JEEP XJ 1995 Service And Repair Manual

(20) Remove the key warning buzzer switch and
contacts as a unit (Fig. 5). Use needle-nose pliers or
a paper clip bent at a right angle (90 degrees).
(21) Turn ignition key/lock cylinder to the ON po-
sition. Insert a thin screwdriver into the slot adjacent
to the switch attaching screw boss (right-hand slot).
Depress the spring latch located at the bottom of the
slot to release the key/lock cylinder. Remove the cyl-
inder (Fig. 6).
(22) Remove the ignition switch and dimmer switch
(Fig. 7) from the lower end of the steering column.
(23) Remove the screws that attach the key/lock
cylinder housing cover to the steering column jacket.
Remove the cover.
(24) Remove the upper bearing race and the bear-
ing seat from the steering shaft (Fig. 8).
(25) Install the tilt-release lever and place the
steering column in the full upward tilt position.
WARNING: THE TILT SPRING GUIDE RETAINER RE-
TAINS STRONG SPRING FORCE.
(26) Press the tilt spring guide retainer inward.
Turn it counterclockwise until the tabs disengage
from the key/lock cylinder housing lugs. Ensure that
the screwdriver blade properly fits the retainer slot.
Remove the tilt spring guide retainer, the guide and
the spring from the housing (Fig. 9).
Fig. 3 Turn Signal Switch Wire Harness Connector
Fig. 4 Turn Signal Switch Removal
Fig. 5 Key Warning Buzzer/Contacts Removal
Fig. 6 Key/lock Cylinder Removal
JSTEERING 19 - 67

(27) Position the steering column in the center,
non-tilt position.
(28) Remove the support pivot pins with Pivot Pin
Remover C-4016 (Fig. 10).
(29) Lift the tilt-release lever to release the lock
shoes. Pull the key/lock cylinder housing upward to
disengage the shoes. Turn the housing clockwise to
separate the lock rack from the remote rod. Remove
the cylinder housing from the support (Fig. 11).
(30) Remove the tilt-release lever from the key/lock
cylinder housing.
Fig. 10 Pivot Pin Removal
Fig. 11 Key/Lock Cylinder Housing Removal
Fig. 7 Ignition Switch & Dimmer Switch
Fig. 8 Steering Shaft Bearing Race & Seat
Fig. 9 Retainer/Guide/Spring Removal
19 - 68 STEERINGJ

(31) Remove the lock sector spring retaining screw
and then remove the spring (Fig. 12). Rotate the
spring in a clockwise direction to remove it from the
lock bolt.
(32) Remove the lock bolt, the lock rack, the rack
preload spring and the remote rod from the cylinder
housing.
(33) Insert a wedge between the lock shoes and the
key/lock cylinder housing (Fig. 13). This will relieve
spring tension on the tilt-release lever pin and lock
shoe pin.(34) Remove the tilt-release lever pin from the key/
lock cylinder housing with a standard pin punch (Fig.
14).
(35) Remove the lock shoe pin from the key/lock
cylinder housing with a standard pin punch (Fig. 15).
Remove the lock shoes, the springs and wedge.
(36) Remove the upper and the lower bearings and
races from the key/lock cylinder only if they are dam-
aged or worn. If the bearings and the races must be
Fig. 12 Lock Sector Spring Removal
Fig. 13 Wedge Between Lock Shoes & Housing
Fig. 14 Tilt-release Lever Pin Removal
Fig. 15 Lock Shoe Pin Removal
JSTEERING 19 - 69

replaced, remove them with a hammer and punch.
Discard the bearings and races after removal. They
are not reusable.
(37) Remove the steering shaft from the upper end
of the steering column.
(38) Separate the steering shaft by folding it 90 de-
grees at the flexible joint. Detach the upper and the
lower shaft halves (Fig. 16).
(39) Remove the attaching bolts and the steering
column support (Fig. 17).(40) Remove the retaining screws and shift gate
from the steering column support.
(41) Remove the retainer and the bearing from the
lower end of the steering column.
(42) Remove the shift tube retaining ring and the
thrust washer.
(43) Remove the shift tube from the steering col-
umn jacket with Shift Tube Remover C-4120 (Fig.
18).
(44) Tilt the upper end of the retainer plate toward
the lower end of the column, turn the plate counter-
clockwise and remove it (Fig. 19).
Fig. 16 Steering Shaft Separation
Fig. 17 Steering Column Support Removal
Fig. 18 Shift Tube Removal
Fig. 19 Retainer Plate Removal
19 - 70 STEERINGJ

(45) If equipped with a column shift:
²Remove the wave washer and the shift tube spring
²Remove the shift bowl from the steering column
jacket
(46) If equipped with a console shift, remove the
key-release lever and the lever spring from the
shroud. Tilt the lever forward and lift upward to re-
move it (Fig. 20).
ASSEMBLY
WARNING: USE ONLY THE ORIGINAL OR EXACT
REPLACEMENT SCREWS, BOLTS AND NUTS TO
ASSEMBLE THE STEERING COLUMN. INCORRECT
SCREW OR BOLT LENGTH COULD PREVENT THE
COLUMN FROM COMPRESSING WITH IMPACT
(FRONT-END COLLISION). ALL FASTENERS USED
FOR ASSEMBLY MUST BE TIGHTENED WITH THE
CORRECT TORQUE. THIS WILL ENSURE THE COL-
UMN WILL BREAKAWAY WITH IMPACT.
CAUTION: Apply chassis lubricant to all the bear-
ing, thrust and friction producing mating surfaces
before assembly.
(1) Install the shift bowl on the steering column
jacket.
(2) Install the shift tube spring, wave washer and
retainer plate in the shift bowl.
(3) Insert the shift tube through the lower end of
the steering column jacket. Align the tube key/spline
with the shift bowl keyway.
(4) Insert the Shift Tube Installer C-4119 in the
shift tube. The spring-loaded lower foot of the toolmust engage the shift tube inner shoulder. The tool
guide must be seated in the shift tube (Fig. 21).
(5) Tighten the nut on the stud (Fig. 21) only
enough to obtain a snug fit against the spring ten-
sion.
(6) Remove the nut and place the receiver installa-
tion tool over the stud (Fig. 22).
(7) Install the nut and tighten it to force the shift
tube into the shift bowl (Fig. 22).
(8) Remove the shift tube installation tools.
Fig. 20 Key-Release Lever & Spring Removal
Fig. 21 Shift Tube Installation
Fig. 22 Shift Tube Installation
JSTEERING 19 - 71

(9) Install the shift tube thrust washer and the re-
tainer plate snap ring.
(10) Install the lower bearing in the steering col-
umn.
(11) Position the shift gate in the steering column
support. Install the attaching screws.
(12) Position the support in the steering column.
(13) Install all support attaching screws finger-
tight. Next, tighten the screws alternately and evenly
to7Nzm (60 in. lbs.) torque.
(14) Install the remote rod in the support. Route
the rod through the upper end of the shroud and in-
sert it into the rod slot located in the support.
(15) Install the dimmer switch and ignition switch.
(16) Install the steering shaft in the steering col-
umn.
(17) Install replacement races and bearings in the
key/lock cylinder, if removed.Ensure that the bear-
ings are lubricated with chassis lubricant be-
fore installation.
(18) Install the lock shoes, the lock shoe springs
and the lock shoe pin the key/lock cylinder housing.
Use a 4.5-mm (0.18-in) diameter rod to align the
shoes and the pin during installation.
(19) Install the tilt-release lever, the lever spring
and the lever pin in the key/lock cylinder housing.
Insert a wedge between the housing and the lever to
relieve the spring tension. This will allow easier re-
lease lever pin installation.
(20) Install the lock bolt in the key/lock cylinder
housing and engage it in the lock sector cam surface.
(21) Install the lock rack, the rack preload spring
and a replacement shim in the key/lock cylinder
housing. Align and mate the square block tooth on
the lock rack and the lock sector.
(22) Install the lock spring and the spring retain-
ing screw. Tighten the screw to 4 Nzm (35 in. lbs.)
torque.
(23) Align and install the assembled key/lock cylin-
der housing on the support. Retain the lock shoes in
the disengaged position for easier housing installa-
tion.
(24) Align the pivot pin holes in the housing with
those in the support. Insert the pivot pins.Press the
housing firmly downward when inserting the
pivot pins. This prevents damaging the holes in
the support.When the pivot pins are within both
the housing and the support holes, seat them fully
with a punch and a hammer.
(25) Insert tilt-release lever in key/lock cylinder
housing and place housing in the full-upward tilt po-
sition.
(26) Lubricate the tilt spring guide and the tilt
spring liberally with chassis lubricant and position
the spring on the guide.
(27) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re-tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down-
ward and turning clockwise with a screwdriver.
(28) Place the cover on the key/lock cylinder hous-
ing. Align and install the cover retaining screws.
Tighten the screws to 7 Nzm (60 in. lbs.) torque.
(29) Install the gear selector indicator lamp mount-
ing bracket screw.
(30) Install the gear selector indicator cover and
retaining screws.
(31) Route the dimmer switch wire harness and
gear selector indicator down through the steering col-
umn.
(32) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive
shaft. Force it inward and move the ignition switch
actuator rod up and down to align the components.
When the components align, the key/lock cylinder
will move inward and the spring-loaded retainer will
snap and lock it in place (Fig. 23).
(33) Insert the ignition key in the cylinder and
turn it to the ON position. Install the key warning
buzzer switch.
(34) Install the turn signal switch. Fold the wires
against the connector. Route the wire harness and
connector down through the steering column. Posi-
tion the switch in the key/lock cylinder housing.Do
notinstall the switch retaining screws at this time.
(35) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
Fig. 23 Key/Lock Cylinder Installation
19 - 72 STEERINGJ

(36) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(37) Insert the hazard warning knob in the hazard
warning switch and press it inward. Align and install
the turn signal switch retaining screws. Ensure that
the turn signal switch is properly seated before tight-
ening the screws. Tighten the screws to 4 Nzm (33 in.
lbs.) torque. Thread the hazard warning switch knob
into the switch and pull the knob outward.
(38) Install and seat the upper bearing race in the
key/lock cylinder housing.
(39) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(40) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor
C-4156. Install the tool on the steering shaft (Fig.
24).
(41) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(42) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be-
fore removing the tool.
(43) Position the wire harness protectors if
equipped, over the harnesses and snap in place on
steering column.
(44) Install the lockplate cover.
(45) Install the gear selector lever and the retain-
ing pin.
(46) Install the steering wheel. Refer to the instal-
lation procedure.
(47) Insert the ignition key in the key/lock cylin-
der; turn the cylinder to the OFF-UNLOCK position ;
move the ignition switch downward to eliminate any
switch-to-remote rod lash; and tighten the ignition
switch attaching screws to 4 Nzm (35 in. lbs.) torque.(48) Depress the dimmer switch slightly and insert
a 3/32-inch drill bit into the adjustment hole.
(49) Loosen the retaining screws and move the
dimmer switch toward the steering wheel. Tighten
the dimmer switch retaining screws to 4 Nzm (35 in.
lbs.) torque.
(50) Remove the drill bit and test operation by
moving the dimmer switch stalk. Test the dimmer
switch operation in the full-up, down and center
steering wheel positions.
(51) Install the steering column, if applicable. Re-
fer to the installation procedure.
Fig. 24 Lockplate Retaining Ring Installation
JSTEERING 19 - 73

STEERING RHD
GENERAL SERVICE PROCEDURE INFORMATION
Right hand drive service procedures and torque
specifications involving steering; linkage, gear and
column are the same as left hand drive vehicles ex-
cept where shown. Refer to appropriate service pro-
cedures regarding each component in the system.
The steering linkage consists of a pitman arm, drag
link, and tie rod. Adjustment sleeves are used on the
tie rod and drag link for toe and steering wheel
alignment (Fig. 1).
RECIRCULATING-BALL POWER STEERING GEARS
The steering gears can be adjusted and internally
serviced. The components CANNOT be interchanged
with those of a left hand drive vehicle.
The steering gear has a 17.5:1 ratio.
POWER STEERING PUMP
PRESSURE AND RETURN LINE
REPLACEMENT
Cap hose open ends and pump/steering gear fit-
tings to prevent entry of foreign material.
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE LINES TO TOUCH A
HOT EXHAUST MANIFOLD.REMOVAL
(1) Place a drain pan under the pump and gear.
(2) Disconnect the pressure and return line from
the steering gear (Fig. 2, 3).
(3) Disconnect the pressure and return line from
the pump (Fig. 4). Drain the fluid from pump and
reservoir.
Fig. 1 RHD Steering Linkage
Fig. 2 Fluid Lines On Steering Gear
19 - 74 STEERINGJ

(4) Remove pressure and return line bracket at
belt tensioner (Fig. 5).
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.(2) Install pressure and return line on the pump
and gear (Fig. 2, 3, 4).
(3) Align the pressure and return line bracket to
the tensioner bracket. Install the screw. Tighten the
screw to 28 Nzm (21 ft. lbs.) torque.
Fig. 4 Fluid Lines At Pump
Fig. 5 Pressure And Return Line Routing
Fig. 3 Pressure And Return Lines
JSTEERING 19 - 75

(4) Tighten fittings at pump and gear to 28 Nzm
(21 ft. lbs.) torque.
(5) After installation, add power steering fluid, in-
spect and test for fluid leaks.
PUMP REPLACEMENT
REMOVAL
(1) Remove and cap pressure and return lines from
pump. Refer to Pressure and Return Line Replace-
ment in this section.(2) Remove belt tension, turn tensioner clock-wise
and slip belt off pulley (Fig. 6).
(3) Remove the screws retaining front bracket and
pump to the rear bracket (Fig. 7, 8).
(4) Remove screws that attach the front bracket to
the rear bracket (Fig. 9).
(5) Remove pump from bracket.
To remove the rear bracket from engine, the air
conditioning compressor and bracket must be re-
moved first. Refer to Group 24, Heating and Air Con-
ditioning for removal procedures.
(6) Remove fan from pulley and hub on rear
bracket.
(7) Remove 4 screws attaching the rear bracket to
block (Fig. 10, 11).
(8) Remove bracket from engine.
Fig. 6 Belt Tensioner
Fig. 7 Pump Mounting Screw Removal/Installation
Fig. 8 Power Steering Pump Mounting
Fig. 9 Front Bracket
19 - 76 STEERINGJ