TJ STEERING 19 - 1

STEERING
CONTENTS

page page

MANUAL STEERING GEAR . . . . . . . . . . . . . . . . . 21 POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . 1

POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 10 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 28
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 4 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 32

POWER STEERING

INDEX
page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 POWER STEERING SYSTEM DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION ported by a thrust bearing at the lower end and a

bearing assembly at the upper end. When the worm
STEERING SYSTEM shaft is turned the rack piston moves. The rack pis-
This vehicle has manual steering or optional power ton teeth mesh with the pitman shaft. Turning the
steering. The power steering system has a hydraulic worm shaft turns the pitman shaft, which turns the
pump. The pump is a constant flow rate and dis- steering linkage.
placement vane-type pump. The pump reservoir on The power steering system consists of:
the 4.0L engine is mounted to the pump body (Fig. • Hydraulic pump
1). The 2.5L engine has a remote pump reservoir • Recirculating ball steering gear
mounted to the fan shroud (Fig. 2). • Steering column
The steering gear used is a recirculating ball type • Steering linkage
gear. The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-

Fig. 2 Power Steering Gear & Pump – 2.5L

Fig. 1 Power Steering Gear & Pump – 4.0L

19 - 2 STEERING TJ

DIAGNOSIS AND TESTING

POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE

There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing
through an orifice. There is no relationship between this noise and steering performance.

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash 1. Check and repair seal at dash
WHISTLE panel seal. panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension 2. Inspect and repair suspension.
components.
3. Loose or damaged steering linkage. 3. Inspect and repair steering linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other 5. Reposition hose.
components.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other 2. Reposition hose.
components.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose 2. Replace o-ring.
fitting.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.
KNOCKING 2. Wrong gear. 2. Verify gear.

BINDING AND STICKING

CONDITION POSSIBLE CAUSE CORRECTION

DIFFICULT TO TURN WHEEL 1. Low fluid level. 1. Fill to proper level.
STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure.
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of 7. Repair or replace gear.
adjustment.
TJ STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)
INSUFFICIENT ASST. OR POOR RETURN TO CENTER

CONDITION POSSIBLE CAUSE CORRECTION

HARD TURNING OR MOMENTARY 1. Tire pressure. 1. Adjust tire pressure.
INCREASE IN TURNING EFFORT 2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.
STEERING WHEEL 1. Tire pressure. 1. Adjust tire pressure.
DOES NOT WANT TO RETURN TO 2. Wheel alignment. 2. Align front end.
CENTER POSITION 3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.

LOOSE STEERING AND VEHICLE LEAD

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Repair as necessary.
WHEEL steering components.
2. Worn or loose wheel bearings. 2. Repair as necessary.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS OR LEADS TO 1. Tire Pressure. 1. Adjust tire pressure.
ONE SIDE 2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
19 - 4 STEERING TJ

POWER STEERING PUMP

INDEX
page page

DESCRIPTION AND OPERATION PUMP REMOTE RESERVOIR – 2.5L .......... 6

POWER STEERING PUMP . . . . . . . . ......... 4 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING FLOW CONTROL VALVE . . . . . . . . . .......... 8
PUMP FLOW RATE AND PRESSURE ......... 4 PUMP PULLEY . . . . . . . . . . . . . . . . .......... 7
PUMP LEAKAGE DIAGNOSIS . . . . . . ......... 5 PUMP RESERVOIR . . . . . . . . . . . . . .......... 7
SERVICE PROCEDURES SPECIFICATIONS
POWER STEERING PUMP – INITIAL TORQUE CHART . . . . . . . . . . . . . . . .......... 8
OPERATION . . . . . . . . . . . . . . . . . . ......... 5 SPECIAL TOOLS
REMOVAL AND INSTALLATION POWER STEERING PUMP . . . . . . . .......... 9
POWER STEERING PUMP . . . . . . . . ......... 6

DESCRIPTION AND OPERATION

POWER STEERING PUMP
Hydraulic pressure for the power steering system
is provided by a belt driven power steering pump
(Fig. 1). The pump shaft has a pressed-on drive pul-
ley that is belt driven by the crankshaft pulley. The
power steering pump is a constant flow rate and dis-
placement, vane-type pump. The pump internal parts
operate submerged in fluid. The flow control orifice is
part of the high pressure line fitting. The pressure
relief valve inside the flow control valve limits the
pump pressure. The reservoir is attached to the
pump body with spring clips on the 4.0L engine. A
remote pump reservoir is used on the 2.5L engine
mounted to the fan shroud. The power steering pump
is connected to the steering gear by the pressure and
return hoses.

NOTE: Power steering pumps have different pres-

sure rates and are not interchangeable with other
pumps. Fig. 1 Pump With Integral Reservoir
FLOW AND PRESSURE TEST
(1) Check the power steering belt to ensure it is in
DIAGNOSIS AND TESTING good condition and adjusted properly.
(2) Connect pressure gauge hose from the Power
PUMP FLOW RATE AND PRESSURE Steering Analyzer to Tube 6865.
The following procedure is used to test the operation (3) Connect Adapter 6826 to Power Steering Ana-
of the power steering system on the vehicle. This test lyzer test valve end.
will provide the gallons per minute (GPM) or flow rate (4) Disconnect the high pressure hose from the
of the power steering pump along with the maximum power steering pump.
relief pressure. Perform test any time a power steering (5) Connect Tube 6865 to the pump hose fitting.
system problem is present. This test will determine if (6) Connect the power steering hose from the
the power steering pump or power steering gear is not steering gear to Adapter 6826.
functioning properly. The following pressure and flow (7) Open the test valve completely.
test is performed using Power Steering Analyzer Tool (8) Start engine and let idle long enough to circulate
6815 (Fig. 2) and Adapter kit 6893. power steering fluid through flow/pressure test gauge.
TJ STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
PUMP SPECIFICATIONS

RELIEF FLOW RATE

ENGINE
PRESSURE 6 50 (GPM)
2.5L 9653 kPa
(1400 psi) 1500 PM
4.0L 9653 kPa 2.4 - 2.8 GPM
(1400 psi)

PUMP LEAKAGE DIAGNOSIS

Fig. 2 Power Steering Analyzer

(9) Shut off the engine and check the fluid level,
add fluid as necessary. Start engine again and let
idle.
(10) Gauge should read below 862 kPa (125 psi), if
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure reading should be in
the range of 345-552 kPa (50-80 psi).
(11) Increase the engine speed to 1500 RPM and
read the flow meter. The reading should be 2.4 - 2.8
GPM, if the reading is below this specification the
pump should be replaced.

CAUTION: This next step involves testing maxi-

mum pump pressure output and flow control valve
operation. Do not leave test valve closed for more
than three seconds as the pump could be damaged.
(12) Close valve fully three times for three seconds
and record highest pressure indicated each time. All
three readings must be above pump relief pres-
sure specifications and within 345 kPa (50 psi)
of each other. SERVICE PROCEDURES
• Pressures above specifications but not within
345 kPa (50 psi) of each other, replace pump. POWER STEERING PUMP – INITIAL OPERATION
• Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump. WARNING: THE FLUID LEVEL SHOULD BE
(13) Open the test valve, turn steering wheel CHECKED WITH ENGINE OFF TO PREVENT INJURY
extreme left and right positions against the stops. FROM MOVING COMPONENTS.
Record the highest indicated pressure at each posi-
tion. Compare readings to pump relief pressure spec-
CAUTION: Use MOPAR Power Steering Fluid or
ifications. If highest output pressures are not within
equivalent. Do not use automatic transmission fluid
50 psi. against either stop, the gear is leaking inter-
and do not overfill.
nally and must be repaired.
Wipe filler cap clean, then check the fluid level.
CAUTION: Do not force the pump to operate
The dipstick should indicate COLD when the fluid is
against the stops for more than 2 to 4 seconds at a
at normal temperature.
time because, pump damage will result.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
19 - 6 STEERING TJ
SERVICE PROCEDURES (Continued)
(3) Add fluid if necessary. Repeat the above proce- (3) Remove 3 pump mounting bolts through pulley
dure until the fluid level remains constant after run- access holes.
ning the engine. (4) Loosen the 3 pump bracket bolts (Fig. 3).
(4) Raise the front wheels off the ground. (5) Tilt pump downward and remove from engine.
(5) Slowly turn the steering wheel right and left, (6) Remove pulley from pump.
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary. INSTALLATION
(7) Lower the vehicle, start the engine and turn (1) Install pulley on pump.
the steering wheel slowly from lock to lock. (2) Install pump on the engine mounting bracket.
(8) Stop the engine and check the fluid level and (3) Tighten pump bracket bolts to 47 N·m (35 ft.
refill as required. lbs.).
(9) If the fluid is extremely foamy or milky look- (4) Install 3 pump mounting bolts and tighten to
ing, allow the vehicle to stand a few minutes and 27 N·m (20 ft. lbs.).
repeat the procedure. (5) Install the pressure line on the pump and
tighten to 28 N·m (21 ft. lbs.).
CAUTION: Do not run a vehicle with foamy fluid for (6) Install return hoses on pump.
an extended period. This may cause pump damage. (7) Install drive belt, refer to Group 7 Cooling.
(8) Add power steering fluid, refer to Power Steer-
ing Pump Initial Operation.
REMOVAL AND INSTALLATION
PUMP REMOTE RESERVOIR – 2.5L
POWER STEERING PUMP
REMOVAL
REMOVAL (1) Remove the pump return hoses from the reser-
(1) Remove serpentine drive belt, refer to Group 7 voir and drain the reservoir.
Cooling. (2) Remove the push-in fastener from the reservoir
(2) Remove pressure and return hoses from pump (Fig. 4).
and drain the pump.

Fig. 3 Pump Mounting

TJ STEERING 19 - 7
REMOVAL AND INSTALLATION (Continued)
(3) Slide the reservoir up out of the fan shroud (2) Install pulley on pump with Installer C-4063-B
mount. (Fig. 6) flush with the end of the shaft. Ensure the
tool and pulley remain aligned with the pump shaft.

Fig. 4 Pump Reservoir – 2.5L

Fig. 6 Pulley Installation
INSTALLATION
(1) Slide reservoir down onto the fan shroud (3) Install pump assembly.
mount until it clicks in place. (4) With Serpentine Belt, run engine until warm (5
(2) Install the push-in fastener. min.) and note any belt chirp. If chirp exists, move pul-
(3) Install the hoses. ley outward approximately 0.5 mm (0.020 in.). If noise
(4) Fill reservoir to proper level, refer to Power increases, press on 1.0 mm (0.040 in.). Be careful that
Steering Pump Initial Operation. pulley does not contact mounting bolts.

PUMP RESERVOIR
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
PUMP PULLEY (1) Remove power steering pump.
(2) Clean exterior of pump.
DISASSEMBLY (3) Clamp the pump body in a soft jaw vice.
(1) Remove pump assembly. (4) Pry up tab and slide the retaining clips off (Fig. 7).
(2) Remove pulley from pump with Puller C-4333
(Fig. 5).

ASSEMBLY
(1) Replace pulley if bent, cracked, or loose.

Fig. 5 Pulley Removal

Fig. 7 Pump Reservoir Clips
19 - 8 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove fluid reservoir from pump body. (3) Remove and discard O-ring seal.
Remove and discard O-ring seal.
ASSEMBLY
ASSEMBLY (1) Install spring and flow control valve into pump
(1) Lubricate new O-ring Seal with Mopar Power housing bore. Be sure the hex nut end of the
Steering Fluid or equivalent. valve is facing in toward pump.
(2) Install O-ring seal in housing. (2) Install O-ring seal onto fitting.
(3) Install reservoir onto housing. (3) Install flow control valve in pump housing and
(4) Slide and tap in reservoir retainer clips until tighten to 75 N·m (55 ft. lbs.).
tab locks to housing. (4) Install pressure hose to valve.
(5) Install power steering pump.
(6) Add power steering fluid, refer to Pump Initial
Operation. SPECIFICATIONS

FLOW CONTROL VALVE TORQUE CHART

DISASSEMBLY DESCRIPTION TORQUE

(1) Clean area around fitting to prevent dirt from Power Steering Pump
entering pump. Remove pressure hose from pump fit- Bracket to Pump . . . . . . . . . . . .28 N·m (21 ft. lbs.)
ting. Bracket to Engine . . . . . . . . . . .47 N·m (35 ft. lbs.)
(2) Remove fitting from pump housing (Fig. 8). Flow Control Valve . . . . . . . . . .75 N·m (55 ft. lbs.)
Prevent flow control valve and spring from Pressure Line . . . . . . . . . . . . . .28 N·m (21 ft. lbs.)
sliding out of housing bore.

Fig. 8 Flow Control Valve

TJ STEERING 19 - 9

SPECIAL TOOLS
POWER STEERING PUMP

Puller C-4333

Analyzer Set, Power Steering Flow/Pressure 6815

Installer, Power Steering Pulley C-4063–B

Adapters, Power Steering Flow/Pressure Tester

6893
19 - 10 STEERING TJ

POWER STEERING GEAR

INDEX
page page

DESCRIPTION AND OPERATION RACK PISTON AND WORM SHAFT . . . . . . . . . . 16

POWER STEERING GEAR . . . . . . . . . . . . . . . . . 10 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING ADJUSTMENTS
POWER STEERING GEAR LEAKAGE STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS
REMOVAL AND INSTALLATION POWER STEERING GEAR . . . . . . . . . . . . . . . . . 20
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 11 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 20
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . 12 POWER STEERING GEAR . . . . . . . . . . . . . . . . . 20
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . . 12

DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING

POWER STEERING GEAR POWER STEERING GEAR LEAKAGE DIAGNOSIS
The power steering gear is a variable ratio recircu-
lating ball type gear (Fig. 1). The ratio is 15:1 on cen-
ter, reducing to 13:1 at the end of travel. The gear
acts as a rolling thread between the worm shaft and
rack piston. The worm shaft is supported by a thrust
bearing at the lower end and a bearing assembly at
the upper end. When the worm shaft is turned the
rack piston moves. The rack piston teeth mesh with
the pitman shaft. Turning the worm shaft turns the
pitman shaft, which turns the steering linkage.

CAUTION: Components attached with a nut and

cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
TJ STEERING 19 - 11
DIAGNOSIS AND TESTING (Continued)

Fig. 1 Recirculating Ball Type Gear

REMOVAL AND INSTALLATION

POWER STEERING GEAR

REMOVAL
(1) Place the front wheels in the straight ahead
position with the steering wheel centered.
(2) Disconnect and cap the fluid hoses/tubes from
power steering pump.
(3) Remove the column coupler shaft from the
gear.
(4) Remove pitman arm from gear.
(5) Remove the steering gear retaining bolts and
remove the gear (Fig. 2).
(6) Remove power steering hoses/tubes from steer-
ing gear.
Fig. 2 Steering Gear Mounting
19 - 12 STEERING TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install power steering hoses/tubes to steering
gear and tighten to 28 N·m (21 ft. lbs.).
(2) Install steering gear on the frame rail and
tighten bolts to 95 N·m (70 ft. lbs.)
(3) Align the column coupler shaft to steering gear
and tighten coupler bolt.
(4) Align and install the pitman arm and tighten
nut to 251 N·m (185 ft. lbs.).
(5) Install power steering hoses/tubes to power
steering pump.
(6) Fill power steering system to proper level, refer
to Steering Pump Initial Operation.

DISASSEMBLY AND ASSEMBLY

HOUSING END PLUG
DISASSEMBLY
(1) Unseat and remove retaining ring from groove
with a punch through the hole in the end of the
housing (Fig. 3).
Fig. 4 End Plug Components
(2) Install end plug by tapping the plug lightly
with a plastic mallet into the housing.
(3) Install retaining ring so one end of the ring
covers the housing access hole (Fig. 5).

Fig. 3 End Plug Retaining Ring

Fig. 5 Installing The Retaining Ring
(2) Slowly rotate stub shaft with 12 point socket
COUNTER-CLOCKWISE to force the end plug out
PITMAN SHAFT/SEALS/BEARING
from housing.
DISASSEMBLY
CAUTION: Do not turn stub shaft any further than (1) Clean exposed end of pitman shaft and housing
necessary. The rack piston balls will drop out of the with a wire brush.
rack piston circuit if the stub shaft is turned too far. (2) Remove preload adjuster nut (Fig. 6).
(3) Remove O-ring from the housing (Fig. 4). (3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
ASSEMBLY (4) Center the stub shaft by rotating it from the
(1) Lubricate O-ring with power steering fluid and stop 1/2 of the total amount of turns.
install into the housing.
TJ STEERING 19 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove side cover bolts and remove side cover, (9) Remove washer from the housing.
gasket and pitman shaft as an assembly (Fig. 6). (10) Remove oil seal from the housing with a seal
pick.
NOTE: The pitman shaft will not clear the housing (11) Remove pitman shaft bearing from housing
if it is not centered. with a bearing driver and handle (Fig. 8).

Fig. 8 Needle Bearing Removal

ASSEMBLY
(1) Install pitman shaft bearing into housing with
Fig. 6 Side Cover and Pitman Shaft
a bearing driver and handle.
(6) Remove pitman shaft from the side cover. (2) Coat the oil seals and washer with grease.
(7) Remove dust seal from the housing with a seal (3) Install the oil seal with a driver and handle.
pick (Fig. 7). (4) Install backup washer.
(5) Install the retainer ring with snap ring pliers.
CAUTION: Use care not to score the housing bore (6) Install dust seal with a driver and handle.
when prying out seals and washer. (7) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(8) Remove retaining ring with snap ring pliers.
(8) Install preload adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(9) Install gasket to side cover and bend tabs
around edges of side cover (Fig. 6).
(10) Install pitman shaft assembly and side cover
to housing.
(11) Install side cover bolts and tighten to 60 N·m
(44 ft. lbs.).
(12) Adjust Over-Center Rotation Torque.

SPOOL VALVE
DISASSEMBLY
(1) Remove lock nut (Fig. 9).
(2) Remove adjuster nut with Spanner Wrench C-4381.
(3) Remove thrust support assembly out of the
Fig. 7 Pitman Shaft Seals & Bearing housing (Fig. 10).
19 - 14 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Pull stub shaft and valve assembly from the (5) Remove stub shaft from valve assembly by
housing (Fig. 11). lightly tapping shaft on a block of wood to loosen
shaft. Then disengage stub shaft pin from hole in
spool valve and separate the valve assembly from
stub shaft (Fig. 12).

Fig. 9 Lock Nut and Adjuster Nut

Fig. 12 Stub Shaft

(6) Remove spool valve from valve body by pulling and
rotating the spool valve from the valve body (Fig. 13).

Fig. 10 Thrust Support Assembly

Fig. 13 Spool Valve

(7) Remove spool valve O-ring and valve body
teflon rings and O-rings underneath the teflon rings
(Fig. 14).
Fig. 11 Valve Assembly With Stub Shaft (8) Remove the O-ring between the worm shaft
and the stub shaft.
TJ STEERING 19 - 15
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 14 Valve Seals Fig. 15 Stub Shaft Installation

ASSEMBLY

NOTE: Clean and dry all components, then lubri-

cate with power steering fluid.

(1) Install spool valve spool O-ring.

(2) Install spool valve in valve body by pushing
and rotating. Hole in spool valve for stub shaft pin
must be accessible from opposite end of valve body.
(3) Install stub shaft in valve spool and engage locat-
ing pin on stub shaft into spool valve hole (Fig. 15).

NOTE: Notch in stub shaft cap must fully engage

valve body pin and seat against valve body shoul-
der.

(4) Install O-rings and teflon rings over the Fig. 16 Stub Shaft Cap O-Ring
O-rings on valve body. NOTE: The thrust support is serviced as an assem-
(5) Install O-ring into the back of the stub shaft bly. If any component of the thrust support is dam-
cap (Fig. 16). aged the assembly must be replaced.
(6) Install stub shaft and valve assembly in the
housing. Line up worm shaft to slots in the valve (8) Install adjuster nut and lock nut.
assembly. (9) Adjust Thrust Bearing Preload and Over-Cen-
(7) Install thrust support assembly. ter Rotating Torque.
19 - 16 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
RACK PISTON AND WORM SHAFT (7) Remove the rack piston and tool together from
housing.
DISASSEMBLY (8) Remove tool from rack piston.
(1) Remove housing end plug. (9) Remove rack piston balls.
(2) Remove rack piston plug (Fig. 17). (10) Remove clamp bolts, clamp and ball guide
(3) Remove side cover and pitman shaft. (Fig. 19).
(11) Remove teflon ring and O-ring from the rack
piston (Fig. 20).

Fig. 19 Rack Piston

Fig. 17 Rack Piston End Plug

(4) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 18) and hold tool tightly against worm shaft.
(6) Turn the stub shaft with a 12 point socket
COUNTERCLOCKWISE, this will force the rack pis-
ton onto the tool and hold the rack piston balls in
place.

Fig. 20 Rack Piston Teflon Ring and O-Ring

(12) Remove the adjuster lock nut and adjuster
nut from the stub shaft.
(13) Pull the stub shaft with the spool valve and
thrust support assembly out of the housing.
(14) Remove the worm shaft from the housing
(Fig. 21).

Fig. 18 Rack Piston with Arbor

TJ STEERING 19 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install remaining balls in guide using grease to
hold the balls in place (Fig. 23).

Fig. 21 Worm Shaft

ASSEMBLY

NOTE: Clean and dry all components and lubricate

with power steering fluid.

(1) Check for scores, nicks or burrs on the rack

piston finished surface. Slight wear is normal on the
worm gear surfaces. Fig. 23 Balls in the Return Guide
(2) Install O-ring and teflon ring on the rack pis- (6) Install the guide onto rack piston and install
ton. clamp and clamp bolts. Tighten bolts to 58 N·m (43
(3) Install worm shaft in the rack piston and align ft. lbs.).
worm shaft spiral groove with rack piston ball guide (7) Insert Arbor C-4175 into bore of rack piston
hole (Fig. 22). and hold tool tightly against worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWISE
while pushing on the arbor. This will force the rack
piston onto the arbor and hold the rack piston balls
in place.
(9) Install the races and thrust bearing on the
worm shaft and install shaft in the housing (Fig. 21).
(10) Install the stub shaft with spool valve, thrust
support assembly and adjuster nut in the housing.
(11) Install the rack piston and arbor tool into the
housing.
(12) Hold arbor tightly against worm shaft and
turn stub shaft CLOCKWISE until rack piston is
seated on worm shaft.
(13) Install pitman shaft and side cover in the
housing.
(14) Install rack piston plug and tighten to 150
Fig. 22 Installing Balls in Rack Piston N·m (111 ft. lbs.).
(15) Install housing end plug.
CAUTION: The rack piston balls must be installed
(16) Adjust worm shaft thrust bearing preload and
alternately into the rack piston and ball guide. This
over-center rotating torque.
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.

(4) Lubricate and install rack piston balls through

return guide hole while turning worm shaft COUN-
TERCLOCKWISE (Fig. 22).
19 - 18 STEERING TJ

ADJUSTMENTS
STEERING GEAR
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.

NOTE: Adjusting the steering gear in the vehicle is

not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.

WORM THRUST BEARING PRELOAD

(1) Mount the gear in a vise.
(2) Remove adjuster plug locknut (Fig. 24).
(3) Rotate the stub shaft back and forth with a 12
point socket to drain the remaining fluid.
Fig. 25 Alignment Marking On Housing

Fig. 24 Loosening the Adjuster Plug Fig. 26 Second Marking On Housing

(4) Turn the adjuster in with Spanner Wrench (8) Install and tighten locknut to 108 N·m (80 ft.
C-4381. Tighten the plug and thrust bearing in the lbs.). Be sure adjustment cap does not turn while
housing until firmly bottomed in housing. tightening the locknut.
(5) Place an index mark on the housing even with
one of the holes in adjuster plug (Fig. 25). OVER-CENTER
(6) Measure back (counterclockwise) 13 mm (0.50
NOTE: Before performing this procedure, the worm
in) and mark housing (Fig. 26).
bearing preload adjustment should be performed.
(7) Rotate adjustment cap back (counterclockwise)
with spanner wrench until hole is aligned with the (1) Rotate the stub shaft with a 12 point socket
second mark (Fig. 27). from stop to stop and count the number of turns.
TJ STEERING 19 - 19
ADJUSTMENTS (Continued)
NOTE: The stub shaft must rotate smoothly without
not sticking or binding.

(4) Rotate the stud shaft between 90° and 180° to

the left of center and record the left off-center pre-
load. Repeat this to the right of center and record the
right off-center preload. The average of these two
recorded readings is the Preload Rotating Torque.
(5) The Over-Center Rotating Torque should be
0.45 – 0.9 N·m (4 – 8 in. lbs.) higher than the Pre-
load Rotating Torque.
(6) If an adjustment to the Over-Center Rotating
Torque is necessary, first loosen the adjuster lock
nut. Then turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until fully extended, then
turn back in (CLOCKWISE) one full turn.

Fig. 27 Aligning To The Second Mark

(2) Starting at either stop, turn the stub shaft
back 1/2 the total number of turns. This is the center
of the gear travel (Fig. 28).

Fig. 29 Checking Over-center Rotation Torque

(7) Remeasure Over-Center Rotating Torque. If
necessary turn the adjuster screw and repeat mea-
surement until correct Over-Center Rotating Torque
is reached.

NOTE: To increase the Over-Center Rotating Torque

turn the screw CLOCKWISE.

(8) Prevent the adjuster screw from turning while

Fig. 28 Steering Gear Centered tightening adjuster lock nut. Tighten the adjuster
(3) Place the torque wrench in the vertical position lock nut to 49 N·m (36 ft. lbs.).
on the stub shaft. Rotate the wrench 45 degrees each
side of the center and record the highest rotational
torque in this range (Fig. 29). This is the Over-Cen-
ter Rotating Torque.
19 - 20 STEERING TJ

SPECIFICATIONS SPECIAL TOOLS

POWER STEERING GEAR POWER STEERING GEAR

Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . .Recirculating Ball
Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . .15 to 13:1
Worm Shaft Bearing
Preload. . . . . . . . . . . .0.45–1.13 N·m (4–10 in. lbs.)
Pitman Shaft Over-Center Drag
New Gear
(under 400 miles). . . . . . . . . . . . . . .0.45–0.90 N·m
(4–8 in. lbs.)
+ Worm Shaft Preload Remover/Installer, Steering Plug C-4381
Used Gear
(over 400 miles) . . . . . . . . . . . . . . . . . .0.5–0.6 N·m
(4–5 in. lbs.)
+ Worm Shaft Preload

TORQUE CHART

DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut. . . . .108 N·m (80 ft. lbs.)
Adjustment Screw Locknut . . . .49 N·m (36 ft. lbs.) Remover, Pitman Arm C-4150A
Gear to Frame Bolts . . . . . . . . .95 N·m (70 ft. lbs.)
Pitman Shaft Nut . . . . . . . . .251 N·m (185 ft. lbs.)
Rack Piston Plug . . . . . . . . . . .102 N·m (75 ft. lbs.)
Side Cover Bolts . . . . . . . . . . . .60 N·m (44 ft. lbs.)
Pressure Line . . . . . . . . . . . . . .28 N·m (21 ft. lbs.)
Return Line . . . . . . . . . . . . . . . .28 N·m (21 ft. lbs.)

Remover/Installer Steering Rack Piston C-4175

TJ STEERING 19 - 21

MANUAL STEERING GEAR

INDEX
page page

DESCRIPTION AND OPERATION WORM SHAFT AND BALL NUT . . . . . . . . . . . . . 24

MANUAL STEERING GEAR . . . . . . . . . . . . . . . . 21 ADJUSTMENTS
DIAGNOSIS AND TESTING OVER-CENTER PRELOAD . . . . . . . . . . . . . . . . . 26
MANUAL STEERING SYSTEM . . . . . . . . . . . . . . 22 WORM BEARING PRELOAD . . . . . . . . . . . . . . . 26
REMOVAL AND INSTALLATION SPECIFICATIONS
MANUAL STEERING GEAR . . . . . . . . . . . . . . . . 22 MANUAL STEERING GEAR . . . . . . . . . . . . . . . . 27
DISASSEMBLY AND ASSEMBLY TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 27
PITMAN SHAFT, SEAL AND COVER . . . . . . . . . 23 SPECIAL TOOLS
WORM BEARING ADJUSTER . . . . . . . . . . . . . . . 26 MANUAL STEERING GEAR . . . . . . . . . . . . . . . . 27

DESCRIPTION AND OPERATION mounted on the worm and the balls act as a rolling
thread between the worm and nut. Teeth on the ball
MANUAL STEERING GEAR nut engage teeth on the pitman shaft. The teeth on
The manual steering gear is a recirculating-ball, the ball nut are made to fit tighter between the ball
nut and worm type (Fig. 1). The worm is located on nut and pitman shaft when the front wheels are posi-
the lower end of the worm shaft. The ball nut is tion straight ahead.

Fig. 1 Manual Steering Gear

19 - 22 STEERING TJ

DIAGNOSIS AND TESTING

MANUAL STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

RATTLE OR CHUCKLE IN 1. Insufficient lubricant in gear. 1. Add lubricant as required.
STEERING GEAR. 2. Loose or damaged suspension 2. Inspect and repair as necessary.
components.
3. Pitman arm or steering gear 3. Tighten to specifications.
loose.
4. Loose or worn steering shaft 4. Replace bearing.
bearing.
5. Excessive over-center lash. 5. Adjust steering to specifications.
POOR STEERING WHEEL 1. Insufficient lubricate. 1. Add lubricate as required.
RETURN. 2. Steering gear adjusted too tight. 2. Adjust steering gear to
specifications.
3. Vehicle out of alignment. 3. Align vehicle to specifications.
4. Worn or binding steering linkage. 4. Inspect and repair as necessary.
EXCESSIVE STEERING WHEEL 1.Vehicle out of alignment. 1. Align vehicle to specifications.
PLAY 2. Worn or loose wheel bearings. 2. Replace or adjust wheel bearings.
3. Worn or loose steering 3. Inspect and repair as necessary.
components.
4. Improper steering gear 4. Adjust steering gear to
adjustment. specifications.
EXCESSIVE STEERING WHEEL 1. Low or uneven tire pressure. 1. Inflate tires to specifications.
EFFORT. 2. Vehicle out of alignment. 2. Align vehicle to specifications.
3. Improper steering gear 3. Adjust steering gear to
adjustment. specifications.
4. Lack of lubricant to steering 4. Lubricate steering linkage and
linkage or suspension components. suspension components.

NOTE: On turns a slight rattle may occur from the

steering gear. This is caused by increased gear
tooth clearance between the ball nut and pitman
shaft as the gear moves off center of the high point
position. This is normal and lash must not be
reduced to eliminate this slight rattle.

REMOVAL AND INSTALLATION

MANUAL STEERING GEAR
REMOVAL
(1) Raise and support vehicle.
(2) Remove tie rod from pitman arm with puller
(Fig. 2). Fig. 2 Tie Rod End
(3) Remove pitman arm with Remover C-4150A.
(4) Remove gear mounting bolts and remove gear
(Fig. 3).
TJ STEERING 19 - 23
REMOVAL AND INSTALLATION (Continued)

Fig. 3 Steering Gear

INSTALLATION
(1) Install gear on frame rail and install mounting
bolts.
(2) Tighten mounting bolts to 95 N·m (70 ft. lbs.).
(3) Install pitman arm and tighten mounting nut
to 251 N·m (185 ft. lbs.).
(4) Install tie rod end on pitman arm and tighten
nut to 74 N·m (55 ft. lbs.). Install cotter pin.
Fig. 4 Manual Steering Gear
(5) Remove support and lower vehicle.

DISASSEMBLY AND ASSEMBLY

PITMAN SHAFT, SEAL AND COVER
DISASSEMBLY
(1) Remove steering gear from the vehicle.
(2) Center the steering gear.
(3) Remove pitman shaft preload adjustment lock-
nut (Fig. 4).
(4) Remove cover bolts and remove cover.
(5) Remove preload adjuster and shim(s) from pit-
man shaft T-slot (Fig. 4).
(6) Remove pitman shaft from the gear housing.
(7) Pry out pitman shaft seal (Fig. 5).

ASSEMBLY
(1) Install new pitman shaft seal with suitable size
socket.
(2) Install preload adjuster in pitman shaft T-slot.
(3) Measure the end-play of preload adjuster with Fig. 5 Pitman Shaft Seal
a feeler gauge (Fig. 6). End-play must not exceed .05
mm (.002 in.). If end-play exceeds specifications (6) Install the cover gasket and cover on the hous-
install replacement shim to obtain correct end-play. ing. Thread preload adjuster counter-clockwise into
(4) Tape threads and spline of the pitman shaft to the cover until the cover makes contact with the
protect the seal during shaft installation. housing.
(5) Lubricate the pitman shaft and install the (7) Install cover bolts finger tight, then back off
shaft into the gear housing. The pitman shaft center adjuster 1/2 turn.
tooth must be engaged with the center groove of the (8) Tighten cover bolts to 61 N·m (45 ft. lbs.).
ball nut (Fig. 7). (9) Adjust over-center preload.
19 - 24 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Install steering gear. be damaged if ball nut is stopped by the end of the
worm.

(4) Pry worm shaft seal out of the gear housing.

(5) Remove ball guide clamp screws and clamp.
(6) Separate the guides and remove balls from the
guides. Remove the remaining balls by rotating the
worm shaft back and forth.

NOTE: There are 50 balls, 25 in each circuit of the

ball nut.

(7) Remove the ball nut from the worm shaft.

(8) Remove upper worm shaft bearing cup from
the gear housing with a brass punch (Fig. 9).
(9) Clean and inspect all components for wear,
scoring, and pitting.

Fig. 6 Preload Adjuster End-Play

Fig. 8 Worm Shaft and Ball Nut

Fig. 7 Pitman Shaft and Ball Nut

WORM SHAFT AND BALL NUT
DISASSEMBLY
(1) Remove the pitman shaft.
(2) Remove the worm bearing adjuster locknut and
adjuster (Fig. 8).
(3) Remove worm shaft and ball nut.

CAUTION: Do not allow ball nut to run down to

Fig. 9 Upper Bearing Cup
either end of the worm shaft. The ball guides may
TJ STEERING 19 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Install ball nut onto the worm shaft until an
equal amount of threads are showing on either side
of the ball nut (Fig. 10).
(2) Install one ball into each ball nut guide hole.
Move worm shaft around until the balls roll to the
bottom of the worm shaft and support the shaft.
(3) Assemble and install ball guides into ball nut.
(4) Install the remaining balls into the guide holes
(Fig. 11). Each guide has a total of 25 balls.
(5) Install the guide clamp and tighten screws to
14 N·m (10 ft. lbs.)
(6) Lubricate worm shaft with chassis lubricate
and thread worm shaft in and out of the ball nut to
lubricate balls.
(7) Install upper bearing cup into gear housing
with a bearing cup driver (Fig. 12).
(8) Install worm shaft seal into gear housing.
(9) Lubricate upper bearing and install on the
worm shaft. Fig. 11 Ball Nut Guide Holes
(10) Install worm shaft into the steering gear.

NOTE: Wide/deep side of the ball nut teeth face the

cover opening.

(11) Install worm shaft adjuster cap and adjust

shaft to zero end-play. Install adjuster locknut.
(12) Install pitman shaft and fill gear with lubri-
cate.
(13) Adjust worm bearing preload and over-center
preload.

Fig. 12 Upper Bearing Cup Installation

Fig. 10 Worm Shaft and Ball Nut

19 - 26 STEERING TJ
DISASSEMBLY AND ASSEMBLY (Continued)
WORM BEARING ADJUSTER ADJUSTMENTS
DISASSEMBLY WORM BEARING PRELOAD
(1) Pry out the lower bearing retainer (Fig. 13). (1) Tighten the worm bearing adjuster plug until it
(2) Remove lower bearing (Fig. 14). bottoms, then loosen 1/4 turn.
(3) Place locknut on the adjuster and place in a (2) Turn the stub shaft/worm shaft with a 12 point
vise. Remove lower bearing cup with Puller 7794–A socket all the way to the end of travel, then turn
and a slid hammer. back 1/2 turn.
(3) Tighten adjuster plug until torque to turn the
stub shaft/worm shaft is 0.6 to 1.0 N·m (5 to 8 in.
lbs.) (Fig. 15).
(4) Tighten the adjuster plug locknut to 68 N·m
(50 ft. lbs.).

Fig. 13 Lower Bearing Retainer

Fig. 15 Worm Bearing Preload

OVER-CENTER PRELOAD
NOTE: Adjust worm bearing preload before adjust-
ing over-center preload if worm shaft was serviced.
(1) Back off preload adjuster until it stops, then
turn it in one full turn.
(2) With gear at center of travel, check torque to
turn stub shaft/worm shaft and record this reading
(Fig. 16).
(3) Turn adjuster in until torque to turn stub
Fig. 14 Lower Bearing Cup shaft/worm shaft is 0.5 to 1 N·m (4 to 10 in. lbs.)
more than recorded reading.
ASSEMBLY (4) Hold pitman shaft adjustment screw and
(1) Install lower bearing cup with a bearing cup tighten adjuster lock nut to 34 N·m (25 ft. lbs.).
driver.
(2) Lubricate lower bearing and install into the
adjuster.
(3) Install the retainer by tapping it in with a
plastic hammer.
TJ STEERING 19 - 27
ADJUSTMENTS (Continued)
TORQUE CHART

DESCRIPTION TORQUE
Manual Steering Gear
Adjustment Cap Locknut. . . . . .68 N·m (50 ft. lbs.)
Adjustment Screw Locknut . . . .34 N·m (25 ft. lbs.)
Pitman Shaft Nut . . . . . . . . .251 N·m (185 ft. lbs.)
Guide Clamp Screws . . . . . . . . .14 N·m (10 ft. lbs.)
Cover Bolts . . . . . . . . . . . . . . . .61 N·m (45 ft. lbs.)
Gear to Frame Bolts . . . . . . . .105 N·m (78 ft. lbs.)

SPECIAL TOOLS
MANUAL STEERING GEAR

Fig. 16 Over-Center Preload

SPECIFICATIONS
Remover C-41509A
MANUAL STEERING GEAR

Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . .Recirculating Ball
Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . .24:1
Worm Shaft Bearing
Preload . . . . . . . . . . . . . .0.6–1.0 N·m (5–8 in. lbs.)
Pitman Shaft Over-Center Drag
Preload . . . . . . . . . . . . .0.5–1.0 N·m (4–10 in. lbs.)
+ Worm Shaft Preload

Puller 7794–A
19 - 28 STEERING TJ

STEERING COLUMN

INDEX
page page

GENERAL INFORMATION SPECIFICATIONS

STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 28 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 29

GENERAL INFORMATION WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
STEERING COLUMN ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
The standard non-tilt and tilt steering column has THE AIRBAG SYSTEM COMPONENTS YOU MUST
been designed to be serviced as an assembly. The key FIRST DISCONNECT AND ISOLATE THE BATTERY
cylinder, switches, clock spring, trim shrouds and NEGATIVE (GROUND) CABLE. THEN WAIT TWO
steering wheel are serviced separately. On the non- MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
tilt column the upper mounting bracket is also ser- CHARGE. FAILURE TO DO SO COULD RESULT IN
viced separately. ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
The column is connected to the steering gear with POSSIBLE PERSONAL INJURY. THE FASTENERS,
an upper and lower shaft. The lower shaft has a sup- SCREWS, AND BOLTS, ORIGINALLY USED FOR
port bearing mounted to a bracket. The bracket THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
mounts to the frame rail with two bolts. These shafts INGS AND ARE SPECIFICALLY DESIGNED FOR THE
and bearing are serviceable. AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
SERVICE PRECAUTIONS NEW FASTENER IS NEEDED, REPLACE WITH THE
Safety goggles should be worn at all times when CORRECT FASTENERS PROVIDED IN THE SERVICE
working on steering columns. PACKAGE OR FASTENERS LISTED IN THE PARTS
To service the steering wheel, switches or airbag, BOOKS.
refer to Group 8M and follow all WARNINGS and
CAUTIONS.
TJ STEERING 19 - 29

REMOVAL AND INSTALLATION (5) Turn ignition cylinder to the on position and
remove cylinder by pressing release through lower
STEERING COLUMN shroud access hole (Fig. 2).
(6) Remove knee blocker cover and knee blocker,
WARNING: BEFORE SERVICING THE STEERING refer to Group 8E Instrument Panel Systems.
COLUMN THE AIRBAG SYSTEM MUST BE DIS- (7) Remove lower column shroud (Fig. 3).
ARMED. REFER TO GROUP 8M RESTRAINT SYS- (8) Remove the steering coupler bolt and column
TEMS FOR SERVICE PROCEDURES. FAILURE TO mounting nuts (Fig. 4) and lower column.
DO SO MAY RESULT IN ACCIDENTAL DEPLOY- (9) Remove upper column shroud (Fig. 3).
MENT OF THE AIRBAG AND POSSIBLE PERSONAL (10) Disconnect and remove the wiring harness
INJURY. from the column (Fig. 5).

NOTE: If vehicle is equipped with automatic trans-

REMOVAL mission, remove shifter interlock cable. Refer to
(1) Position front wheels straight ahead. Group 21 Transmission and Transfer Case for pro-
(2) Remove negative ground cable from the bat- cedure.
tery.
(3) Remove the airbag, refer to Group 8M (11) Remove column.
Restraint Systems for service procedures. (12) Remove the nut and bolt from the upper col-
(4) Remove the steering wheel with an appropriate umn mounting bracket on non-tilt column (Fig. 6).
puller (Fig. 1). Remove the bracket from the column and note the
bracket location.
CAUTION: Ensure the puller bolts are fully engaged (13) Remove clock spring and all switches, refer to
into the steering wheel before attempting to remove Group 8 Electrical for service procedures.
the wheel. Failure to do so may damage the steer-
ing wheel.

Fig. 2 Key Cylinder Release Access Hole

Fig. 1 Steering Wheel

19 - 30 STEERING TJ
REMOVAL AND INSTALLATION (Continued)

Fig. 5 Steering Column Harness

Fig. 3 Column Shrouds

Fig. 4 Steering Column Mounting Fig. 6 Non-Tilt Column

INSTALLATION (5) Install upper column shrouds.
(1) Install upper column mounting bracket on non- (6) Install column onto the mounting studs.
tilt column. Install the mounting bolt and tighten the (7) Install mounting nuts and tighten to 23 N·m
nut to 17 N·m (150 in. lbs.). (17 ft. lbs.).
(2) Install switches and clock spring, refer to (8) Install steering column coupler bolt and tighten
Group 8 Electrical for service procedures. to 49 N·m (36 ft. lbs.).
(3) Align and install column into the steering cou- (9) Install lower column shrouds.
pler. (10) Install ignition cylinder.
(4) Install column harness and connect harness to (11) Install knee blocker and knee blocker cover,
switches. refer to Group 8E Instrument Panel Systems.
(12) Install steering wheel.
NOTE: If vehicle is equipped with automatic trans- (13) Install airbag, refer to Group 8M Restraint
mission, install shifter interlock cable. Refer to Systems for service procedures.
Group 21 Transmission and Transfer Case for pro- (14) Install negative battery terminal.
cedure.
TJ STEERING 19 - 31

SPECIFICATIONS DESCRIPTION TORQUE

Non-Tilt Steering Column
TORQUE CHART Steering Wheel Nut. . . . . . . . . .54 N·m (40 ft. lbs.)
Mounting Nuts . . . . . . . . . . . . .23 N·m (17 ft. lbs.)
DESCRIPTION TORQUE Coupler Bolt . . . . . . . . . . . . . . .49 N·m (36 ft. lbs.)
Tilt Steering Column Upper Bracket Nut . . . . . . . . .17 N·m (150 in. lbs.)
Steering Wheel Nut. . . . . . . . . .54 N·m (40 ft. lbs.)
Mounting Nuts . . . . . . . . . . . . .23 N·m (17 ft. lbs.)
Coupler Bolt . . . . . . . . . . . . . . .49 N·m (36 ft. lbs.)
19 - 32 STEERING TJ

STEERING LINKAGE

INDEX
page page

GENERAL INFORMATION STEERING DAMPENER . . . . . . . . . . . . . . . . . . . 33

STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 32 TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SERVICE PROCEDURES SPECIFICATIONS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 32 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL AND INSTALLATION SPECIAL TOOLS
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 34
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

GENERAL INFORMATION SERVICE PROCEDURES

STEERING LINKAGE STEERING LINKAGE
The steering linkage consists of a pitman arm, The tie rod end and ball stud seals should be
drag link, tie rod, and steering dampener (Fig. 1). inspected during all oil changes. If a seal is damaged,
Adjustment sleeves are used on the tie rod and drag it should be replaced. Before installing a new seal,
link for toe and steering wheel alignment. inspect ball stud at the throat opening. Check for
lubricant loss, contamination, ball stud wear or cor-
CAUTION: Components attached with a nut and rosion. If these conditions exist, replace the tie rod. A
cotter pin must be torqued to specification. Then if replacement seal can be installed if lubricant is in
the slot in the nut does not line up with the cotter good condition. Otherwise, a complete replacement
pin hole, tighten nut until it is aligned. Never loosen ball stud end should be installed.
the nut to align the cotter pin hole.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
NOTE: Periodic lubrication of the steering system ensure the vehicle meets all alignment specifica-
components is required. Refer to Group 0, Lubrica- tions.
tion And Maintenance for the recommended mainte-
nance schedule.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.

REMOVAL AND INSTALLATION

TIE ROD
REMOVAL
(1) Remove the cotter pins and nuts at the steer-
ing knuckle and drag link (Fig. 1).
(2) Remove the ball studs with puller tool.
(3) If necessary, loosen the end clamp bolts and
Fig. 1 Steering Linkage remove the tie rod ends from the tube.
TJ STEERING 19 - 33
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) If necessary, install the tie rod ends in the
tube. Position the tie rod clamp (Fig. 2) and tighten
to 27 N·m (20 ft. lbs.).
(2) Install the tie rod on the drag link and steering
knuckle.
(3) Tighten the ball stud nut on the steering
knuckle to 47 N·m (35 ft. lbs.). Tighten the ball stud
nut to drag link to 47 N·m (35 ft. lbs.) torque. Install
new cotter pins.

Fig. 3 Pitman Arm Removal

(3) Remove the drag link from the steering
knuckle with a puller tool. Remove the same for tie
rod and pitman arm.
Fig. 2 Tie Rod/Drag Link Clamp Bolt (4) If necessary, loosen the end clamp bolts and
remove the tie rod end from the link.
PITMAN ARM
INSTALLATION
REMOVAL (1) Install the drag link adjustment sleeve and tie
(1) Remove the cotter pin and nut from the drag rod end. Position clamp bolts (Fig. 2).
link at the pitman arm. (2) Position the drag link at the steering linkage.
(2) Remove the drag link ball stud from the pit- Install the drag link to the steering knuckle nut. Do
man arm with a puller. the same for the tie rod and pitman arm.
(3) Remove the nut and washer from the steering (3) Tighten the nut at the steering knuckle to 47
gear shaft. Mark the pitman shaft and pitman arm N·m (35 ft. lbs.). Tighten the pitman nut to 81 N·m
for installation reference. Remove the pitman arm (60 ft. lbs.) and tie rod ball stud nut to 47 N·m (35 ft.
from steering gear with Puller C-4150A (Fig. 3). lbs.). Install new cotter pins and bend end 60°.
(4) Install the steering dampener onto the drag
INSTALLATION link and tighten the nut to 74 N·m (55 ft. lbs.).
(1) Align and install the pitman arm on steering Install a new cotter pin and bend end 60°.
gear shaft.
(2) Install the washer and nut on the shaft and STEERING DAMPENER
tighten the nut to 251 N·m (185 ft. lbs.).
(3) Install drag link ball stud to pitman arm. REMOVAL
Install nut and tighten to 81 N·m (60 ft. lbs.). Install (1) Place the front wheels in a straight ahead posi-
a new cotter pin. tion.
(2) Remove the steering dampener retaining nut
DRAG LINK and bolt from the axle bracket (Fig. 1).
(3) Remove the cotter pin and nut from the ball
REMOVAL stud at the drag link.
(1) Remove the cotter pins and nuts at the steer- (4) Remove the steering dampener ball stud from
ing knuckle and drag link (Fig. 1). the drag link using C-3894-A puller.
(2) Remove the steering dampener ball stud from
the drag link with a puller tool.
19 - 34 STEERING TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION SPECIAL TOOLS
(1) Install the steering dampener to the axle
bracket and drag link. STEERING LINKAGE
(2) Install the steering dampener bolt in the axle
bracket and tighten nut to 74 N·m (55 ft. lbs.).
(3) Install the ball stud nut at the drag link and
tighten nut to 74 N·m (55 ft. lbs.). Install a new cot-
ter pin.

SPECIFICATIONS
TORQUE CHART

DESCRIPTION TORQUE Puller C-3894–A

Pitman Arm
Shaft . . . . . . . . . . . . . . . . . . .251 N·m (185 ft. lbs.)
Drag Link
Ball Studs . . . . . . . . . . . . . . . . .74 N·m (55 ft. lbs.)
Clamp . . . . . . . . . . . . . . . . . . . .49 N·m (36 ft. lbs.)
Tie Rod Ends
Ball Studs . . . . . . . . . . . . . . . . .74 N·m (55 ft. lbs.)
Clamp . . . . . . . . . . . . . . . . . . . .27 N·m (20 ft. lbs.)
Tie Rod
Ball Stud . . . . . . . . . . . . . . . . . .88 N·m (65 ft. lbs.)
Steering Damper Remover Pitman C-4150A
Frame . . . . . . . . . . . . . . . . . . . .74 N·m (55 ft. lbs.)
Drag Link . . . . . . . . . . . . . . . . .74 N·m (55 ft. lbs.)