JEEP CHEROKEE 1988 Service Repair Manual

2) Ensure sector shaft cover bolts are tightened to
specification. Using an INCH lb. torque wrench, measure highest torque
required to rotate steering wheel back and forth through the center
position. Meshload must be adjusted if not within specification. See
the MESHLOAD SPECIFICATIONS table.
MESHLOAD SPECIFICATIONS TABLE









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Application INCH Lbs. (N.m)
Cherokee, Comanche & Wrangler .......... ( 1) 4-10 (.5-1.1)
( 1) - In excess of worm bearing preload. Maximum preload is
18 INCH lbs. (2.0 N.m) on Jeep models or 16 INCH lbs.
(1.8 N.m) on all others.









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3) Loosen sector shaft adjuster screw lock nut. Adjust sector
shaft adjuster screw to obtain correct reading. Tighten lock nut to
specification while holding adjusting screw.
4) Reverse removal procedures for components removed. Ensure
reference mark is aligned on pitman arm and sector shaft. Tighten
pitman arm retaining nut to specification. On Jeep models, stake
pitman arm retaining nut in 2 places.
REMOVAL & INSTALLATION
STEERING GEAR
CAUTION: All steering component fasteners are made of special quality
materials. Replacement fasteners must be of same part number
or equivalent. Tighten all fasteners to proper torque.
Install new cotter pin where used.
Removal
1) Disconnect negative battery cable. Set front wheels in
straight-ahead position. Note position of steering wheel. Remove
flexible coupling shield retaining screw (if equipped).
2) Remove flexible coupling-to-steering worm shaft flange
bolts or lower universal joint pinch bolt. Remove sector shaft nut and
washer. Place reference mark in relation of pitman arm-to-sector
shaft. Using Puller (J-6632-01), remove pitman arm. Remove steering
gear-to-frame bolts. Remove steering gear.
Installation
1) Install flexible coupling on worm shaft. Align flat on
coupling with flat on worm shaft. Push coupling on shaft until shaft
touches shoulder. Install pinch bolt. Pinch bolt must pass through
shaft undercut.
2) To install remaining components, reverse removal
procedure. Align reference mark on pitman arm and sector shaft. Ensure
splines are properly aligned. Tighten bolts to specification. On Jeep
models, stake sector shaft nut in 2 areas.
SECTOR SHAFT SEAL
NOTE: On some models, sector shaft seal may be replaced without
removing steering box. It may be necessary to remove
steering gear to gain access to remove sector shaft seal.
Removal & Installation
1) Place steering gear at center of travel. Remove sector

shaft nut. Place reference mark in relation of pitman arm-to-sector
shaft. Using puller, remove pitman arm.
2) Remove sector shaft cover retaining bolts. Lift sector
shaft and cover from housing. Using a screwdriver, pry sector shaft
seal from housing. Use care not to damage housing area. Note direction
of seal installation.
3) Loosen sector shaft adjusting screw lock nut. Rotate
adjusting screw clockwise and remove cover from sector shaft. Inspect
gear lubricant for contamination. Steering gear must be overhauled if
contamination exists.
4) Lubricate new sector shaft seal with steering gear
lubricant. Position seal in housing bore. Using proper sized socket,
tap seal into housing until it bottoms.
5) Install sector shaft so center tooth of sector shaft
enters center tooth of ball nut. Fill housing with lubricant. Install
new sector shaft cover gasket on gear housing (if equipped). Apply a
thin bead of sealant to sector shaft cover on models which do not use
a gasket.
6) Using a screwdriver through the center hole, align
adjusting screw and install cover on sector shaft. See Fig. 1. Turn
adjusting screw counterclockwise until screw bottoms, then back off
1/4 turn.
7) Coat cover bolts with non-hardening sealant. On all
models, install cover retaining bolts. Tighten to specification.
Install sector shaft lock nut. Perform adjustments on steering box.
See ADJUSTMENTS in this article.
Fig. 1: Installing Sector Shaft Cover
OVERHAUL

STEERING GEAR
Disassembly
1) Place steering gear in a holding fixture. Worm shaft
should be centered in steering gear. Remove sector shaft cover bolts.
Remove sector shaft and cover from housing.
2) Remove sector shaft adjusting screw lock nut. Rotate
adjusting screw clockwise to remove cover from shaft. DO NOT lose shim
located on adjusting screw.
3) Loosen worm bearing adjuster lock nut. Remove worm bearing
adjuster and worm shaft lower bearing. Remove worm shaft and ball nut
assembly from housing. Remove upper bearing.
CAUTION: DO NOT allow ball nut to rotate down worm shaft as ball
guides may be damaged.
4) If ball nut fails to rotate smoothly on worm shaft,
disassembly is required. Remove ball guide clamp and guides. Rotate
worm shaft in both directions to remove balls. Note and record number
of balls in each circuit area of the ball nut.
5) Note direction of ball nut on worm shaft prior to removal.
Remove ball nut from worm shaft.
CAUTION: Note and record number of balls removed from each circuit of
ball nut during disassembly. Determine location of ball nut
on worm shaft prior to removal. Ball nut must be installed
on worm shaft with shallow teeth in proper direction.
6) Use slide hammer and puller attachment to remove worm
bearing adjuster bearing cup. See Fig. 2. Using a bearing driver or
socket, remove bearing cup from housing.
7) Remove bearings from housing. Pry out all seals from
housing. Note direction of seals.
Fig. 2: Removing Worm Adjuster Bearing Cup
Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect bearings and races for signs of wear. Inspect ball nut and

worm shaft for wear or pitting.
2) Inspect sector shaft fit at side cover bushing assembly
(if equipped). Bushing is replaceable.
3) Inspect housing for cracks or damage. Inspect bearings for
damage. Inspect sector gear teeth for chipping or excessive wear.
Replace components as necessary.
Reassembly
1) Install sector shaft adjusting screw and shim in sector
shaft. Using feeler gauge, measure clearance between adjusting screw
and bottom of sector shaft "T" slot. See Fig. 3.
Fig. 3: Checking Sector Shaft "T" Slot Clearance
2) Different thickness shims should be used if clearance is
not within specification. See ADJUSTING SCREW CLEARANCE SPECIFICATIONS
table.
ADJUSTING SCREW CLEARANCE SPECIFICATIONS TABLE









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Application In. (mm)
Cherokee, Comanche & Wrangler ................. .002 (.05)









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3) Once correct shim is determined, install shim and
adjusting screw. Hold sector adjuster screw while turning sector
shaft. If sector shaft does not turn freely, increase clearance by

replacing shims as necessary.
4) Install ball nut on worm shaft. Ensure ball nut is
installed so shallow end of teeth are to the left as viewed from
steering wheel end of worm shaft. Align grooves in worm and nut by
sighting through ball guide holes.
5) There are 2 types of ball guides used. One type contains a
hole in the middle, while the other does not. If ball guides contain
the middle hole, install ball guides in the ball nut.
6) Divide balls into 2 equal groups. Insert each group into a
ball guide, while slowly turning worm shaft away from the hole. Repeat
procedure for remaining circuit.
7) On guides with no holes, separate guide halves and fill
each one half of each circuit with balls. Install remaining guide
half. Hold guides and plug ends with grease to prevent the balls from
falling out.
8) Fill each circuit of ball nut with half of remaining balls
in one circuit, and half in other. DO NOT turn worm shaft while
installing. It may be necessary to use small punch to aid in ball
installation. Install ball guides. On both types, install ball guide
clamp.
9) To install, reverse removal procedure. Lubricate all
seals, bearings and sector shaft prior to installation. Coat worm
bearing adjuster, sector shaft adjuster screw and sector shaft cover
bolts with non-hardening sealant prior to installation.
10) Screw worm bearing adjuster down until nearly all end
play has been removed. Lubricate steering gear by rotating worm shaft
until ball nut is at end of its travel.
11) Pack as much grease as possible into steering gear
housing without losing it out sector shaft opening. Rotate ball nut to
other end of its travel and pack more grease into housing.
12) Rotate ball nut until it is in center of its travel.
Insert sector shaft assembly, containing adjusting screw and shim into
housing. Center tooth of sector gear must engage center rack tooth
space in ball nut.
13) Pack housing with grease. Apply a thin bead of sealant to
sector shaft cover on models which do not use gasket. Install cover
and gasket on housing. Engage sector adjuster screw with tapped hole
in center of sector cover by turning screw counterclockwise.
14) Turn adjusting screw until sector cover is flush with
housing. Install sector cover bolts but do not tighten unless there is
a lash between sector shaft and worm shaft.
15) Tighten sector cover bolts to specification. Adjust
steering gear preload and meshload. See ADJUSTMENTS in this article.
Fig. 4: Exploded View of Saginaw Model 525 Steering Gear (Typical)
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Adjuster Screw Lock Nut .......................... 25 (34)
Flex Coupling Pinch Bolt ......................... 45 (61)
Sector Shaft Nut ............................... 185 (252)
Sector Cover Bolt ................................ 32 (43)
Steering Gear-to-Frame Bolt ..................... 75 (102)
Worm Bearing Adjuster Lock Nut ................... 50 (68)









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\003STE ER IN G G EA R - P O W ER

1988 J e ep C hero ke e
1987-88 STEERING
Jeep Power Steering Gears - Saginaw Rotary Valve
Cherokee, Comanche, Grand Wagoneer, Pickup, Wagoneer,
Wrangler
DESCRIPTION
Steering gear is a recirculating ball-type, available in
either a constant or a variable ratio design. Steel balls form a
"rolling thread" between steering gear worm shaft and rack/piston nut.
Worm shaft thrust is absorbed by a thrust bearing and two races at
lower end, and by a bearing in adjuster plug at upper end.
This design puts spring pressure on worm shaft to ensure
proper thrust bearing preload. Adjuster plug provides initial preload
adjustment and service adjustment (when repairing gear). As worm shaft\
is turned right, rack/piston is moved upward in gear.
As worm shaft is turned left, rack/piston is moved downward
in gear. The rack/piston teeth mesh with sector, which is forged as
part of sector shaft. Rotating worm shaft moves sector shaft, which
turns wheels through mechanical linkage. See Fig. 1.
TROUBLE SHOOTING
Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.
LUBRICATION
See POWER STEERING GENERAL SERVICING article.
TESTING
See POWER STEERING GENERAL SERVICING article.

Fig. 1: Exploded View of Saginaw Rotary Valve Power Steering Gear
ADJUSTMENTS
THRUST BEARING PRELOAD ADJUSTMENT
1) Remove steering gear from vehicle. Remove adjuster plug
lock nut. Turn adjuster plug clockwise with a spanner wrench until
plug is seated in housing. This will require 20-30 ft. lbs. (27-41 N.
m) of torque.
2) Place an index mark on housing opposite one spanner wrench
hole in adjuster plug. Measure 1/2" (13 mm) counterclockwise from mark\
and again mark housing. Rotate plug counterclockwise until hole in
adjuster lines up with second mark.
3) Tighten lock nut. Ensure adjuster remains in position.
Attach an INCH lb. torque wrench to end of input shaft. Turn input
shaft to right stop, then back 1/4 turn.
4) Using torque wrench measure rotational torque required to
turn shaft. Reading should be taken with beam of torque wrench near
vertical while turning it counterclockwise at an even rate. Torque
reading should be 4-10 INCH lbs. (.4-1.1 N.m). See. Fig. 2.

NOTE: If reading does not fall within this range, adjuster plug
may have turned while lock nut was being tightened. Steering
gear may be incorrectly assembled or worm shaft thrust
bearings and races may be defective. Repair as required and
readjust preload.
Fig. 2: Measuring Thrust Bearing Preload
OVER-CENTER PRELOAD TORQUE ADJUSTMENT
1) Loosen adjuster screw lock nut. Back off adjuster screw
until stopped, then turn in 1 full turn. Rotate input shaft from stop
to stop counting number of turns. Turn shaft half way back to center
position.
2) Attach an INCH lb. torque wrench to input shaft. Turn

shaft from side to side through specified arc on each side of center.
See OVER-CENTER PRELOAD chart. Note torque reading going over center.
Adjust thrust bearing preload before over-center preload. See Fig. 3.
OVER-CENTER PRELOAD SPECIFICATIONS - INCH LBS. (N.m)









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Application Arc Over-Center (1) Total
New Gears .......... 45
 ........ 4-8 (.4-.9) ......... 14 (1.5)
Used Gears ( 2) ..... 45 ........ 4-5 (.5-.6) ......... 14 (1.5)
( 1) - Total preload is sum of thrust bearing and over-center preload.
( 2) - In service for more than 400 miles (640 km.).









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Fig. 3: Adjusting Over-Center Preload
REMOVAL & INSTALLATION
POWER STEERING PUMP
Removal & Installation
1) Loosen and remove pump drive belt. Disconnect pressure and
return hoses from pump. Cap ends to prevent loss of fluid or
contamination.
2) Remove bracket-to-engine bolts. Remove pump and mounting
bracket as an assembly. To install, reverse removal procedure. Fill
and bleed system.