STEERING

CONTENTS
page page
POWER STEERING GEAR . . . . . . . . . . . . . . . . . . . 9
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 4
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 20
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 24
POWER STEERING
INDEX
page page
GENERAL INFORMATION
POWER STEERING SYSTEM . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
POWER STEERING SYSTEM
The power steeri ng pump (Fi g. 1) i s a constant
fl ow rate and di spl acement vane type pump. The
pump reservoi r i s attached to the pump body. The
pump i s connected to the steeri ng by the pressure
and return hoses.
The steeri ng gear (Fi g. 1) used i s a reci rcul ati ng
bal l type gear. The gear acts as a rol l i ng thread
between the worm shaft and rack pi ston. The worm
shaft i s supported by a thrust beari ng at the l ower
end and a beari ng assembl y at the upper end. When
the worm shaft i s turned the rack pi ston moves. The
rack pi ston teeth mesh wi th the pi tman shaft. Turn-
i ng the worm shaft turns the pi tman shaft, whi ch
moves the steeri ng l i nkage.
The power steeri ng system consi sts of:
Hydraul i c pump
Reci rcul ati ng bal l steeri ng gear
Steeri ng col umn
Steeri ng l i nkage
Fig. 1 Power Steering Gear & Pump
ZJ STEERING 19 - 1
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash
panel seal.
1. Check and repair seal at dash
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
components.
2. Inspect and repair suspension.
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
components.
5. Reposition hose.
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
components.
2. Reposition hose.
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
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
1. Low fluid level. 1. Fill to proper level.
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
adjustment.
7. Repair or replace gear.
19 - 2 STEERING ZJ
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
1. Tire pressure. 1. Adjust tire pressure.
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
DOES NOT WANT TO RETURN TO
CENTER POSITION
1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
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
WHEEL
1. Worn or loose suspension or
steering components.
1. Repair as necessary.
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
ONE SIDE
1. Tire Pressure. 1. Adjust tire pressure.
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
suspension components.
6. Repair as necessary.
ZJ STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)
POWER STEERING PUMP
INDEX
page page
DESCRIPTION AND OPERATION
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
PUMP FLOW RATE AND PRESSURE . . . . . . . . . 4
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
POWER STEERING PUMP 5.2L/5.9L . . . . . . . . . 6
POWER STEERING PUMP 4.0L . . . . . . . . . . . . . 6
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 8
DESCRIPTION AND OPERATION
POWER STEERING PUMP
Hydraul i c pressure for the power steeri ng system
i s provi ded by a bel t dri ven power steeri ng pump
(Fi g. 1). The pump shaft has a pressed-on dri ve pul -
l ey that i s bel t dri ven by the crankshaft pul l ey. The
power steeri ng pump i s a constant fl ow rate and di s-
pl acement, vane-type pump. The pump i nternal parts
operate submerged i n fl ui d. The fl ow control ori fi ce i s
part of the hi gh pressure l i ne fi tti ng. The pressure
rel i ef val ve i nsi de the fl ow control val ve l i mi ts the
pump pressure. The reservoi r i s attached to the
pump body wi th spri ng cl i ps. The power steeri ng
pump i s connected to the steeri ng gear by the pres-
sure and return hoses.
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
DIAGNOSIS AND TESTING
PUMP FLOW RATE AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool ki t 6815 (Fi g. 2) and Adapter
Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6865.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect Tube 6865 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to Adapter 6826.
(7) Open the test val ve compl etel y.
Fig. 1 Pump With Integral Reservoir
19 - 4 STEERING ZJ
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge.
(9) Shut off the engi ne and check the fl ui d l evel ,
add fl ui d as necessary. Start engi ne agai n and l et
i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM, i f the readi ng i s bel ow thi s speci fi cati on the
pump shoul d be repl aced.
CAUTION: This next step involves testing maxi-
mum pump pressure output and flow control valve
operation. Do not leave valve closed for more than
three seconds as the pump could be damaged.
(12) Cl ose val ve ful l y three ti mes for three seconds
and record hi ghest pressure i ndi cated each ti me. All
three readings must be above pump relief pres-
sure specifications and within 345 kPa (50 psi)
of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons agai nst
the stops. Record the hi ghest pressure readi ng at
each posi ti on. Compare readi ngs to the pump speci fi -
cati ons chart. I f pressures readi ngs are not wi thi n 50
psi . of each other, the gear i s l eaki ng i nternal l y and
must be repai red.
CAUTION: Do not force the pump to operate
against the stops for more than 2 to 4 seconds at a
time because, pump damage will result.
PUMP LEAKAGE DIAGNOSIS
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
Fig. 2 Power Steering Analyzer
PUMP SPECIFICATIONS
ENGINE
RELIEF PRESSURE
50
FLOW RATE
(GPM)
4.0L 9653 kPa (1400 psi)
1500 RPM
2.4 - 2.8 GPM
5.2L 9653 kPa (1400 psi)
5.9L 9653 kPa (1400 psi)
ZJ STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION
POWER STEERING PUMP 4. 0L
REMOVAL
(1) Remove serpenti ne dri ve bel t, refer to Group 7
Cool i ng.
(2) Vehi cl es equi pped wi th Speed Proporti onal
Steeri ng, di sconnect actuator harness.
(3) Remove pressure and return hoses from pump
and drai n pump.
(4) Remove 3 pump mounti ng bol ts through pul l ey
access hol es.
(5) Loosen the 3 pump bracket bol ts (Fi g. 3).
(6) Ti l t pump downward and remove from engi ne.
(7) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on engi ne.
(3) Ti ghten pump bracket bol ts to 47 Nm (35 ft.
l bs.).
(4) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(5) I nstal l the pressure and return hoses to pump.
(6) Vehi cl es equi pped wi th Speed Pro Steeri ng,
connect actuator harness.
(7) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(8) Add power steeri ng fl ui d. Refer to Power Steer-
i ng Pump I ni ti al Operati on i n thi s secti on.
POWER STEERING PUMP 5. 2L/5. 9L
REMOVAL
(1) Remove the serpenti ne dri ve bel t. Refer to
Group 7 Cool i ng.
(2) Remove the pressure and return hoses from
pump and drai n pump.
(3) Vehi cl es equi pped wi th Speed Proporti onal
Steeri ng, di sconnect actuator harness.
(4) Remove pump mounti ng bol ts and remove the
pump (Fi g. 4).
(5) Remove pul l ey from pump.
Fig. 3 Pump Mounting 4.0L
19 - 6 STEERING ZJ
SERVICE PROCEDURES (Continued)
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) Mount pump on bracket and i nstal l bol ts.
Ti ghten bol ts to 27 Nm (20 ft. l bs.).
(3) I nstal l the pressure and return hoses to pump.
(4) Vehi cl es equi pped wi th Speed Pro Steeri ng,
connect actuator harness.
(5) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(6) Add power steeri ng fl ui d. Refer to Power Steer-
i ng Pump I ni ti al Operati on i n thi s secti on.
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY
DISASSEMBLY
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
(Fi g. 5).
ASSEMBLY
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
(Fi g. 6) fl ush wi th the end of the shaft. Ensure the
tool and pul l ey remai n al i gned wi th the pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be care-
ful that pulley does not contact mounting bolts.
PUMP RESERVOIR
DISASSEMBLY
(1) Remove power steeri ng pump.
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
(4) Pry up tab and sl i de the retai ni ng cl i ps off (Fi g. 7).
Fig. 4 Pump Mounting 5.2L/59L
Fig. 5 Pulley Removal
Fig. 6 Pulley Installation
Fig. 7 Pump Reservoir Clips
ZJ STEERING 19 - 7
REMOVAL AND INSTALLATION (Continued)
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
ASSEMBLY
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n reservoi r retai ner cl i ps unti l
tab l ocks to housi ng.
(5) I nstal l power steeri ng pump.
(6) Add power steeri ng fl ui d, refer to Pump I ni ti al
Operati on.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Pump
Bracket Bol ts. . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Pump Bol ts . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Fl ow Control Val ve . . . . . . . . . .75 Nm (55 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
SPECIAL TOOLS
POWER STEERING PUMP
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
19 - 8 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
POWER STEERING GEAR
INDEX
page page
DESCRIPTION AND OPERATION
POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL AND INSTALLATION
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 10
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . 11
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . . 11
RACK PISTON AND WORM SHAFT . . . . . . . . . . 15
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 19
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 19
DESCRIPTION AND OPERATION
POWER STEERING GEAR
The power steeri ng gear i s a reci rcul ati ng bal l type
gear (Fi g. 1). The gear acts as a rol l i ng thread
between the worm shaft and rack pi ston. The worm
shaft i s supported by a thrust beari ng at the l ower
end and a beari ng assembl y at the upper end. When
the worm shaft i s turned the rack pi ston moves. The
rack pi ston teeth mesh wi th the pi tman shaft. Turn-
i ng the worm shaft turns the pi tman shaft, whi ch
turns the steeri ng l i nkage.
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.
Fig. 1 Recirculating Ball Type Gear
ZJ STEERING 19 - 9
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE DIAGNOSIS
REMOVAL AND INSTALLATION
STEERING GEAR
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered.
(2) Remove and cap the pressure and return hoses
from the steeri ng gear.
(3) Remove the col umn coupl er shaft from the gear
(Fi g. 2).
(4) Remove pi tman arm from gear wi th Pul l er
C-4150A (Fi g. 3).
(5) Remove the steeri ng gear retai ni ng bol ts and
nuts. Remove the steeri ng gear from the vehi cl e (Fi g. 4).
INSTALLATION
(1) Posi ti on the steeri ng gear on the frame rai l and
i nstal l the bol ts. Ti ghten the bol ts to 88 Nm (65 ft.
l bs.) torque.
(2) I nstal l the col umn coupl er shaft.
(3) I nstal l the pi tman arm and ti ghten nut to 251
Nm (185 ft. l bs.).
(4) Connect pressure and return hoses to steeri ng
gear and ti ghten to 28 Nm (21 ft. l bs.).
Fig. 2 Coupling Shaft
Fig. 3 Pitman Arm Removal
Fig. 4 Steering Gear Mounting
19 - 10 STEERING ZJ
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG
DISASSEMBLY
(1) Unseat and remove retai ni ng ri ng from groove
wi th a punch through the hol e i n the end of the
housi ng (Fi g. 5).
(2) Sl owl y rotate stub shaft wi th 12 poi nt socket
COUNTER-CLOCKWI SE to force the end pl ug out
from housi ng.
CAUTION: Do not turn stub shaft any further than
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far.
(3) Remove O-ri ng from the housi ng (Fi g. 6).
ASSEMBLY
(1) Lubri cate O-ri ng wi th power steeri ng fl ui d and
i nstal l i nto the housi ng.
(2) I nstal l end pl ug by tappi ng the pl ug l i ghtl y
wi th a pl asti c mal l et i nto the housi ng.
(3) I nstal l retai ni ng ri ng so one end of the ri ng
covers the housi ng access hol e (Fi g. 7).
PITMAN SHAFT/SEALS/BEARING
DISASSEMBLY
(1) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
Fig. 5 End Plug Retaining Ring
Fig. 6 End Plug Components
Fig. 7 Installing The Retaining Ring
ZJ STEERING 19 - 11
(2) Remove prel oad adjuster nut (Fi g. 8).
(3) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotati ng i t from the
stop 1/2 of the total amount of turns.
(5) Remove si de cover bol ts and remove si de cover,
gasket and pi tman shaft as an assembl y (Fi g. 8).
NOTE: The pitman shaft will not clear the housing
if it is not centered.
(6) Remove pi tman shaft from the si de cover.
(7) Remove dust seal from the housi ng wi th a seal
pi ck (Fi g. 9).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(9) Remove washer from the housi ng.
(10) Remove oi l seal from the housi ng wi th a seal
pi ck.
(11) Remove pi tman shaft beari ng from housi ng
wi th a beari ng dri ver and handl e (Fi g. 10).
ASSEMBLY
(1) I nstal l pi tman shaft beari ng i nto housi ng wi th
a beari ng dri ver and handl e.
(2) Coat the oi l seal s and washer wi th grease.
(3) I nstal l the oi l seal wi th a dri ver and handl e.
(4) I nstal l backup washer.
(5) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(6) I nstal l dust seal wi th a dri ver and handl e.
(7) I nstal l pi tman shaft to si de cover by screwi ng
shaft i n unti l i t ful l y seats to si de cover.
(8) I nstal l prel oad adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(9) I nstal l gasket to si de cover and bend tabs
around edges of si de cover (Fi g. 8).
(10) I nstal l pi tman shaft assembl y and si de cover
to housi ng.
(11) I nstal l si de cover bol ts and ti ghten to 60 Nm
(44 ft. l bs.).
(12) Adjust Over-Center Rotati on Torque.
Fig. 8 Side Cover and Pitman Shaft
Fig. 9 Pitman Shaft Seals & Bearing
Fig. 10 Needle Bearing Removal
19 - 12 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
SPOOL VALVE
DISASSEMBLY
(1) Remove l ock nut (Fi g. 11).
(2) Remove adjuster nut wi th Spanner Wrench
C-4381.
(3) Remove thrust support assembl y out of the
housi ng (Fi g. 12).
(4) Pul l stub shaft and val ve assembl y from the
housi ng (Fi g. 13).
(5) Remove stub shaft from val ve assembl y by
l i ghtl y tappi ng shaft on a bl ock of wood to l oosen
shaft. Then di sengage stub shaft pi n from hol e i n
spool val ve and separate the val ve assembl y from
stub shaft (Fi g. 14).
Fig. 11 Lock Nut and Adjuster Nut
Fig. 12 Thrust Support Assembly
Fig. 13 Valve Assembly With Stub Shaft
Fig. 14 Stub Shaft
ZJ STEERING 19 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove spool val ve from val ve body by pul l i ng
and rotati ng the spool val ve from the val ve body (Fi g.
15).
(7) Remove spool val ve O-ri ng and val ve body
tefl on ri ngs and O-ri ngs underneath the tefl on ri ngs
(Fi g. 16).
(8) Remove the O-ri ng between the worm shaft
and the stub shaft.
ASSEMBLY
NOTE: Clean and dry all components, then lubri-
cate with power steering fluid.
(1) I nstal l spool val ve spool O-ri ng.
(2) I nstal l spool val ve i n val ve body by pushi ng
and rotati ng. Hol e i n spool val ve for stub shaft pi n
must be accessi bl e from opposi te end of val ve body.
(3) I nstal l stub shaft i n val ve spool and engage
l ocati ng pi n on stub shaft i nto spool val ve hol e (Fi g.
17).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
(4) I nstal l O-ri ngs and tefl on ri ngs over the
O-ri ngs on val ve body.
(5) I nstal l O-ri ng i nto the back of the stub shaft
cap (Fi g. 18).
Fig. 15 Spool Valve
Fig. 16 Valve Seals
Fig. 17 Stub Shaft Installation
Fig. 18 Stub Shaft Cap O-Ring
19 - 14 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I nstal l stub shaft and val ve assembl y i n the hous-
i ng. Li ne up worm shaft to sl ots i n the val ve assembl y.
(7) I nstal l thrust support assembl y.
NOTE: The thrust support is serviced as an assem-
bly. If any component of the thrust support is dam-
aged the assembly must be replaced.
(8) I nstal l adjuster nut and l ock nut.
(9) Adjust Thrust Beari ng Prel oad and Over-Cen-
ter Rotati ng Torque.
RACK PISTON AND WORM SHAFT
DISASSEMBLY
(1) Remove housi ng end pl ug.
(2) Remove rack pi ston pl ug (Fi g. 19).
(3) Remove si de cover and pi tman shaft.
(4) Turn stub shaft COUNTERCLOCKWI SE unti l
the rack pi ston begi ns to come out of the housi ng.
(5) I nsert Arbor C-4175 i nto bore of rack pi ston
(Fi g. 20) and hol d tool ti ghtl y agai nst worm shaft.
(6) Turn the stub shaft wi th a 12 poi nt socket
COUNTERCLOCKWI SE, thi s wi l l force the rack pi ston
onto the tool and hol d the rack pi ston bal l s i n pl ace.
(7) Remove the rack pi ston and tool together from
housi ng.
(8) Remove tool from rack pi ston.
(9) Remove rack pi ston bal l s.
(10) Remove cl amp bol ts, cl amp and bal l gui de
(Fi g. 21).
(11) Remove tefl on ri ng and O-ri ng from the rack
pi ston (Fi g. 22).
Fig. 19 Rack Piston End Plug
Fig. 20 Rack Piston with Arbor
Fig. 21 Rack Piston
Fig. 22 Rack Piston Teflon Ring and O-Ring
ZJ STEERING 19 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Remove the adjuster l ock nut and adjuster
nut from the stub shaft.
(13) Pul l the stub shaft wi th the spool val ve and
thrust support assembl y out of the housi ng.
(14) Remove the worm shaft from the housi ng
(Fi g. 23).
ASSEMBLY
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, ni cks or burrs on the rack
pi ston fi ni shed surface. Sl i ght wear i s normal on the
worm gear surfaces.
(2) I nstal l O-ri ng and tefl on ri ng on the rack pi s-
ton.
(3) I nstal l worm shaft i n the rack pi ston and al i gn
worm shaft spi ral groove wi th rack pi ston bal l gui de
hol e (Fi g. 24).
CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.
(4) Lubri cate and i nstal l rack pi ston bal l s through
return gui de hol e whi l e turni ng worm shaft COUN-
TERCLOCKWI SE (Fi g. 24).
(5) I nstal l remai ni ng bal l s i n gui de usi ng grease to
hol d the bal l s i n pl ace (Fi g. 25).
(6) I nstal l the gui de onto rack pi ston and i nstal l
cl amp and cl amp bol ts. Ti ghten bol ts to 58 Nm (43
ft. l bs.).
(7) I nsert Arbor C-4175 i nto bore of rack pi ston
and hol d tool ti ghtl y agai nst worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWI SE
whi l e pushi ng on the arbor. Thi s wi l l force the rack
pi ston onto the arbor and hol d the rack pi ston bal l s
i n pl ace.
(9) I nstal l the races and thrust beari ng on the
worm shaft and i nstal l shaft i n the housi ng (Fi g. 23).
(10) I nstal l the stub shaft wi th spool val ve, thrust
support assembl y and adjuster nut i n the housi ng.
(11) I nstal l the rack pi ston and arbor tool i nto the
housi ng.
(12) Hol d arbor ti ghtl y agai nst worm shaft and
turn stub shaft CLOCKWI SE unti l rack pi ston i s
seated on worm shaft.
(13) I nstal l pi tman shaft and si de cover i n the
housi ng.
(14) I nstal l rack pi ston pl ug and ti ghten to 150
Nm (111 ft. l bs.).
(15) I nstal l housi ng end pl ug.
Fig. 23 Worm Shaft
Fig. 24 Installing Balls in Rack Piston
Fig. 25 Balls in the Return Guide
19 - 16 STEERING ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
(16) Adjust worm shaft thrust beari ng prel oad and
over-center rotati ng torque.
ADJ USTMENTS
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 careful l y i nto a vi se.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Remove adjuster pl ug l ocknut (Fi g. 26).
(3) Rotate the stub shaft back and forth wi th a 12
poi nt socket to drai n the remai ni ng fl ui d.
(4) Turn the adjuster i n wi th Spanner Wrench
C-4381. Ti ghten the pl ug and thrust beari ng i n the
housi ng unti l fi rml y bottomed i n the housi ng about
34 Nm (25 ft. l bs.).
(5) Pl ace an i ndex mark on the housi ng even wi th
one of the hol es i n adjuster pl ug (Fi g. 27).
(6) Measure back (countercl ockwi se) 10 mm (0.40
i n) and mark housi ng (Fi g. 28).
Fig. 26 Loosening the Adjuster Plug
Fig. 27 Alignment Marking On Housing
Fig. 28 Second Marking On Housing
ZJ STEERING 19 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Rotate adjustment cap back (countercl ockwi se)
wi th spanner wrench unti l hol e i s al i gned wi th the
second mark (Fi g. 29).
(8) I nstal l and ti ghten l ocknut to 108 Nm (80 ft.
l bs.). Be sure adjustment cap does not turn whi l e
ti ghteni ng the l ocknut.
OVER-CENTER
NOTE: Before performing this procedure, the worm
bearing preload adjustment must be performed.
(1) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(2) Starti ng at ei ther stop, turn the stub shaft
back 1/2 the total number of turns. Thi s i s the center
of the gear travel (Fi g. 30).
(3) Pl ace the torque wrench i n the verti cal posi ti on
on the stub shaft. Rotate the wrench 45 degrees each
si de of the center and record the hi ghest rotati onal
torque i n thi s range (Fi g. 31). Thi s i s the Over-Cen-
ter Rotati ng Torque.
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
(4) Rotate the stud shaft between 90 and 180 to
the l eft of center and record the l eft off-center pre-
l oad. Repeat thi s to the ri ght of center and record the
ri ght off-center prel oad. The average of these two
recorded readi ngs i s the Prel oad Rotati ng Torque.
(5) The Over-Center Rotati ng Torque shoul d be
0.45-0.9 Nm (4-8 i n. l bs.) higher than the Prel oad
Rotati ng Torque.
(6) I f an adjustment to the Over-Center Rotati ng
Torque i s necessary, fi rst l oosen the adjuster l ock
nut. Then turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) unti l ful l y extended, then
turn back i n (CLOCKWI SE) one ful l turn.
(7) Remeasure Over-Center Rotati ng Torque. I f
necessary turn the adjuster screw and repeat mea-
surement unti l correct Over-Center Rotati ng Torque
i s reached.
Fig. 29 Aligning To The Second Mark
Fig. 30 Steering Gear Centered
Fig. 31 Checking Over-center Rotation Torque
19 - 18 STEERING ZJ
ADJ USTMENTS (Continued)
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.
(8) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut. Ti ghten the adjuster
l ock nut to 49 Nm (36 ft. l bs.).
SPECIFICATIONS
POWER STEERING GEAR
Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . .Reci rcul ati ng Bal l
Gear Rati o. . . . . . . . . . . . . . . . . . . . . . . . . . .12.7:1
WormShaft Bearing
Prel oad . . . . . . . . . . . .0.45-1.13 Nm (4-10 i n. l bs.)
Pitman Shaft Overcenter Drag
New Gear (under 400 mi l es) . . . . . . .0.45-0.90 Nm
(4-8 i n. l bs.) + Worm Shaft Prel oad
Used Gear (over 400 mi l es). . . . . . . . . .0.5-0.6 Nm
(4-5 i n. l bs.) + Worm Shaft Prel oad
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut. . . . .108 Nm (80 ft. l bs.)
Adjustment Screw Locknut . . . .49 Nm (36 ft. l bs.)
Gear to Frame Bol ts . . . . . . . . .88 Nm (65 ft. l bs.)
Pi tman Shaft Nut . . . . . . . . .251 Nm (185 ft. l bs.)
Rack Pi ston Pl ug . . . . . . . . . .150 Nm (111 ft. l bs.)
Si de Cover Bol ts . . . . . . . . . . . .60 Nm (44 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
Return Li ne. . . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
Return Gui de Cl amp Bol t . . . . .58 Nm (43 ft. l bs.)
SPECIAL TOOLS
POWER STEERING GEAR
Remover/Installer, Steering Plug C-4381
Remover, Pitman Arm C-4150A
Remover/Installer Steering Rack Piston C-4175
ZJ STEERING 19 - 19
ADJ USTMENTS (Continued)
STEERING COLUMN
INDEX
page page
GENERAL INFORMATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 23
GENERAL INFORMATION
STEERING COLUMN
The ti l t col umn (Fi g. 1) has been desi gned to be
servi ced as an assembl y, l ess the wi ri ng, swi tches,
shrouds, steeri ng wheel , etc. Most steeri ng col umn
components can be servi ced wi thout removi ng the
steeri ng col umn from the vehi cl e.
SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Group 8M and fol l ow al l WARNI NGS and
CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
Fig. 1 Steering Column
19 - 20 STEERING ZJ
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove ignition locking link, shaft lock plate or
plate retainer. This will damage the column (Fig. 2)
and (Fig. 3).
DIAGNOSIS AND TESTING
IGNITION SWITCH
TEST AND REPAIR
I f the i gni ti on swi tch effort i s excessi ve, remove the
i gni ti on swi tch from the steeri ng col umn. Refer to
Group 8D I gni ti on System. Usi ng a key cyl i nder,
check the turni ng effort of the swi tch. I f the i gni ti on
swi tch bi nds l ook for the fol l owi ng condi ti ons.
(1) Look for rough areas or fl ash i n the casti ng
and i f found remove wi th a fi l e (Fi g. 4).
(2) Wi th the i gni ti on swi tch removed, sl i de the
sl i der i n i ts sl ot i n the sl eeve and veri fy a l oose fi t
over the l ength of the sl ot. I f the sl i der bi nds i n the
sl ot at any poi nt l i ghtl y fi l e the sl i der or sl ot unti l
cl earance i s achi eved.
(3) I f no bi ndi ng i s found, l i ghtl y fi l e the ramp on
the i gni ti on swi tch, (The ramp fi ts i nto the casti ng)
unti l bi ndi ng no l onger occurs.
Fig. 2 Observe Cautions
Fig. 3 Observe Cautions
Fig. 4 Steering Column Flash Removal And
Non-Serviceable Components
ZJ STEERING 19 - 21
GENERAL INFORMATION (Continued)
REMOVAL AND INSTALLATION
STEERING COLUMN
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. FAILURE TO DO SO MAY RESULT IN ACCI-
DENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. REFER TO GROUP
8M RESTRAINT SYSTEMS FOR SERVICE PROCE-
DURES.
REMOVAL
(1) Posi ti on front wheel s strai ght ahead.
(2) Di sconnect the negati ve (ground) cabl e from
the battery.
(3) Remove the ai rbag, refer to Group 8M
Restrai nt Systems for servi ce procedures.
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel.
(5) Remove col umn coupl er upper pi nch bol t (Fi g.
5).
(6) Remove the knee bl ocker, refer to Group 8E
I nstrument Panel Systems.
(7) Remove ti l t l ever from col umn.
(8) Remove the upper and l ower l ock housi ng
shrouds.
(9) Loosen the col umn mounti ng nut/washer
assembl i es to al l ow the col umn to drop.
(10) Remove the I nterl ock cabl e from the steeri ng
col umn. Refer to Group 21 Transmi ssi on and Trans-
fer Case.
(11) Remove mul ti -functi on swi tch connector screw
and remove connector.
(12) Remove the wi ri ng harness from the remai n-
i ng swi tches and the steeri ng col umn (Fi g. 6).
(13) Remove the i gni ti on swi tch.
(14) Remove the cl ock spri ng, and swi tches refer to
Group 8 El ectri cal for servi ce procedures.
(15) Remove the toe pl ate to dash panel nuts.
Fig. 6 Steering Column Wiring Harness
Fig. 5 Column Coupler Shaft
19 - 22 STEERING ZJ
(16) Remove the mounti ng nut/washer assembl i es
and remove the col umn.
INSTALLATION
(1) Wi th the front wheel s i n the strai ght ahead
posi ti on. Al i gn and i nstal l the col umn to coupl er. Do
not apply force at the top of the steering col-
umn shaft.
(2) Remove the col umn shaft shi ppi ng l ock pi n
(i nstal l ed i n servi ce col umn).
(3) Ensure the ground cl i p i s on spacer sl ot.
(4) I nstal l the I nterl ock cabl e from the steeri ng
col umn. Refer to Group 21 Transmi ssi on and Trans-
fer Case.
(5) I nstal l wi ri ng harness connecti ons to steeri ng
col umn. Ensure the wiring is not pinched and
all connections are correctly locked in place.
(6) I nstal l the cl ock spri ng, and swi tches refer to
Group 8 El ectri cal for servi ce procedures.
(7) I nstal l the harness connector to the swi tches.
(8) I nstal l the i gni ti on swi tch.
(9) I nstal l shaft coupl er pi nch bol t l oose, l oad col -
umn up to panel bracket.
(10) Be sure both spacers are ful l y seated i n the
col umn support bracket. Ti ghten the col umn mount-
i ng nut/washer assembl i es to 12 Nm (105 i n. l bs.).
(11) Ti ghten the toe pl ate attachi ng nuts to 12
Nm (105 i n. l bs.).
(12) Ti ghten the coupl er pi nch bol t to 49 Nm (36
ft. l bs.).
(13) I nstal l the heater cross over tube under the
col umn.
(14) I nstal l the upper and l ower shrouds and ti l t
l ever.
(15) I nstal l the knee bl ocker, refer to Group 8E
I nstrument Panel Systems
(16) I nstal l the steeri ng wheel and ai rbag, refer to
Group 8M Passi ve Restrai nt Systems for procedures.
(17) Connect the battery ground (negati ve) cabl e.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Steering Column
Steeri ng Wheel Nut. . . . . . . . . .61 Nm (45 ft. l bs.)
Col umn Bracket Nuts . . . . . . .12 Nm (105 i n. l bs.)
Shaft Coupl er Bol ts . . . . . . . . . .49 Nm (36 ft. l bs.)
Toe Pl ate Bol ts . . . . . . . . . . . .12 Nm (105 i n. l bs.)
ZJ STEERING 19 - 23
REMOVAL AND INSTALLATION (Continued)
STEERING LINKAGE
INDEX
page page
GENERAL INFORMATION
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 24
SERVICE PROCEDURES
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL AND INSTALLATION
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STEERING DAMPENER . . . . . . . . . . . . . . . . . . . 26
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION
STEERING LINKAGE
The steeri ng l i nkage consi sts of a pi tman arm,
drag l i nk, ti e rod, and steeri ng dampener (Fi g. 1) and
(Fi g. 2). Adjustment sl eeves are used on the ti e rod
and drag l i nk for toe and steeri ng wheel al i gnment.
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.
NOTE: Periodic lubrication of the steering system
components is required. Refer to Group 0, Lubrica-
tion And Maintenance for the recommended mainte-
nance schedule.
SERVICE PROCEDURES
STEERING LINKAGE
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
i t shoul d be repl aced. Before i nstal l i ng a new seal ,
i nspect bal l stud at the throat openi ng. Check for
l ubri cant l oss, contami nati on, bal l stud wear or cor-
rosi on. I f these condi ti ons exi st, repl ace the ti e rod. A
repl acement seal can be i nstal l ed i f l ubri cant i s i n
good condi ti on. Otherwi se, a compl ete repl acement
bal l stud end shoul d be i nstal l ed.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
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.
Fig. 1 Steering Linkage-6 Cylinder Engine
Fig. 2 Steering Linkage-8 Cylinder Engine
19 - 24 STEERING ZJ
REMOVAL AND INSTALLATION
TIE ROD
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1) and (Fi g. 2).
(2) Loosen the bal l studs wi th a pul l er tool to
remove the ti e rod.
(3) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod ends from the tube.
INSTALLATION
(1) I f necessary, i nstal l the ti e rod ends i n the
tube. Posi ti on the ti e rod cl amp (Fi g. 3) and ti ghten
to:
Drag Li nk: 49 Nm (36 ft. l bs.)
Ti e Rod-6 Cyl . Engi ne: 27 Nm (20 ft. l bs.)
Ti e Rod-8 Cyl . Engi ne: 49 Nm (36 ft. l bs.)
(2) I nstal l the ti e rod on the drag l i nk and steeri ng
knuckl e. I nstal l the retai ni ng nuts.
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 47 Nm (35 ft. l bs.). Ti ghten the bal l stud
nut to drag l i nk to 75 Nm (55 ft. l bs.) torque. I nstal l
new cotter pi ns and bend end 60.
PITMAN ARM
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm.
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150A (Fi g. 4).
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten the nut to 251 Nm (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm.
I nstal l nut and ti ghten to 81 Nm (60 ft. l bs.). I nstal l
a new cotter pi n.
DRAG LINK
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1).
(2) Remove the steeri ng dampener bal l stud from
the drag l i nk wi th a pul l er tool .
(3) Remove the drag l i nk from the steeri ng
knuckl e wi th a pul l er tool . Remove the same for ti e
rod and pi tman arm.
(4) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod end from the l i nk.
INSTALLATION
(1) I nstal l the drag l i nk adjustment sl eeve and ti e
rod end. Posi ti on cl amp bol ts (Fi g. 3).
(2) Posi ti on the drag l i nk at the steeri ng l i nkage.
I nstal l the drag l i nk to the steeri ng knuckl e nut. Do
the same for the ti e rod and pi tman arm.
(3) Ti ghten the nut at the steeri ng knuckl e to 47
Nm (35 ft. l bs.). Ti ghten the pi tman nut to 81 Nm
(60 ft. l bs.) and ti e rod bal l stud nut to 47 Nm (35 ft.
l bs.). I nstal l new cotter pi ns and bend end 60.
Fig. 3 Tie Rod/Drag Link Clamp Bolt
Fig. 4 Pitman Arm Removal
ZJ STEERING 19 - 25
(4) I nstal l the steeri ng dampener onto the drag
l i nk and ti ghten the nut to 74 Nm (55 ft. l bs.).
I nstal l a new cotter pi n and bend end 60.
STEERING DAMPENER
REMOVAL
(1) Pl ace the front wheel s i n a strai ght ahead posi -
ti on.
(2) Remove the steeri ng dampener retai ni ng nut
and bol t from the axl e bracket (Fi g. 1).
(3) Remove the cotter pi n and nut from the bal l
stud at the drag l i nk.
(4) Remove the steeri ng dampener bal l stud from
the drag l i nk usi ng C-3894-A pul l er.
INSTALLATION
(1) I nstal l the steeri ng dampener to the axl e
bracket and drag l i nk.
(2) I nstal l the steeri ng dampener bol t i n the axl e
bracket and ti ghten nut to 74 Nm (55 ft. l bs.).
(3) I nstal l the bal l stud nut at the drag l i nk and
ti ghten nut to 74 Nm (55 ft. l bs.). I nstal l a new cot-
ter pi n.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Pitman Arm
Shaft Nut. . . . . . . . . . . . . . . .251 Nm (185 ft. l bs.)
Drag Link
Pi tman Arm Nut . . . . . . . . . . . .81 Nm (60 ft. l bs.)
Knuckl e Nut . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Cl amp Bol ts. . . . . . . . . . . . . . . .49 Nm (36 ft. l bs.)
Tie Rod Ends
4.0L Cl amp Bol ts . . . . . . . . . . . .27 Nm (20 ft. l bs.)
5.2L Cl amp Bol ts . . . . . . . . . . . .49 Nm (36 ft. l bs.)
Tie Rod
Knuckl e Nut . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Drag Link Nut . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Steering Damper
Frame Bol t . . . . . . . . . . . . . . . .74 Nm (55 ft. l bs.)
Drag Li nk Nut. . . . . . . . . . . . . .74 Nm (55 ft. l bs.)
SPECIAL TOOLS
STEERING LINKAGE
Puller C-3894A
Remover Pitman C-4150A
19 - 26 STEERING ZJ
REMOVAL AND INSTALLATION (Continued)