ZJ STEERING 19 - 1

STEERING
CONTENTS

page page

POWER STEERING GEAR . . . . . . . . . . . . . . . . . . . 9 SPEED PROPORTIONAL STEERING . . . . . . . . . . 25

POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 4 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 21
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . 1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 28

POWER STEERING

INDEX
page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

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

GENERAL INFORMATION
STEERING SYSTEM
The power steering system consists of;
• Hydraulic pump
• Recirculating ball steering gear
• Steering column
• Steering linkage

Power Steering Gear & Pump

19 - 2 STEERING ZJ

DIAGNOSIS AND TESTING at a standstill parking. Or when the steering wheel

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

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR 1. Damaged steering coupler 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 components. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Pump flow control valve. 5. Test and replace if necessary.
6. Column coupler binding. 6. Replace coupler.
7. Steering gear worn or out of 7. Repair or replace gear.
adjustment.
ZJ 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. Test and repair as necessary.
6. Internal gear leak. 6. Test and repair as necessary.
STEERING WHEEL DOES NOT 1. Tire pressure. 1. Adjust tire pressure.
WANT TO RETURN TO CENTER 2. Wheel alignment. 2. Align front end.
POSITION 3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and repair as necessary.

LOOSE STEERING AND VEHICLE LEAD

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Inspect and repair as necessary.
WHEEL steering components.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear to specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO 1. Radial tire lead. 1. Rotate tires.
ONE SIDE. 2. Brakes dragging. 2. Repair as necessary.
3. Wheel alignment. 3. Align front end.
19 - 4 STEERING ZJ

POWER STEERING PUMP

INDEX
page page

DESCRIPTION AND OPERATION POWER STEERING PUMP — 5.2L ........... 6

POWER STEERING PUMP . . . . . . . .......... 4 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING PUMP PULLEY . . . . . . . . . . . . . . . ........... 7
POWER STEERING PUMP . . . . . . . .......... 4 TC-SERIES PUMP RESERVOIR . . . ........... 7
PUMP LEAKAGE DIAGNOSIS . . . . . .......... 5 SPECIFICATIONS
SERVICE PROCEDURES TORQUE CHART . . . . . . . . . . . . . . ........... 8
POWER STEERING PUMP—INITIAL SPECIAL TOOLS
OPERATION . . . . . . . . . . . . . . . . . .......... 5 POWER STEERING PUMP . . . . . . ........... 8
REMOVAL AND INSTALLATION
POWER STEERING PUMP — 4.0L . .......... 6

DESCRIPTION AND OPERATION

POWER STEERING PUMP
Hydraulic pressure is provided for operation of the power
steering gear by a belt driven power steering pump. The
power steering pump is a constant flow rate and displace-
ment, vane-type pump. The internal parts in the housing
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.
The power steering pump is connected to the steering
gear by the pressure and return hoses. The pump shaft has
a pressed-on drive pulley that is belt driven by the crank-
shaft pulley (Fig. 1).

NOTE: Power steering pumps have different pressure

rates and are not interchangeable with other pumps.

DIAGNOSIS AND TESTING

Fig. 1 TC Series Pump With Integral Reservoir
POWER STEERING PUMP
The following procedure is used to test the operation of
the power steering system on the vehicle. This test will
provide the flow rate of the power steering pump along
with the maximum relief pressure. Perform test any time a
power steering system problem is present. This test will
determine if the power steering pump or power steering
gear is not functioning properly. The following pressure
and flow test is performed using Pressure/Flow tester, Spe-
cial Tool 6815 (Fig. 2).

Fig. 2 Pressure Test Gauge

ZJ STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
POWER STEERING PUMP PRESSURE TEST PUMP LEAKAGE DIAGNOSIS
(1) Check belt tension and adjust as necessary.
(2) Disconnect high pressure hose at gear or pump.
Use a container for dripping fluid.
(3) Connect pressure gauge from Power Steering
Analyzer Tool kit 6815 to both hoses using appropri-
ate adapter. Connect spare pressure hose to gear or
pump.
(4) Open the test valve completely.
(5) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test
gauge and to get air out of the fluid. Then shut off
engine.
(6) Check fluid level, add fluid as necessary. Start
engine again and let idle.
(7) 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).

CAUTION: The following test procedure involves

testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than five seconds as the pump could be
damaged.

(8) Close valve fully three times and record high-

est pressure indicated each time. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
• Pressures above specifications but not within SERVICE PROCEDURES
345 kPa (50 psi) of each other, replace pump.
• Pressures within 345 kPa (50 psi) of each other POWER STEERING PUMP—INITIAL OPERATION
but below specifications, replace pump.
CAUTION: The fluid level should be checked with
NOTE: Refer to pump relief pressure chart. engine off to prevent injury from moving compo-
nents. Use MOPAR Power Steering Fluid or equiva-
lent. Do not use automatic transmission fluid and
CAUTION: Do not force the pump to operate do not overfill.
against the stops for more than 2 to 4 seconds at a
time because, pump damage will result. Wipe filler cap clean, then check the fluid level.
The dipstick should indicate COLD when the fluid is
(9) Open the test valve, turn steering wheel at normal temperature.
extreme left and right positions against the stops. (1) Fill the pump fluid reservoir to the proper level
Record the highest indicated pressure at each posi- and let the fluid settle for at least two (2) minutes.
tion. Compare readings to specifications. If highest (2) Start the engine and let run for a few seconds
output pressures are not the same against either then turn engine off.
stop, the gear is leaking internally and must be (3) Add fluid if necessary. Repeat the above proce-
repaired. dure until the fluid level remains constant after run-
ning the engine.
ENGINE RELIEF PRESSURE 6 50 (4) Raise the front wheels off the ground.
4.0L 9653 kPa (1400 psi) (5) Slowly turn the steering wheel right and left,
5.2L 9653 kPa (1400 psi) lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
19 - 6 STEERING ZJ
SERVICE PROCEDURES (Continued)
(8) Stop the engine and check the fluid level and (8) Add power steering fluid. Refer to Power Steer-
refill as required. ing Pump Initial Operation in this section.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the procedure. POWER STEERING PUMP — 5.2L
REMOVAL
REMOVAL AND INSTALLATION (1) Remove the serpentine drive belt. Refer to
Group 7 Cooling.
POWER STEERING PUMP — 4.0L (2) Remove the pressure and return hoses from
pump and drain pump.
REMOVAL (3) Vehicles equipped with Speed Proportional
(1) Remove serpentine drive belt, refer to Group 7 Steering, disconnect actuator harness.
Cooling. (4) Remove pump mounting bolts and remove the
(2) Vehicles equipped with Speed Proportional pump (Fig. 4).
Steering, disconnect actuator harness. (5) Remove pulley from pump.
(3) Remove pressure and return hoses from pump
and drain pump.
(4) Remove 3 pump mounting bolts through pulley
access holes.
(5) Loosen the 3 pump bracket bolts (Fig. 3).
(6) Tilt pump downward and remove from engine.
(7) Remove pulley from pump.

INSTALLATION
(1) Install pulley on pump.
(2) Install pump on engine.
(3) Tighten pump bracket bolts to 47 N·m (35 ft.
lbs.).
(4) Install 3 pump mounting bolts and tighten to
27 N·m (20 ft. lbs.).
(5) Install the pressure and return hoses to pump.
(6) Vehicles equipped with Speed Pro Steering,
connect actuator harness. Fig. 4 Power Steering Pump — 5.2L
(7) Install drive belt, refer to Group 7 Cooling.

Fig. 3 Pump Mounting

ZJ STEERING 19 - 7
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install pulley on pump.
(2) Mount pump on bracket and install bolts.
Tighten bolts to 27 N·m (20 ft. lbs.).
(3) Install the pressure and return hoses to pump.
(4) Vehicles equipped with Speed Pro Steering,
connect actuator harness.
(5) Install drive belt, refer to Group 7 Cooling.
(6) Add power steering fluid. Refer to Power Steer-
ing Pump Initial Operation in this section.

DISASSEMBLY AND ASSEMBLY

PUMP PULLEY
REMOVAL
Fig. 6 Pulley Installation
(1) Remove pump assembly.
(2) Remove pulley from pump with Puller C-4333 (4) Pry up tab and slide the retaining clips off (Fig.
(Fig. 5). 7).

Fig. 5 Pulley Removal

INSTALLATION
(1) Replace pulley if bent, cracked, or loose.
(2) Install pulley on pump with Installer C-4063-B
(Fig. 6) flush with the end of the shaft. Ensure the
tool and pulley remain aligned with the pump shaft. Fig. 7 Pump Reservoir Clips
(3) Install pump assembly.
(4) With Serpentine Belts; Run engine until warm (5) Remove fluid reservoir from pump body.
(5 min.) and note any belt chirp. If chirp exists, move Remove and discard O-ring seal.
pulley outward approximately 0.5 mm (0.020 in.). If
INSTALLATION
noise increases, press on 1.0 mm (0.040 in.). Be
(1) Lubricate new O-ring Seal with Mopar Power
careful that pulley does not contact mounting
Steering Fluid or equivalent.
bolts.
(2) Install O-ring seal in housing.
(3) Install reservoir onto housing.
TC-SERIES PUMP RESERVOIR
(4) Slide and tap in reservoir retainer clips until
REMOVAL tab locks to housing.
(1) Remove power steering pump. (5) Install power steering pump. Refer to Pump
(2) Clean exterior of pump with solvent. Replacement in this section.
(3) Clamp the pump body in a soft jaw vice.
19 - 8 STEERING ZJ

SPECIFICATIONS
TORQUE CHART

DESCRIPTION TORQUE
Power Steering Pump
Bracket Bolts. . . . . . . . . . . . . . .41 N·m (30 ft. lbs.)
Pump Bolts . . . . . . . . . . . . . . . .27 N·m (20 ft. lbs.)
Flow Control Valve . . . . . . . . . .75 N·m (55 ft. lbs.)
Pressure Line . . . . . . . . . . . . . .28 N·m (21 ft. lbs.)
Puller C-4333
SPECIAL TOOLS
POWER STEERING PUMP

Installer, Power Steering Pulley C-4063–B

Analyzer Set, Power Steering Flow/Pressure 6815

Adapters, Power Steering Flow/Pressure Tester

6893
ZJ STEERING 19 - 9

POWER STEERING GEAR

INDEX
page page

DESCRIPTION AND OPERATION PITMAN SHAFT SEALS AND BEARING . . . . . . . 17

POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 9 PITMAN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING RACK PISTON AND WORM SHAFT . . . . . . . . . . 15
POWER STEERING GEAR LEAKAGE SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ADJUSTMENTS
REMOVAL AND INSTALLATION STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 18
PITMAN SHAFT SEALS (IN VEHICLE) . . . . . . . . 10 SPECIFICATIONS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 10 POWER STEERING GEAR . . . . . . . . . . . . . . . . . 19
DISASSEMBLY AND ASSEMBLY TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 20
ADJUSTER PLUG ASSEMBLY . . . . . . . . . . . . . . 12 SPECIAL TOOLS
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . 11 POWER STEERING GEAR . . . . . . . . . . . . . . . . . 20

DESCRIPTION AND OPERATION at the upper end. When the worm shaft is turned the
rack piston moves. The rack piston teeth mesh with the
POWER STEERING GEAR pitman shaft. Turning the worm shaft turns the pitman
The power steering gear is a recirculating ball type shaft, which turns the steering linkage.
gear. The gear acts as a rolling thread between the worm The steering gear can be adjusted and internally
shaft and rack piston. The worm shaft is supported by a serviced.
thrust bearing at the lower end and a bearing assembly

DIAGNOSIS AND TESTING

POWER STEERING GEAR LEAKAGE DIAGNOSIS
19 - 10 STEERING ZJ

REMOVAL AND INSTALLATION (6) Install single lip dust seal with a suitable size
deep socket.
PITMAN SHAFT SEALS (IN VEHICLE) (7) Center the steering gear and install pitman
arm.
REMOVAL (8) Add power steering fluid, refer to Power Steer-
ing Initial Operation.
CAUTION: Use care not to score the housing bore
when prying out seals and washers. STEERING GEAR
(1) Remove pitman arm from gear. REMOVAL
(2) Clean exposed end of pitman shaft and hous- (1) Place the front wheels in the straight ahead
ing. Use a wire brush to clean the shaft splines. position with the steering wheel centered.
(3) Remove single lip dust seal. (2) Remove and cap the pressure and return hoses
(4) Remove retaining ring with snap ring pliers from the steering gear.
(Fig. 1). (3) Remove the column coupler shaft from the gear
(Fig. 2).
(4) Remove pitman arm from gear with Puller
C-4150A (Fig. 3).
(5) Remove the steering gear retaining bolts and
nuts. Remove the steering gear from the vehicle (Fig.
4).

Fig. 1 Pitman Shaft Seal Fig. 2 Coupling Shaft

(5) Remove backup washers with screwdriver. INSTALLATION
(6) Start the engine and turn steering wheel fully (1) Position the steering gear on the frame rail and
to the LEFT. Hydraulic pressure will force the double install the bolts. Tighten the bolts to 88 N·m (65 ft.
lip oil seal out. lbs.) torque.
(7) Turn off engine and remove double lip seal (2) Install the column coupler shaft.
with screwdriver. (3) Install the pitman arm and tighten nut to 251
(8) Inspect the housing for burrs and remove if N·m (185 ft. lbs.).
necessary. Inspect the pitman shaft seal surface for (4) Connect pressure and return hoses to steering
roughness and pitting. If shaft is damaged it will gear and tighten to 28 N·m (21 ft. lbs.).
have to be replaced.

INSTALLATION DISASSEMBLY AND ASSEMBLY

(1) Coat the seals and washers with grease.
(2) Install double lip oil seal with a suitable size PITMAN SHAFT
deep socket. Steering gear must be removed from the vehicle for
(3) Install nylon backup washer. this procedure.
(4) Install steel backup washer.
(5) Install the retainer ring with snap ring pliers.
ZJ STEERING 19 - 11
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 3 Pitman Arm Removal

Fig. 5 Side Cover and Pitman Shaft

(3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 N·m
(44 ft. lbs.).
(6) Adjust pitman shaft, refer to Over-Center
Adjustment.

HOUSING END PLUG

Fig. 4 Steering Gear Mounting Steering gear must be removed from the vehicle for
REMOVAL this procedure.
(1) Clean exposed end of pitman shaft and housing
with a wire brush. REMOVAL
(2) Remove preload adjuster nut. (1) Rotate retaining ring until one end is under
(3) Rotate stub shaft with socket to center gear. the hole in the housing. Unseat and force ring from
(4) Remove side cover bolts and remove side cover, groove (Fig. 6).
gasket and pitman shaft as an assembly. (2) Rotate stub shaft slowly COUNTER-CLOCK-
(5) Remove pitman shaft from the side cover (Fig. WISE to remove end plug out from housing.
5).
CAUTION: Do not turn stub shaft any further than
INSTALLATION necessary. The recirculating balls will drop out of
(1) Install pitman shaft to side cover by screwing the rack piston circuit and fall inside the rack pis-
shaft in until it fully seats to side cover. ton chamber.
(2) Install preload adjuster nut. Do not tighten
nut until after pitman shaft adjustment has (3) Remove O-ring seal (Fig. 7).
been made.
19 - 12 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 8 Installing The Retaining Ring

ADJUSTER PLUG ASSEMBLY
Steering gear must be removed from the vehicle for
this procedure.
Fig. 6 End Plug Retaining Ring
REMOVAL
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span-
ner Wrench C-4381 (Fig. 9).

Fig. 7 End Plug Components

INSTALLATION
(1) Lubricate O-ring seal with power steering fluid.
(2) Install O-ring into housing.
(3) Install plug, tap lightly with a plastic mallet to Fig. 9 Adjustment Plug
seat it. (3) Remove thrust washer bearing retainer from
(4) Install retaining ring with open end 25 mm (1 adjuster plug with screwdriver (Fig. 10).
inch) from access hole (Fig. 8). (4) Remove bearing spacer, races and thrust bear-
(5) Adjust pitman arm shaft, refer to Over-Center ing (Fig. 11).
Adjustment. (5) Remove O-ring seal and retaining snap ring.
ZJ STEERING 19 - 13
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 10 Bearing Retainer

Fig. 12 Needle Bearing Removal

(4) Install retainer snap ring.
(5) Install O-ring seal to adjuster plug.
(6) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(7) Install thrust washer bearing retainer to
adjuster plug (Fig. 13).

Fig. 11 Adjustment Plug Components

(6) Remove needle bearing, dust seal and oil seal with
remover/installer C-4177 and handle C-4171 (Fig. 12).

INSTALLATION

CAUTION: Needle bearing must be installed with

identification on bearing facing tool to prevent dam-
age to bearing.

(1) Install needle bearing into adjuster plug with Fig. 13 Install Retainer
remover/install C-4177 and handle C-4171. CAUTION: When installing adjuster plug, care
(2) Apply white petroleum grease on oil seal. should be taken not to cut the seals.
Install oil seal into adjuster plug with remover/in-
staller C-4177 and handle C-4171. (8) Install adjuster plug into housing with Spanner
(3) Apply white petroleum grease to dust seal cav- Wrench C-4381.
ity and install dust seal into adjuster plug with (9) Adjust bearing preload, refer to Thrust Bearing
remover/installer C-4177 and handle C-4171. Preload Adjustment.
19 - 14 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Install adjuster plug lock nut, and using a punch Then pull cap and valve body and disengage stub
(drift) in a notch, tighten securely (Fig. 14). Hold adjuster shaft pin from hole in valve body (Fig. 16).
plug to maintain alignment of the marks.

Fig. 16 Stub Shaft

Fig. 14 Tighten Lock Nut
(4) Remove valve spool by pulling and rotating
(11) Adjust pitman shaft, refer to Over-Center from valve body (Fig. 17).
Adjustment.

SPOOL VALVE
Steering gear must be removed from the vehicle for
this procedure.

REMOVAL
(1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement.
(2) Remove stub shaft and valve assembly (Fig. 15).

Fig. 17 Spool Valve

(5) Remove valve spool O-ring seal and valve body
teflon rings and O-ring seals (Fig. 18).

INSTALLATION

CAUTION: Speed Proportional Steering has a differ-

ent spool valve. Do not interchange valves. Steering
response will be affected if wrong valve is installed.
(1) Install valve spool O-ring seal to valve spool.
Fig. 15 Bearing, Worm and Valve Assembly
(2) Lubricate valve spool and O-ring seal with
(3) Remove stub shaft from valve assembly by power steering fluid.
lightly tapping on a block of wood to loosen shaft cap.
ZJ STEERING 19 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install O-ring seals and teflon rings to valve
body.
(6) Lubricate O-ring seals and teflon rings with
power steering fluid.
(7) Install stub shaft and valve assembly to worm
shaft. Line up worm shaft to slot in the valve assem-
bly.
(8) Install adjuster plug.
(9) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment.

RACK PISTON AND WORM SHAFT

Steering gear must be removed from the vehicle for
this procedure.

REMOVAL
(1) Remove pitman shaft and side cover.
(2) Remove housing end plug.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 20).

Fig. 18 Valve Seals

(3) Install valve spool to valve body by pushing
and rotating. Hole in valve spool for stub pin must be
accessible from opposite end of valve body.
(4) Assemble stub shaft to valve spool, if necessary
and insert pin (Fig. 19).

NOTE: Notch in stub shaft cap must fully engage

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

Fig. 20 Rack Piston End Plug

(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 21). Hold tool tightly against worm shaft while
turning the stub shaft COUNTERCLOCKWISE.
(6) The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(7) Remove the rack piston, rack balls, and tool
together from housing.
(8) Remove valve, worm shaft and thrust bearing
and races.
(9) Remove tool from rack piston.
Fig. 19 Stub Shaft Installation (10) Remove rack piston balls.
(11) Remove screws, clamp and ball guide.
19 - 16 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 21 Rack Piston Fig. 23 Installing Balls in Rack Piston

(12) Remove teflon ring and O-ring seal (Fig. 22). installed alternately into the rack piston and ball
guide. This procedure will maintain worm shaft pre-
load.

(5) Lubricate and install rack piston balls through

return guide hole while turning worm shaft COUN-
TERCLOCKWISE.

WARNING: MAKE SURE ALL RACK PISTON BALLS

ARE INSTALLED PROPERLY. IMPROPER INSTALLA-
TION MAY RESULT IN PERSONAL INJURY.

(6) Install remaining balls to guide using grease or

petroleum jelly at each end to hold in place (Fig. 24).

Fig. 22 Rack Piston Teflon Ring and O-Ring

INSTALLATION
(1) Clean all components in solvent and dry with
compressed air.
(2) Check for scores, nicks or burrs on the rack
piston finished surface. Slight wear is normal on the
worm gear surfaces.
(3) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(4) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align
worm shaft spiral groove with rack piston ball guide
hole (Fig. 23).

NOTE: There are 12 black and 12 silver (Chrome) Fig. 24 Balls in the Return Guide
balls in the rack piston circuit. The black balls are
smaller than the silver balls. The balls must be
ZJ STEERING 19 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Install guide onto rack piston and return with
clamp and screws. Tighten screws to 58 N·m (43 ft.
lbs.).
(8) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly against worm shaft while turning
the stub shaft COUNTERCLOCKWISE.
(9) The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(10) Install the races and thrust bearing to worm
shaft (Fig. 25).

Fig. 26 Pitman Shaft Seals & Bearing

CAUTION: Use care not to score the housing bore
when prying out seals and washers.

(6) Remove double lip oil seal with screwdriver.

(7) Inspect the housing for burrs and remove if
necessary.
(8) Remove needle bearing from housing (Fig. 27).

Fig. 25 Worm Shaft and Bearing

(11) Install worm shaft to housing.
(12) Install valve
(13) Install rack piston to worm shaft from tool,
compress seals.
(14) Hold Arbor tightly against worm shaft and
turn stub shaft CLOCKWISE until rack piston is
seated on worm shaft.
(15) Install rack piston plug and tighten to 150
N·m (111 ft. lbs.).
(16) Install housing end plug.
(17) Install pitman shaft and side cover.
(18) Adjust steering gear.

PITMAN SHAFT SEALS AND BEARING

REMOVAL
(1) Remove pitman arm from gear.
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Remove single lip dust seal. Fig. 27 Needle Bearing Removal
(4) Remove retaining ring with snap ring pliers
(Fig. 26). INSTALLATION
(5) Remove backup washers with screwdriver. (1) Install needle bearing into housing (Fig. 26).
19 - 18 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Coat the double lip seal and washers with
grease.
(3) Install the double lip oil seal with a suitable
size deep socket.
(4) Install nylon backup washer.
(5) Install steel backup washer.
(6) Install the retainer ring with snap ring pliers.
(7) Install single lip dust seal with a suitable size
deep socket.

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 Fig. 29 Alignment Marking On Housing
and drain the fluid. Then mount gear in a vise to (4) Measure back (counterclockwise) 13 mm (0.50
perform adjustments. in) and mark housing (Fig. 30).

WORM THRUST BEARING PRELOAD

(1) Remove adjuster plug locknut (Fig. 28).

Fig. 30 Remarking The Housing

(5) Rotate adjustment cap back (counterclockwise)
with spanner wrench until hole is aligned with the
second mark (Fig. 31).
(6) Install and tighten locknut to 108 N·m (80 ft.
Fig. 28 Loosening the Adjuster Plug lbs.). Be sure adjustment cap does not turn while
(2) Turn the adjuster in with Spanner Wrench tightening the locknut.
C-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed in housing. OVER-CENTER
(3) Place an index mark on the housing even with (1) Rotate the stub shaft from stop to stop and
one of the holes in adjuster plug (Fig. 29). count the number of turns.
ZJ STEERING 19 - 19
ADJUSTMENTS (Continued)

Fig. 31 Aligning To The Second Mark Fig. 33 Checking Over-center Rotation Torque
(2) Starting at either stop turn the stub shaft back (5) Turn the adjuster in until torque to turn stub
1/2 the total number of turns. This is the center of shaft is 0.6 to 1.2 N·m (6.0 to 10.0 in. lbs.) more than
the gear travel (Fig. 32). previous reading recorded.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 27 N·m (20 ft. lbs.).

SPECIFICATIONS
POWER STEERING GEAR

Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . .Recirculating Ball
Gear Code and Ratio
BH, NZ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14:1
BF, XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16:1
AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7:1
Worm Shaft Bearing
Preload. . . . . . . . . . . .0.45–1.13 N·m (4–10 in. lbs.)
Pitman Shaft Overcenter Drag
New Gear (under 400 miles). . . . . . .0.45–0.90 N·m
(4–8 in. lbs.) + Worm Shaft Preload
Used Gear (over 400 miles) . . . . . . . . .0.5–0.6 N·m
(4–5 in. lbs.) + Worm Shaft Preload
Fig. 32 Steering Gear Centered
(3) Turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until extended, then turn
back in (CLOCKWISE) one full turn.
(4) Place the torque wrench in the vertical position
on the stub shaft. Rotate the wrench 45 degrees each
side of the center and record the highest rotational
torque on center (Fig. 33).
19 - 20 STEERING ZJ
SPECIFICATIONS (Continued)
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.)
Gear to Frame Bolts . . . . . . . . .88 N·m (65 ft. lbs.)
Pitman Shaft Nut . . . . . . . . .251 N·m (185 ft. lbs.)
Rack Piston Plug . . . . . . . . . .150 N·m (111 ft. lbs.)
Side Cover Bolts . . . . . . . . . . . .60 N·m (44 ft. lbs.)
Pressure Line . . . . . . . . . . . . . .28 N·m (21 ft. lbs.) Remover, Pitman Shaft Bearing C-4177
Return Line . . . . . . . . . . . . . . . .28 N·m (21 ft. lbs.)
Return Guide Clamp Bolt . . . . .58 N·m (43 ft. lbs.)

SPECIAL TOOLS
POWER STEERING GEAR

Handle C-4171

Remover/Installer, Steering Plug C-4381

Remover/Installer Steering Rack Piston C-4175

Remover, Pitman Arm C-4150A
ZJ STEERING 19 - 21

STEERING COLUMN

INDEX
page page

GENERAL INFORMATION REMOVAL AND INSTALLATION

STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 21 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING SPECIFICATIONS
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 22 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 24

GENERAL INFORMATION FIRST DISCONNECT AND ISOLATE THE BATTERY

NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
STEERING COLUMN COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
The tilt and standard column (Fig. 1) has been THE AIRBAG AND POSSIBLE PERSONAL INJURY.
designed to be serviced as an assembly; less wiring, THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
switches, shrouds, steering wheel, etc. Most steering NALLY USED FOR THE AIRBAG COMPONENTS,
column components can be serviced without remov- HAVE SPECIAL COATINGS AND ARE SPECIFI-
ing the steering column from the vehicle. CALLY DESIGNED FOR THE AIRBAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
SERVICE PRECAUTIONS STITUTES. ANYTIME A NEW FASTENER IS
Safety goggles should be worn at all times when NEEDED, REPLACE WITH THE CORRECT FASTEN-
working on steering columns. ERS PROVIDED IN THE SERVICE PACKAGE OR
To service the steering wheel, switches or airbag, FASTENERS LISTED IN THE PARTS BOOKS.
refer to Group 8 M and follow all WARNINGS and
CAUTIONS.
CAUTION: Do not attempt to remove the pivot pins
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, to disassemble the tilting mechanism. Do not
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE remove ignition locking link, shaft lock plate or
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL plate retainer. This will damage the column (Fig. 2)
THE AIRBAG SYSTEM COMPONENTS YOU MUST and (Fig. 3).

Fig. 1 Steering Column

19 - 22 STEERING ZJ

Fig. 4 Steering Column Flash Removal And

Fig. 2 Observe Cautions Non-Serviceable Components
REMOVAL AND INSTALLATION
STEERING COLUMN
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.

REMOVAL
(1) Position front wheels straight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove airbag, refer to Group 8M Electrical
for procedure.
(4) Remove steering wheel with appropriate puller
(Fig. 5).
Fig. 3 Observe Cautions
DIAGNOSIS AND TESTING
IGNITION SWITCH
TEST AND REPAIR
If the ignition switch effort is excessive, remove the
ignition switch from the steering column. Refer to
Group 8D Ignition System. Using a key cylinder,
check the turning effort of the switch. If the ignition
switch binds look for the following conditions.
(1) Look for rough areas or flash in the casting
and if found remove with a file (Fig. 4).
(2) Remove the link and slider and check the link
to see if it is bent. If so replace with a new part.
(3) Put the slider in its slot in the sleeve and ver-
ify a loose fit over the length of the slot. If the slider
binds in the slot at any point lightly file the slider
until clearance is achieved.
(4) If no binding is found, lightly file the ramp on
the ignition switch, (The ramp fits into the casting)
until binding no longer occurs.
Fig. 5 Steering Wheel Removal
ZJ STEERING 19 - 23
REMOVAL AND INSTALLATION (Continued)

Fig. 6 Column Coupler Shaft

(5) Remove column coupler upper pinch bolt (Fig.
6).
(6) Remove the trim panel column cover and sup-
port plate (Fig. 7).
(7) Remove tilt lever (if equipped) from column.
(8) Remove the upper and lower lock housing Fig. 7 Trim Panel Column Cover
shrouds. (13) Remove the toe plate to dash panel nuts.
(9) Remove the heater cross over tube from under (14) Remove the panel bracket nuts/studs and
the column. remove the column.
(10) Loosen the panel bracket nuts/studs to allow
the column to drop. INSTALLATION
(11) Remove the wiring harness from steering col-
umn (Fig. 8). CAUTION: If vehicle is equipped with Speed Pro-
(12) Remove the Interlock cable from the steering portional Steering do not transfer Wheel Speed
column. Refer to Group 3 Differential and Driveline. Sensor to replacement column. Install new sensor
only on column.

Fig. 8 Steering Column Wiring Harness

19 - 24 STEERING ZJ
REMOVAL AND INSTALLATION (Continued)
(1) With the front wheels in the straight ahead (6) Be sure both spacers are fully seated in the col-
position. Align and install the column to coupler. Do umn support bracket. Tighten the column panel
not apply force at the top of the steering col- bracket support nuts/studs to 12 N·m (105 in. lbs.).
umn shaft. Ensure the nut is installed on the SHORT
(2) Ensure the ground clip is on the left spacer slot threaded side of the stud.
(Fig. 9). (7) Tighten the toe plate attaching nuts to 12 N·m
(105 in. lbs.).
(8) Tighten the coupler pinch bolt to 49 N·m (36 ft.
lbs.).
(9) Install the heater cross over tube under the col-
umn.
(10) Install the upper and lower shrouds. Install
the tilt lever (if equipped).
(11) Install the trim panel column cover and sup-
port plate.
(12) Install the steering wheel and airbag, refer to
Group 8M Electrical for procedure.
(13) Remove the column shaft shipping lock pin
(installed in service column).
(14) Connect the battery ground (negative) cable.

Fig. 9 Ground Clip & Spacer SPECIFICATIONS

(3) Install the Interlock cable from the steering TORQUE CHART
column. Refer to Group 3 Differential and Driveline..
(4) Install wiring harness connections to steering
DESCRIPTION TORQUE
column. Ensure the wiring is not pinched and
all connections are correctly locked in place. Steering Column
(5) Install shaft coupler pinch bolt loose, load col- Steering Wheel Nut. . . . . . . . . .61 N·m (45 ft. lbs.)
umn up to panel bracket. Column Bracket Nuts . . . . . . .12 N·m (105 in. lbs.)
Shaft Coupler Bolts . . . . . . . . . .49 N·m (36 ft. lbs.)
Toe Plate Bolts . . . . . . . . . . . .12 N·m (105 in. lbs.)
ZJ STEERING 19 - 25

SPEED PROPORTIONAL STEERING

INDEX
page page

DESCRIPTION AND OPERATION STEERING WHEEL SPEED SENSOR . . . . . . . . . 25

POWER STEERING GEAR . . . . . . . . . . . . . . . . . 26 DIAGNOSIS AND TESTING
SPEED PROPORTIONAL STEERING CONTROL SPEED PROPORTIONAL STEERING . . . . . . . . . 26
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 REMOVAL AND INSTALLATION
SPEED PROPORTIONAL STEERING SPEED PROPORTIONAL STEERING CONTROL
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPEED PROPORTIONAL STEERING . . . . . . . . . 25 STEERING WHEEL SPEED SENSOR . . . . . . . . . 26

DESCRIPTION AND OPERATION

SPEED PROPORTIONAL STEERING
Speed Proportional Steering consist of;
• Speed Proportional Steering Control Module
(SPSCM)
• Steering Wheel Speed Sensor (SWSS)
• Speed Proportional Steering Solenoid (SPSS)
• Speed Proportional Steering Gear (SPSG)
Speed Proportional Steering provides variable
power assist based on inputs from the Vehicle Speed
Sensor and Steering Wheel Speed Sensor. The sen-
sors are monitored by the Speed Proportional Steer-
ing Control Module. The module controls the
operation of the Speed Proportional Steering Solenoid
which regulated power steering pump flow rate.
When parking or at low speeds, full power assist is
provided. As the vehicle speed increases pump flow is
reduce. This reduces the power assist, providing the
driver with a better feel for the road and improved
directional stability.
When a quick steering maneuver is made while the
system is operating at reduced power assist, full Fig. 1 Speed Proportional Steering Control Module
assist is provided for the maneuver. STEERING WHEEL SPEED SENSOR
The Steering Wheel Speed Sensor is mounted on
SPEED PROPORTIONAL STEERING CONTROL the steering column shaft below the clock spring (Fig.
MODULE 2).
The control module is mounted to a bracket on the
passenger side of the front cowl panel just left of the SPEED PROPORTIONAL STEERING SOLENOID
steering column (Fig. 1). A 14-way connector is The solenoid is mounted to the power steering
attached to the module. The module monitors steer- pump outlet port (Fig. 3). The solenoid controls pump
ing wheel speed and vehicle speed to determine the output volume by moving a metering rod in and out
amount of power steering assist needed. The module of a fixed orifice. The SPSCM energizes and de-ener-
controls power steering assist by sending a 12-volt gizes the solenoid to move the metering rod up to 250
duty-cycle signal (pulsed on and off) to the Speed times per second. By varying the time energized ver-
Proportional Steering Solenoid. sus de-energize steering pump output volume and
steering assist is controlled.
19 - 26 STEERING ZJ
1996 Grand Cherokee
DESCRIPTION AND OPERATION (Continued) Publication No. 81-370-6147
TSB 26-10-95 December, 1995

DIAGNOSIS AND TESTING

SPEED PROPORTIONAL STEERING
For diagnosis and testing procedures refer to the
Chassis Diagnostic Manual.

REMOVAL AND INSTALLATION

STEERING WHEEL SPEED SENSOR
REMOVAL
(1) Disconnect the negative (ground) cable from
the battery.
(2) Remove airbag, refer to Group 8M Electrical
for procedure.
(3) Remove steering wheel with appropriate puller
(Fig. 4).
(4) Remove clock spring, refer to Group 8M Elec-
trical for procedure.
(5) Pry sensor retaining ring tabs up and remove
sensor (Fig. 5).
Fig. 2 Steering Wheel Speed Sensor

Fig. 4 Steering Wheel Removal

INSTALLATION

CAUTION: Never install a used sensor. Once the

sensor has been removed it must be replace with a
new sensor.

Fig. 3 Speed Proportional Steering Solenoid (1) Install new sensor on column shaft with a piece
of thin wall conduit 3 inch long by 3/4 inch ID. Move
POWER STEERING GEAR turn signal canceler off to one side and ensure locat-
The steering gear used with Speed Proportional ing tab is in the proper position and push the sensor
Steering has a special spool valve. The valve provides down on the shaft.
improved response at lower flow rates. The gear is a
serviceable component. CAUTION: The conduit installer must only touch the
inner metal ring of the sensor and not the plastic
CAUTION: A Speed Proportional Steering gear housing or the sensor will be damaged.
should not be interchanged with any other steering
gear. (2) Install clock spring, refer to Group 8M Electri-
cal for procedure.
ZJ STEERING 19 - 27
REMOVAL AND INSTALLATION (Continued)
SPEED PROPORTIONAL STEERING CONTROL
MODULE
REMOVAL
(1) Unplug harness from control module, located
left of steering column on front cowl panel.
(2) Slid the module off mounting bracket (Fig. 6).

Fig. 5 Steering Wheel Speed Sensor

(3) Install steering wheel. Fig. 6 Speed Proportional Steering Control Module
(4) Install airbag, refer to Group 8M Electrical for
INSTALLATION
procedure.
(1) Slid module onto mounting bracket.
(5) Connect negative (ground) cable to the battery.
(2) Plug harness into module.
19 - 28 STEERING ZJ

STEERING LINKAGE

INDEX
page page

GENERAL INFORMATION STEERING DAMPENER . . . . . . . . . . . . . . . . . . . 29

STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 28 TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE PROCEDURES SPECIFICATIONS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 28 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL AND INSTALLATION SPECIAL TOOLS
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 30
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

GENERAL INFORMATION NOTE: Use a Puller tool C-3894-A for tie rod
removal. Failure to use this tool could damage the
STEERING LINKAGE ball stud and seal (Fig. 2).
The steering linkage consists of a pitman arm,
drag link, tie rod, and steering dampener (Fig. 1).
Adjustment sleeves are used on the tie rod and drag
link for toe and steering wheel alignment.

Fig. 2 Ball Stud Removal

SERVICE PROCEDURES
STEERING LINKAGE
Fig. 1 Steering Linkage Before removing any steering component, the boot
NOTE: Refer to Group 2, Suspension for additional seals should be closely inspected for damage. If a seal
information. is damaged, it should be replaced. Before installing a
new seal, inspect ball stud. Replace ball stud if worn
The tie rod end ball stud seals should be inspected and lubricate the ball studs with MOPAR Multi-Mile-
during all oil changes. age Lubricant, or an equivalent.
A damaged ball stud seal requires removal of the
seal. Inspect the tie rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball REMOVAL AND INSTALLATION
stud wear or corrosion. If these conditions exist,
replace the tie rod. A replacement seal can be TIE ROD
installed if lubricant is in good condition. Otherwise,
a complete replacement ball stud end should be REMOVAL
installed. Lubricate the tie rod end with MOPARt (1) Remove the cotter pins and nuts at the steer-
Multi-Mileage Lubricant, or equivalent product. ing knuckle and drag link (Fig. 1).
(2) Loosen the ball studs with a puller tool to
remove the tie rod.
ZJ STEERING 19 - 29
REMOVAL AND INSTALLATION (Continued)
(3) If necessary, loosen the end clamp bolts and
remove the tie rod ends from the tube.

INSTALLATION
(1) If necessary, install the tie rod ends in the
tube. Position the tie rod clamp (Fig. 3) and tighten
to;
• 4.0L Engine: 27 N·m (20 ft. lbs.)
• 5.2L Engine: 49 N·m (36 ft. lbs.)
(2) Install the tie rod on the drag link and steering
knuckle. Install the retaining nuts.
(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 and bend end 60°.

Fig. 4 Pitman Arm Removal

DRAG LINK
REMOVAL
(1) Remove the cotter pins and nuts at the steer-
ing knuckle and drag link (Fig. 1).
(2) Remove the steering dampener ball stud from
the drag link with a puller tool.
(3) Remove the drag link from the steering
Fig. 3 Tie Rod/Drag Link Clamp Bolt knuckle with a puller tool. Remove the same for tie
rod and pitman arm.
PITMAN ARM (4) If necessary, loosen the end clamp bolts and
remove the tie rod end from the link.
REMOVAL
(1) Remove the cotter pin and nut from the drag INSTALLATION
link at the pitman arm. (1) Install the drag link adjustment sleeve and tie
(2) Remove the drag link ball stud from the pit- rod end. Position clamp bolts (Fig. 2).
man arm with a puller. (2) Position the drag link at the steering linkage.
(3) Remove the nut and washer from the steering Install the drag link to the steering knuckle nut. Do
gear shaft. Mark the pitman shaft and pitman arm the same for the tie rod and pitman arm.
for installation reference. Remove the pitman arm (3) Tighten the nut at the steering knuckle to 47
from steering gear with Puller C-4150A (Fig. 4). N·m (35 ft. lbs.). Tighten the pitman nut to 81 N·m
(60 ft. lbs.) and tie rod ball stud nut to 47 N·m (35 ft.
INSTALLATION
lbs.). Install new cotter pins and bend end 60°.
(1) Align and install the pitman arm on steering
(4) Install the steering dampener onto the drag
gear shaft.
link and tighten the nut to 74 N·m (55 ft. lbs.).
(2) Install the washer and nut on the shaft and
Install a new cotter pin and bend end 60°.
tighten the nut to 251 N·m (185 ft. lbs.).
(3) Install drag link ball stud to pitman arm.
STEERING DAMPENER
Install nut and tighten to 81 N·m (60 ft. lbs.). Install
a new cotter pin. REMOVAL
(1) Place the front wheels in a straight ahead posi-
tion.
(2) Remove the steering dampener retaining nut
and bolt from the axle bracket (Fig. 1).
19 - 30 STEERING ZJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove the cotter pin and nut from the ball SPECIAL TOOLS
stud at the drag link.
(4) Remove the steering dampener ball stud from STEERING LINKAGE
the drag link using C-3894-A puller.

INSTALLATION
(1) Install the steering dampener to the axle
bracket and drag link.
(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.

Puller C-3894–A
SPECIFICATIONS
TORQUE CHART

DESCRIPTION TORQUE
Pitman Arm
Shaft Nut. . . . . . . . . . . . . . . .251 N·m (185 ft. lbs.)
Drag Link
Pitman Arm Nut . . . . . . . . . . . .81 N·m (60 ft. lbs.)
Knuckle Nut . . . . . . . . . . . . . . .47 N·m (35 ft. lbs.)
4.0L Clamp Bolts. . . . . . . . . . . .27 N·m (20 ft. lbs.) Remover Pitman C-4150A
5.2L Clamp Bolts. . . . . . . . . . . .49 N·m (36 ft. lbs.)
Tie Rod Ends
Ball Stud Nut . . . . . . . . . . . . . .47 N·m (35 ft. lbs.)
4.0L Clamp Bolts. . . . . . . . . . . .27 N·m (20 ft. lbs.)
5.2L Clamp Bolts. . . . . . . . . . . .49 N·m (36 ft. lbs.)
Tie Rod
Ball Stud Nut . . . . . . . . . . . . . .47 N·m (35 ft. lbs.)
Steering Damper
Frame Bolt . . . . . . . . . . . . . . . .74 N·m (55 ft. lbs.)
Drag Link Nut. . . . . . . . . . . . . .74 N·m (55 ft. lbs.)