JEEP CHEROKEE 1994 Service Repair Manual

REARÐXJ,YJ VEHICLES
REMOVAL
(1) Shift the transmission and transfer case (if ap-
plicable) to their Neutral positions. Raise the vehicle.
(2) Scribe alignment marks at the pinion shaft and
at each end of the propeller shaft. These marks will
be used for installation reference.
(3) Remove the U-joint strap bolts at the pinion
shaft yoke.
(4) Slide the slip yoke off of the transmission/
transfer case output shaft and remove the propeller
shaft (Fig. 3).
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
case output shaft. Align the installation reference
marks at the axle yoke and install the propeller shaft
(Fig. 3).
Replacement U-joint straps and bolts must be
installed.
(2) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 Nzm (14 ft. lbs.) torque.
(3) Lower the vehicle.
FRONTÐYJ VEHICLES
REMOVAL
(1) Raise the vehicle.
(2) Scribe alignment marks on the yokes at the
transfer case. Place marks at the pinion shaft and at
each end of the propeller shaft. These marks will be
used for installation reference (Fig. 4).(3) Remove the U-joint strap bolts at the pinion
shaft yoke.
(4) Disconnect the propeller shaft at the transfer
case and remove the propeller shaft.
INSTALLATION
(1) Position the propeller shaft with the reference
marks aligned (Fig. 4). Install the propeller shaft.
Replacement U-joint straps and bolts must be
installed.
(2) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 Nzm (14 ft. lbs.) torque.
(3) Tighten the U-joint strap/clamp to transfer case
bolts to 27 Nzm (19.5 ft. lbs.) torque.
(4) Tighten the U-joint strap bolts to 19 Nzm (14 ft.
lbs.) torque.
(5) Lower the vehicle.
Fig. 3 Rear Propeller Shaft
Fig. 4 YJ Front Propeller Shaft
Fig. 2 Front Propeller Shaft
16 - 8 PROPELLER SHAFTSJ

UNIVERSAL JOINT REPLACEMENT
PRECAUTIONS
It is very important to put reference marks on the
yokes before removal or component service (Fig. 1).
This will assure correct phasing and eliminate possi-
ble vibration.
SINGLE CARDAN
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2)Paint or score alignment marks on the yokes
and propeller shaft for installation reference.
(3) Using a soft drift, tap the outside of the bear-
ing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke
(Fig. 2).
(5) Set the yoke in an arbor press or vise with a large
socket beneath it. Position the yoke with the lube fit-
ting pointing up (if equipped). Place a smaller socket on
the upper bearing assembly and press it through to re-
lease the lower bearing assembly (Fig. 3).
(6) If the bearing assembly will not pull out by
hand after pressing, tap the base of the lug near it to
dislodge.
(7) To remove the opposite bearing, turn the yoke
over and straighten the cross in the open hole. Then
carefully press the end of the cross until the remain-
ing bearing can be removed (Fig. 4).
CAUTION: If the cross or bearing assembly are cocked
when being pressed, the bearing assembly will score
the walls of the yoke bore and ruin the yoke.
CLEANING AND INSPECTION
(1) Clean all the universal joint yoke bores with
cleaning solvent and a wire brush.
(2) Inspect the yokes for distortion, cracks and
worn bearing assembly bores.
ASSEMBLY/INSTALLATION
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to aid in installation.
(2) Position the cross in the yoke with its lube fit-
ting (if equipped) pointing up (Fig. 5).
(3) Place a bearing assembly over the trunnion and
align it with the cross hole (Fig. 6). Keep the needle
bearings upright in the bearing assembly. A needle
roller lying at the bottom will prevent proper assembly.
Fig. 1 Reference Marks on Yokes
Fig. 2 Remove Snap Ring
Fig. 3 Press Out Bearing
JPROPELLER SHAFTS 16 - 9

(4) Press the bearing assembly into the cross hole
enough to install a snap ring. Install a snap ring.
(5) Repeat steps 3 and 4 to install the opposite
bearing assembly. If the joint is stiff, strike the yoke
with a soft hammer to seat the needle bearings. In-
stall a snap ring.
(6) Add grease to lube fitting (if equipped).
(7) Install the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
DOUBLE CARDAN (CV)
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2)Paint or score alignment marks on the yokes
and propeller shaft for installation reference.
(3) Remove all the bearing assembly snap rings (Fig.
7).
Fig. 4 Press Out Remaining Bearing
Fig. 5 Install Cross In Yoke
Fig. 6 Install Bearing On Trunnion
Fig. 7 Remove Snap Rings
16 - 10 PROPELLER SHAFTSJ

(4) Press the bearing assembly partially from the
outboard side of the center yoke, enough to grasp by
vise jaws (Fig. 8). Be sure to remove any lube fittings
that may interfere with removal.
(5) Grasp the protruding bearing by vise jaws. Tap
the tube yoke with a mallet and drift to dislodge
from the yoke (Fig. 9).
(6) Flip assembly and repeat steps 4 and 5 for re-
moving the opposite side bearing. This will then al-
low removal of the cross centering kit assembly and
spring (Fig. 10).(7) Press the remaining bearing assemblies out the
other cross as described above to complete the disas-
sembly.
CLEANING AND INSPECTION
(1) Clean all the U-joint yoke bores with cleaning
solvent and a wire brush.
(2) Inspect the yokes for distortion, cracks and
worn bearing assembly bores.
ASSEMBLY/INSTALLATION
During installation, ensure that the spiders
and yokes are aligned to the reference marks.
(1) Fit a cross into the tube yoke (Fig. 11).
Fig. 8 Press Out Bearing
Fig. 9 Remove Bearing From Yoke
Fig. 10 Remove Centering Kit
Fig. 11 Install Cross In Yoke
JPROPELLER SHAFTS 16 - 11

(2) Place a bearing assembly in a tube yoke hole
and over a trunnion. Keep the needle bearings up-
right in the bearing assembly (Fig. 12). A needle
roller lying at the bottom will prevent proper assem-
bly. Be sure to remove any lube fittings that may in-
terfere with removal.
(3) Press the bearing assembly in place and install
a snap ring (Fig. 13).(4) Flip the tube yoke and bearing assembly instal-
lation on the opposite trunnion. Install a snap ring
(Fig. 14).
(5) Fit the center yoke on the remaining two trun-
nions and press bearing assemblies in place, both
sides (Fig. 15). Install a snap ring.
Fig. 12 Install Bearing Assembly
Fig. 13 Press In Bearing Assembly
Fig. 14 Press In Bearing Assembly
Fig. 15 Install Center Yoke
16 - 12 PROPELLER SHAFTSJ

(6) Install the centering kit assembly inside the
center yoke making sure the spring is in place (Fig.
16). Align the lube fitting on the centering kit with
the lube fitting on the installed cross.
(7) Place two bearing assemblies on the remaining
cross (opposite sides). Fit the open trunnions into the
center yoke holes and the bearing assemblies into
the centering kit (Fig. 17). Align the lube fitting on
the cross with the other two lube fittings.(8) Press the remaining two bearing assemblies
into place and install snap rings (Fig. 18).
(9) Tap the snap rings to allow them to seat into
the grooves (Fig. 19).
Fig. 16 Install Centering Kit
Fig. 17 Install Remaining Cross
Fig. 18 Press In Bearing Assembly
Fig. 19 Seat Snap Rings In Groove
JPROPELLER SHAFTS 16 - 13

(10) Check for proper assembly. Flex the CV joint
beyond center, it should snap over-center in both di-
rections when correctly assembled (Fig. 20).
(11) Add grease to all three lube fittings.
(12) Install the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
TORQUE SPECIFICATIONS
Fig. 20 Check Assembly
PROPELLER SHAFTS AND U-JOINTS
16 - 14 PROPELLER SHAFTSJ

STEERING
CONTENTS
page page
GENERAL INFORMATION.................. 1
MANUAL STEERING GEAR............... 35
NON-TILT STEERING COLUMN............ 50
POWER STEERING PUMP................. 9
POWER STEERING SYSTEM DIAGNOSIS..... 3
RECIRCULATING BALL POWER STEERING GEAR.19STEERING COLUMN GENERAL SERVICE.... 45
STEERING LINKAGEÐXJ................. 14
STEERING LINKAGEÐYJ................. 17
STEERING RHD........................ 69
TILT STEERING COLUMN................ 59
TORQUE SPECIFICATIONS................ 73
GENERAL INFORMATION
STEERING SYSTEM COMPONENTS
Jeep vehicles can have either a manual or power
steering system (Fig. 1). A recirculating-ball type
steering gear is used for both systems.
Power steering systems use;
²Steering gear
²Pressure and return fluid hoses and fittings
²Belt driven steering pump
²Integral or remote body mounted pump reservoir
POWER STEERING GEAR
The steering gear is mounted on the left frame rail.
The gear is joined to the intermediate shaft by a uni-
versal joint coupling. The coupling helps isolate noise
and road shock from the interior.
The major internal components of the gear are the:
²Rotary valve assembly
²Steering worm shaft
²Rack piston assembly
²Pitman shaft
The movement of these parts, while turning or
parking, is aided by hydraulic pressure and flow sup-plied by the pump. Manual steering is always avail-
able at times when the engine is not running or in
the event of pump or belt failure. Steering effort is
higher under such conditions.
The steering stub shaft, rotary valve, worm shaft,
and rack piston assembly are all in line. The oil pas-
sages are internal within the gear housing except for
pressure and return hoses between the gear and
pump.
The power steering gear has a recirculating ball
system. This acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned right, the rack piston moves up in
gear. Turning the worm shaft left moves the rack
piston down in gear. The rack piston teeth mesh with
the sector, which is part of the pitman shaft. Turning
the worm shaft turns the pitman shaft, which turns
the wheels through the steering linkage.
The control valve in the steering gear directs the
power steering fluid to either side of the rack piston.
The rack piston is assisted by hydraulic pressure. If
the steering system loses hydraulic pressure, the ve-
hicle can be controlled manually, but with higher
steering effort.
An identification code located on the side cover des-
ignates the gear ratio (Fig. 2).
²Code BH designates 14:1 ratio used in XJ vehicles
²Code BF designates 13-16:1 ratio used in YJ vehi-
cles
A recirculating-ball steering gear is used with the
power (assisted) steering system (Fig. 1). The power
steering gear can be adjusted and internally serviced.
POWER STEERING PUMP
Hydraulic pressure is provided for operation of the
power steering gear by a belt driven power steering
Fig. 1 Steering Gears
JSTEERING 19 - 1

pump. The power steering pump is a constant flow
rate and displacement, 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 con-
trol valve limits the pump pressure.
Power steering pumps have different pres-
sure rates and are not interchangeable with
other pumps.
The power steering pump is connected to the steer-
ing gear via high pressure and return hose. The
pump shaft has a pressed-on drive pulley that is belt
driven by the crankshaft pulley (Fig. 3).
XJ vehicles with 2.5L engines and all YJ vehicles:
The reservoir is mounted at the front left side of the
engine compartment. XJ vehicles equipped with a
4.0L engine have the reservoir attached to the pump
body with spring clips.
STEERING COLUMNS
Two general types of steering columns are installed
on Jeep vehicles: a fixed, non-tilt column and a tilt
column (Fig. 4).
The ignition key/lock cylinder is located in the
steering column. When the key/lock cylinder is
turned to the LOCK position, the ignition switch and
steering shaft cannot be operated. For vehicles with
an automatic transmission, the lock mechanism also
prevents operation of the gear shift mechanism.The center, slip-type intermediate shaft is attached
to the steering gear and steering column shaft with
universal joints.
Both types of steering columns have anti-theft pro-
visions. They are energy-absorbing.
Fig. 3 TC Series Pump With Integral Reservoir
Fig. 4 Steering Columns
Fig. 2 Ratio Code Location
19 - 2 STEERINGJ

POWER STEERING SYSTEM DIAGNOSIS
PUMP PRESSURE TEST
(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 Gauge 7617 (J21567) to both hoses us-
ing adapter fitting (Fig. 1). Connect spare pressure
hose to gear or pump.
(4) Open the test valve completely.
(5) Start engine and let idle.
(6) Check fluid level, add fluid as necessary.
(7) Gauge should read below 862 kPa (125 psi), if
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure 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 5 seconds as the pump could be
damaged.
(8) Close valve fully three times and record highest
pressure indicated each time.All three readings
must be above specifications and within 345
kPa (50 psi) of each other.
²Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
²Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time.
Pump damage will result.
(9) Open the test valve, turn steering wheel ex-
treme left and right positions against the stops.
Record the highest indicated pressure at each posi-
tion. Compare readings to specifications. If highest
output pressures are not the same against either
stop, the gear is leaking internally and must be re-
paired.
Fig. 1 Pressure Test Gauge
PUMP OPERATING SPECIFICATIONS
JSTEERING 19 - 3