light JEEP CHEROKEE 1994 Service Repair Manual

(2) Remove fitting from pump housing (Fig. 10).
Prevent flow control valve and spring from
sliding out of housing bore.
(3) Remove and discard O-ring seal.
INSTALLATION
(1) If necessary, clean and install flow control valve
and spring in pump housing bore.Be sure the hex
nut end of the valve is facing in toward pump.
(2) Install O-ring seal onto fitting (Fig. 10).(3) Install flow control valve in pump housing and
tighten to 75 Nzm (55 ft. lbs.) torque.
(4) Install pressure hose to valve.
POWER STEERING PUMPÐINITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only Mopar Power Steering Fluid. Do not
use automatic transmission fluid. Do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the
fluid is at normal temperature 21ÉC to 27ÉC (70ÉF to
80ÉF).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 10 Flow Control Valve Fitting
JSTEERING 19 - 13

CAUTION: Do not turn stub shaft any farther than
necessary. The recirculating balls will drop out of
the rack piston circuit and fall inside the rack pis-
ton chamber.
(3) Remove O-ring seal (Fig. 17).
ASSEMBLE
²Lubricate O-ring seal with power steering fluid
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 mm (1
inch) from access hole (Fig. 18).
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
ADJUSTER PLUG ASSEMBLY REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span-
ner Wrench C-4381 (J7624) (Fig. 19).
(3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 20).
Fig. 17 End Plug Components
Fig. 18 Installing The Retaining Ring
Fig. 19 Remove/Install Adjustment Plug
Fig. 20 Remove Retainer
JSTEERING 19 - 27

(2) Remove stub shaft and valve assembly (Fig.
25).
(3) Remove stub shaft from valve assembly, if nec-
essary.
²Tap stub shaft lightly on a block of wood to loosen
shaft cap
²Pull cap and valve body and disengage stub shaft
pin from hole in valve body (Fig. 26).
(4) Remove valve assembly if necessary.
²Remove valve spool by pulling and rotating from
valve body (Fig. 27).
²Remove valve spool O-ring seal
²Remove valve body teflon rings and O-ring seals
(Fig. 28).
ASSEMBLE
(1) Install valve spool O-ring seal to valve spool.
(2) Lubricate valve spool and O-ring seal with
power steering fluid.
(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. 29).
²Notch in stub shaft cap MUST fully engage valve
body pin and seat against valve body shoulder.
(5) Install O-ring seals and teflon rings to valve
body.
(6) Lubricate O-ring seals and teflon rings with
power steering fluid.
Fig. 24 Tighten Lock Nut
Fig. 25 Bearing, Worm and Valve Assembly
Fig. 26 Remove and Install Stub Shaft
Fig. 27 Remove and Install Spool
JSTEERING 19 - 29

CLEAN AND INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
(2) Check for scores, nicks or burrs on the rack pis-
ton finished surface. Slight wear is normal on the
worm gear surfaces.
ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston and
align worm shaft spiral groove with rack piston ball
guide hole (Fig. 33).
WARNING: MAKE SURE ALL RACK PISTON BALLS
ARE REINSTALLED IN THE RACK PISTON. IM-
PROPER INSTALLATION MAY RESULT IN PER-
SONAL INJURY.There are 24 balls in the rack piston circuit,
12 are black and 12 are silver (Chrome). The
black rack piston balls are smaller than the sil-
ver balls. THE BLACK AND SILVER BALLS
MUST BE INSTALLED ALTERNATELY INTO
THE RACK PISTON AND BALL GUIDE. This
procedure will maintain worm shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning wormshaft COUN-
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 34).
(5) Install guide onto rack piston and return with
clamp and screws. Tighten screws to 58 Nzm (43 in.
lbs.) torque.
(6) Insert Arbor C-4175 (J-21552) into bore of rack
piston. Hold tool tightly against worm shaft while
Fig. 34 Balls in the Return Guide
Fig. 31 Remove and Install Rack Piston
Fig. 32 Remove and Install Seal on Rack Piston
Fig. 33 Installing Balls in Rack Piston
JSTEERING 19 - 31

There are a total of 50 recirculating balls
within the ball nut and the guides (25 in each
circuit).
(4) Remove the wormshaft from the ball nut (Fig.
2).
CLEANING AND INSPECTION
(1) Clean all the components in a cleaning solvent
and dry them with a clean cloth and/or compressed
air.
(2) Inspect each component for wear, scoring,
cracks, nicks and surface pitting. Replace as neces-
sary.
WORMSHAFT AND BALL NUT ASSEMBLY
CAUTION: The ball nut teeth are wider and deeper
on one side than on the other.
(1) Position the ball nut with the recirculating ball
guide holes facing upward and the ball nut teeth fac-
ing downward. Install the wormshaft in the ball nut.
Rotate the shaft and thread it into the nut until an
equal number of shaft threads are visible at each end
of the nut (Fig. 4).
(2) Install one recirculating ball in each ball guide
hole. Move the wormshaft up/down and side-to-side
until the balls roll into the ball nut threads at the
bottom of wormshaft and support the wormshaft.
(3) Assemble and install the ball guides in the ball
nut (Fig. 5).
(4) Divide the remaining 48 recirculating balls into
two groups and install 24 balls in each ball nut cir-
cuit. Insert the balls in the ball nut circuits through
the holes in the ball guides (Fig. 5).To aid the recirculating ball installation, ro-
tate wormshaft back and forth slightly while in-
serting the balls.
(5) Place the ball guide clamp on the ball nut and
install the clamp retaining screws. Tighten the
screws to 14 Nzm (10 ft. lbs.) torque.
CAUTION: To avoid damaging the tangs on the ball
guide ends, do not allow the wormshaft to travel to
the end of the thread in either direction.
(6) Lubricate the wormshaft threads with chassis
lubricant. Rotate the shaft to move it in and out of
the ball nut and distribute the lubricant.
Fig. 3 Shaft Seal RemovalFig. 4 Wormshaft & Ball Nut
Fig. 5 Recirculating Ball Installation
JSTEERING 19 - 39

(7) Lubricate the wormshaft upper bearing with
chassis lubricant and install it on the wormshaft.
WORMSHAFT BEARING ADJUSTMENT CAP
DISASSEMBLY
(1) Pry out and remove the wormshaft lower bear-
ing retainer from the adjustment cap (Fig. 6).
(2) Remove the wormshaft lower bearing from the
adjustment cap.
CLEANING/INSPECTION
(1) Clean all the components in cleaning solvent
and dry with a clean cloth only.
(2) Inspect each component for wear and damage.
Replace as necessary.
WORMSHAFT BEARING ADJUSTMENT CAP
ASSEMBLY
(1) Remove the lower bearing cup Remover 7837
(J-29369-1) and Slide Hammer C-637 (J-2619-01)
(Fig. 7). Install a new bearing cup in the cap with a
correct sized socket (Fig. 8).
(2) Lubricate the wormshaft lower bearing and
place it in the bearing cup.
(3) Install the lower bearing retainer on the ad-
justment cap. If necessary, tap the retainer lightly
with a plastic mallet to seat it.
GEAR CLEANING AND INSPECTION
(1) Clean the housing and the pitman shaft with
cleaning solvent and dry them with a clean cloth
and/or compressed air.
(2) Inspect the housing for cracks, porosity, dam-
aged threads and scoring/distortion of the gasket sur-
face area. Repair or replace as necessary.(3) Inspect the pitman shaft contact surface and
the teeth for wear, pitting, and other damage. Re-
place as necessary.
(4) Insert the pitman shaft in the steering gear
housing shaft bore and inspect for excessive shaft or
housing shaft bore wear. The shaft should have a
smooth, bind-free fit with no visible side play when
installed in the shaft bore.
(5) If the shaft fit is loose but it is not visibly
worn, trial fit a replacement pitman shaft in the
housing shaft bore. If the replacement shaft also has
Fig. 6 Wormshaft Lower Bearing Retainer Removal
Fig. 7 Bearing Cup Removal
Fig. 8 Bearing Cup Installation
19 - 40 STEERINGJ

(7) Raise the key-release lever slightly. Install the
end of the lever spring between the lever and the
boss on the housing (Fig. 27).
(8) Apply chassis lubricant to the wave washer
(Fig. 27). Position it on the threaded pivot post and
resting on the release lever.
(9) Position the shroud on the key/lock cylinder
housing and install the attaching screws. Tighten the
screws to 2 Nzm (18 in. lbs.) torque.Ensure that
the wave washer (Fig. 27) is not displaced whileattaching the shroud to the cylinder housing.
(10) Insert the short, hooked end of the remote rod
in the lock rack.
(11) Install the assembled key/lock cylinder hous-
ing and shroud on the steering column jacket. Install
the attaching screws (Fig. 28). Tighten the screws to
7Nzm (60 in. lbs.) torque.
COLUMN SHIFT OR CONSOLE SHIFT FINAL
ASSEMBLY
(1) 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
(Fig. 29). Force it inward and move the ignition
switch actuator rod up and down to align the compo-
nents. When the components align, the key/lock cyl-
inder will move inward and lock in place.
(2) Install the key warning buzzer switch.
(3) Install the ignition switch, refer to Ignition
Switch ÐAll Models in Group 8D, Ignition.
(4) Install the lower bearing, the adapter, the re-
tainer and spring clip at the lower end of the steer-
ing column.
(5) Install the steering shaft through the lower end
of the steering column and insert it into the upper
bearing.
(6) Position the turn signal switch and wire har-
ness in the cylinder housing. Fold the wires against
the connector. Route the connector down through the
steering column jacket.
(7) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
Fig. 28 Key/Lock Cylinder Housing Installation
Fig. 26 Key-Release Lever Installation
Fig. 27 Spring Positioning & Wave Washer
Installation
JSTEERING 19 - 57

(33 in. lbs.) torque. Thread the hazard warning
switch knob into the switch and pull the knob out-
ward.
(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 (J-23653-B). 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.
CONSOLE SHIFT ASSEMBLY
(1) Position the key-release lever spring on the le-
ver and install the lever with the spring in the
shroud.
(2) Align and install the shroud on the steering
column jacket.
(3) Install the retainer plate. Tilt the plate toward
the 12 o'clock position, slide it under the steering col-
umn jacket opening, and seat it in the jacket notches.
(4) Align the steering column jacket V-notch with
the correspondingVon the support. Install the sup-
port in the steering column. To completely seat the
support, press the key-release lever downward while
pressing the support into place (Fig. 25).
(5) Install all the support retaining screws finger-
tight. Next, tighten the screws alternately and evenly
to7Nzm (60 in. lbs.) torque.
(6) Install the remote rod in the support. Route the
rod through the upper end of the shroud and insert it
into the rod slot located in the support.
(7) Install the dimmer switch and the ignition
switch.
(8) Install the steering shaft in the steering col-
umn.
Fig. 23 Key/Lock Cylinder Installation
Fig. 24 Lockplate Retaining Ring Installation
19 - 66 STEERINGJ

(25) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
(26) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(27) 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.
(28) Install and seat the upper bearing race in the
key/lock cylinder housing.
(29) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(30) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor C-
4156 (J-23653-B). Install the tool on the steering
shaft (Fig. 27).
(31) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(32) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be-
fore removing the tool.
(33) Position the wire harness protectors, if
equipped, over the wire harnesses and snap them in
place on the steering column.
(34) Install the lockplate cover.
(35) Install the steering wheel. Refer to the instal-
lation procedure.
(36) Insert the ignition key in the key/lock cylin-
der; turn the cylinder to the OFF-UNLOCK position ;
move the ignition switch downward to eliminateany switch-to-remote rod lash; and tighten the igni-
tion switch attaching screws to 4 Nzm (35 in. lbs.)
torque.
(37) Depress the dimmer switch slightly and insert
a 3/32-inch drill bit into the adjustment hole.
(38) Loosen the retaining screws and move the
dimmer switch toward the steering wheel to remove
any lash. Tighten the dimmer switch retaining
screws to 4 Nzm (35 in. lbs.) torque.
(39) 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.
(40) Install the steering column and steering
wheel. Refer to the installation procedure.
(41) Connect the battery negative cable.
Fig. 27 Lockplate Retaining Ring Installation
19 - 68 STEERINGJ

A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. In some
new or rebuilt transmissions, new synchro rings maytend to stick slightly causing hard or noisy shifts. In
most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi-
cient, improper, or contaminated lubricant can pro-
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVAL
(1) Shift transmission into first or third gear. Then
raise vehicle on hoist.
(2) Support engine with adjustable jack stand. Be
sure to position wood block between jack and oil pan.
(3) Disconnect necessary exhaust system compo-
nents.
(4) Disconnect rear cushion and bracket from
transmission (Fig. 5). Then remove skid plate, or
rear crossmember.
(5) Disconnect transfer case shift linkage, vehicle
speed sensor wires, and vent hose.
Fig. 5 Rear Mount Components (YJ Shown)
JAX 4/5 MANUAL TRANSMISSION 21 - 3