement to
the strut towers. Install the bolt attaching the wiper
module to the reinforcement.
(12) Install the covers over the wiper module and
the cowl (Fig. 35). Install and securely tighten the
attaching screws.
(13) Install the wiper arms on the pivots (Fig. 34).
Install and securely tighten the wiper arm to pivot
attaching nuts. Install the caps on the wiper arms
covering the pivot nuts.
(14) Install the battery ground cable onto the
ground stud on the shock tower and install nut.
(15) Adjust front toe. Refer to Wheel Alignment in
Suspension.
