front JEEP CHEROKEE 1994 Service Repair Manual

STEERING LINKAGEÐYJ
INDEX
page page
Drag Link.............................. 17
Pitman Arm............................. 18
Service Information....................... 17Steering Dampener....................... 18
Tie Rod ................................ 17
SERVICE INFORMATION
The steering linkage consists of a pitman arm, drag
link, tie rod, and steering dampener. Adjustment
sleeves are used on the tie rod and drag link for toe
and steering wheel alignment.
Refer to Group 2, Front Suspension and Axle for
additional information.
The tie-rod end ball stud seals should be inspected
during all oil changes.
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, re-
place the tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a com-
plete replacement ball stud end should be installed.
Lubricate the tie-rod end with MOPARtMulti-Mile-
age Lubricant, or equivalent product.
Use a Puller tool for tie rod removal. Failure
to use this tool could damage the ball stud and
seal (Fig. 1).
TIE ROD
REMOVAL
(1) Remove the cotter pins and nuts at the steering
knuckles and drag link (Fig. 2). Remove the steering
dampener from the tie rod.
(2) Loosen the ball studs with a puller tool to re-
move the tie rod.
(3) If necessary, loosen the end clamp bolts and re-
move the tie rod end from the tube.
INSTALLATION
(1) If necessary, install the tie rod end in the tube
(Fig. 2). Position the tie rod clamp as shown (Fig. 3).
Tighten the ball-stud end clamp bolts to 49 Nzm (36
ft. lbs.) torque.
(2) Install the tie rod on the drag link and steering
knuckles. Install the retaining nuts. Install the steer-
ing dampener to the tie rod.
(3) Tighten the ball stud nut on the steering
knuckle to 47 Nzm (35 ft. lbs.) torque. Tighten the
ball stud nut to drag link to 75 Nzm (55 ft. lbs.)
torque. Tighten the steering dampener nut to 74 Nzm
(55 ft. lbs.) torque. Install new cotter pins.
DRAG LINK
REMOVAL
(1) Remove the cotter pins and nuts at the tie rod
and pitman arm (Fig. 2).
(2) Remove the drag link from the tie rod and pit-
man arm with a puller tool.
(3) If necessary, loosen the end clamp bolts and re-
move the tie rod ends from the tube.
INSTALLATION
(1) Install the drag link adjustment sleeve and tie
rod ends. Position clamp bolts as shown (Fig. 3).
(2) Position the drag link at the steering linkage
(Fig. 2).
Install the drag link to tie rod and pitman arm.
(3) Tighten the nut at the pitman arm to 74 Nzm
(55 ft. lbs.) torque. Tighten the tie rod ball stud nut
to 75 Nzm (55 ft. lbs.) torque. Install new cotter pins.
Fig. 1 Ball Stud Removal
JSTEERING 19 - 17

STEERING DAMPENER
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
(2) Remove the steering dampener retaining nut
and bolt from the axle bracket (Fig. 2).
(3) Remove the cotter pin and nut from the ball
stud at the tie rod (Fig. 2).
(4) Remove the steering dampener ball stud from
the tie rod with a puller tool.
INSTALLATION
(1) Install the steering dampener to the axle
bracket and tie rod.(2) Install the steering dampener bolt in the axle
bracket. Tighten the nut to 74 Nzm (55 ft. lbs.)
torque.
(3) Install the ball stud nut at the tie rod. Tighten
the nut to 74 Nzm (55 ft. lbs.) torque. Install a new
cotter pin.
PITMAN ARM
REMOVAL
(1) Remove the cotter pin and nut from the drag
link at the pitman arm.
(2) Remove the drag link ball stud from the pit-
man arm with a puller.
(3) Remove the nut and washer from the steering
gear shaft. Mark the pitman shaft and pitman arm
for installation reference. Remove the pitman arm
from steering gear with Puller 7998 or C-4150 (Fig.
4).
Fig. 2 Steering Linkage
Fig. 3 Tie Rod/Drag Link Clamp Bolt
19 - 18 STEERINGJ

PITMAN SHAFT SEALSÐIN CAR REPLACEMENT
REMOVAL
(1) Remove pitman arm from gear. Refer to Pit-
man Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and housing.
Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 2).
CAUTION: Use care not to score the housing bore
when prying out seals and washers.
(4) Remove backup washer and double lip seal
with screwdriver.
²Start the engine and turn the steering wheel fully
to the LEFT to force out the seals and washers.
²Stop the engine
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove if
necessary. Inspect the pitman shaft seal surface for
roughness and pitting. If pitted replace shaft.
INSTALLATION
(1) Install single lip seal with Installer or a suit-
able size deep socket (Fig. 3).
(2) Coat the double lip seal and washer with
grease.
(3) Install the backup washer.
(4) Install the double lip seal.
(5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
(7) Center the steering gear.
(8) Install the pitman arm. Refer to Pitman Arm
Installation in Steering Linkage.(9) Add power steering fluid. Refer to Power Steer-
ing Initial Operation.
INTERMEDIATE (COUPLING) SHAFT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition.
(2) Remove the shaft pinch bolt at the steering
gear and column (Fig. 4, 5). Unbolt steering gear
from frame rail to remove shaft. Refer to Steering
Gear Replacement in this section.
INSTALLATION
(1) Align the intermediate (coupler) shaft to the
steering gear and column.
(2) Position the steering gear on the frame. Refer
to Steering Gear Replacement in this section.
(3) Install and tighten the pinch bolts to 34 Nzm
(25 ft. lbs.) torque.
STEERING GEAR REPLACEMENT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition with the steering wheel centered.
(2) Disconnect and cap the fluid hoses from steer-
ing gear. Refer to Pressure and Return Hose Replace-
ment in this Group.
(3) Remove the column coupler shaft from the gear.
Refer to the removal procedures in this section.
(4) Remove pitman arm from gear. Refer to Pitman
Arm Removal in the Steering Linkage section.
Fig. 2 Pitman Shaft Seals
Fig. 3 Pitman Shaft Seal Installation
JSTEERING 19 - 21

INTERMEDIATE (COUPLER) SHAFT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition.
(2) Remove the shaft pinch bolt at the steering
gear and column (Fig. 15, 16). Un-bolt steering gear
from frame rail to remove shaft. Refer to Steering
Gear Replacement in this section.
INSTALLATION
(1) Align the intermediate (coupler) shaft to the
steering gear and column.
(2) Position the steering gear on the frame. Refer
to Steering Gear Replacement in this section.
(3) Install and tighten the pinch bolts to 34 Nzm
(25 ft. lbs.) torque.
STEERING GEAR REPLACEMENT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition with the steering wheel centered.
(2) Remove the column coupler shaft from the gear.
Refer to the removal procedures in this section.
(3) Remove pitman arm from gear. Refer to Pitman
Arm Removal in the Steering Linkage section.
(4) Remove the steering gear retaining bolts and
nuts. Remove the steering gear from the vehicle (Fig.
17, 18).
Fig. 14 Over-center Adjustment
Fig. 15 Coupler ShaftÐXJ
Fig. 16 Coupler ShaftÐYJ
JSTEERING 19 - 43

STEERING COLUMN GENERAL SERVICE
INDEX
page page
Column ReplacementÐXJ.................. 46
Column ReplacementÐYJ.................. 48
Park-Lock CableÐConsole Shift Automatic..... 45Service Information....................... 45
Steering Wheel.......................... 45
SERVICE INFORMATION
The column may be disassembled and reassembled.
Also most steering column components can be ser-
viced without removing the column from the vehicle.
For additional information, refer to Group 8H, Elec-
trical.
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
CAUTION: Disconnect negative (ground) cable from
the battery before servicing any component on the
column.
Safety goggles should be worn at all times
when involved with steering column service.
STEERING WHEEL
REMOVAL
(1) Make sure the front wheels are in thestraight
aheadposition.
(2) Disconnect the negative (ground) cable from the
battery.
(3) Remove the horn contact components (Fig. 1).
(4) Remove the steering wheel retaining nut and
the vibration dampener, if equipped. Score or paint
alignment marks on the column shaft and steering
wheel (if none exist) for installation reference.
(5) Remove the steering wheel with Puller 7591 (J-
21232-01) (Fig. 2).
INSTALLATION
(1) Install the steering wheel with the scored or
painted marks aligned.
(2) Install the retaining nut and tighten to 34 Nzm
(25 ft. lbs.) torque.Force the steering wheel down
on the shaft with the retaining nut only.
(3) Install the horn contact components (Fig. 1).
(4) Connect the battery ground (negative) cable.
PARK-LOCK CABLEÐCONSOLE SHIFT AUTOMATIC
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
Fig. 1 Horn Pad Removal/Installation
Fig. 2 Steering Wheel Removal
JSTEERING 19 - 45

(1) Make sure the front wheels are in thestraight
aheadposition.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) Column shift vehicles, disconnect the shift cable
grommet by prying it from the shift lever (Fig. 5).
(5) Disconnect the column shaft to steering gear
coupler upper bolt (Fig. 6).(6) Remove the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(7) Column shift vehicles, disconnect the shift indi-
cator cable from the shift housing (Fig. 7).
(8) Remove two nuts holding steering column
bracket to brake sled (Fig. 8).
(9) Remove four bolts holding steering column
bracket to column.
(10) Loosen column brace mounting nut at drivers
side kick panel. This will allow column to drop.
Fig. 5 Shift Cable Grommet
Fig. 6 Column Shaft Coupler
Fig. 7 Indicator Cable Clip
Fig. 8 Column Bracket
JSTEERING 19 - 47

(11) Disconnect the following items from the steer-
ing column connectors:
²Ignition switch wire harness
²Dimmer switch wire harness
²Turn signal switch wire harness
²Windshield wiper wire harness
²Cruise control wire harness (if equipped)
²Park-lock cable (if equipped)
(12) Remove the bolts that attach the toe plate to
the floor pan (Fig. 9).
(13) Carefully remove column from vehicle.
INSTALLATION
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
(1) Carefully position column in vehicle.
(2) Align the column shaft to steering gear cou-
pling. Install and tighten the bolt to 34 Nzm (25 ft.
lbs.) torque.
(3) As applicable, connect the following items to
the steering column connectors:
²Ignition switch wire harness
²Dimmer switch wire harness
²Turn signal switch wire harness
²Windshield wiper wire harness
²Cruise control wire harness (if equipped)
²Park-lock cable (if equipped)
(4) Install the support bracket on the column and
tighten the bolts to 20 Nzm (180 in. lbs.) torque.
(5) Raise the column up to the brake sled studs.
Connect the brace to the column stud.
(6) Install and tighten the column to brake sled
nuts to 30 Nzm (22 ft. lbs.) torque.
(7) Column shift vehicles, install the shift cable
grommet on the shift lever.
(8) Install and tighten the toe plate-to-floor pan
bolts to 8 Nzm (66 in. lbs.) torque.(9) Column shift vehicles, install the shift indicator
cable on the shift housing. Check operation.
(10) Install the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(11) Install steering wheel on column, refer to
Steering Wheel-Installation.
(12) Connect the negative (ground) cable to the
battery.
COLUMN REPLACEMENTÐYJ
REMOVAL
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
(1) Make sure the front wheels are in thestraight
aheadposition.
(2) Disconnect the negative (ground) cable from the
battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) Column shift vehicles, disconnect the shift ca-
ble grommet by prying it from the shift lever.
(5) Disconnect the column shaft to steering gear
coupler upper bolt (Fig. 10).
(6) Remove the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(7) Remove two nuts holding steering column
bracket to brake sled (Fig. 11).
(8) Remove four bolts holding steering column
bracket to column.
(9) Disconnect the following items from the steer-
ing column connectors:
²Ignition switch wire harness
²Dimmer switch wire harness
²Turn signal switch wire harness
²Windshield wiper wire harness
²Cruise control wire harness (if equipped)
Fig. 9 Steering Column Mounting
Fig. 10 Column Shaft Coupler
19 - 48 STEERINGJ

(8) Use a blunt punch to exert force on the block
tooth to disengage and remove the lock sector (Fig.
16).
The steering column must be removed from
the vehicle to disassemble the remaining steer-
ing column components.
(9) Remove the steering shaft (if not previously re-
moved).(10) Remove the spring clip from the lower bearing
retainer. Remove the retainer, the bearing and the
adapter (Fig. 17).
ASSEMBLY
Proceed to Column Shift Assembly Procedure
or Console Shift Assembly Procedure.
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.
COLUMN SHIFT ASSEMBLY
(1) Insert the lock sector through the key/lock cyl-
inder hole in the key/lock cylinder housing. Install
the lock sector on the lock sector shaft (Fig. 18). En-
sure that the lock sector turns freely after installa-
tion.
(2) Install the lock rack preload spring. The bowed
side of the spring must contact the lock rack when
the rack is installed.
(3) Assemble the lock bolt and the lock rack (Fig.
19).
(4) Install the assembled lock bolt and lock rack in
the key/lock cylinder housing (Fig. 20). Mate the lock
rack block tooth with the lock sector block tooth.
(5) Install the shift lever detent plate on the key/
lock cylinder housing (Fig. 21).
Fig. 17 Lower Bearing Components
Fig. 15 Lock Rack & Lock Bolt
Fig. 16 Lock Sector Removal
19 - 54 STEERINGJ

TILT STEERING COLUMN
DISASSEMBLY
(1) Remove the steering column from the vehicle,
if necessary. Refer to the removal procedure.
(2) If the column is removed for service, fabricate a
support fixture to clamp it in a vise (Fig. 1).
(3) If the steering column has not been removed
from the vehicle, place the front wheels in the
straight-ahead position. Disconnect the battery nega-
tive cable.
(4) Protect the painted areas on the steering col-
umn.
(5) Remove the steering wheel. Refer to the re-
moval procedure.
(6) Column shift: Remove the gear selector lever
retaining pin and the lever from the housing.
(7) Remove the lockplate cover. Use two small pry
bars to pry the cover off the lockplate.
WARNING: THE LOCKPLATE RETAINS A VERY
STRONG, SPRING FORCE. DO NOT ATTEMPT TO
REMOVE THE STEERING SHAFT RETAINING SNAP
RING WITHOUT USING LOCKPLATE COMPRESSOR
C-4156 (J-23653-B).
(8) Compress the lockplate with Lock Plate Com-
pressor C-4156 (J-23653-B) and release the steering
shaft retaining snap ring (Fig. 2).
(9) Remove the lockplate compressor tool and the
retaining snap ring. Discard the snap ring.
(10) Remove the lockplate, canceling cam, upper
bearing preload spring, and the thrust washer from
the steering column/shaft.(11) Remove the hazard warning switch knob.
Press the knob inward and remove it from the steer-
ing column by turning it counterclockwise.
(12) If the steering column is the column shift
type, remove the two retaining screws and the gear
selector indicator cover.
(13) If the steering column is the column shift
type, remove the gear selector indicator lamp bracket
retaining screw. Do not remove the lamp and bracket
at this time.
(14) Remove the tilt-release lever.
(15) Disconnect the turn signal wire harness con-
nector from the bracket located at the lower end of
the steering column (Fig. 3).
CAUTION: Wrap tape around the turn signal switch
wire harness connector to prevent it from becoming
entangled during removal.
(16) Remove the plastic protector from the wire
harness.
(17) Remove the turn signal switch retaining
screws (Fig. 4), dimmer switch actuator arm, to re-
move the switch. Guide the switch straight up and
out of the steering column.
(18) Remove the windshield wiper switch wire har-
ness and all the other wire harnesses located within
the steering column.
(19) Insert the ignition switch key into the key/
lock cylinder. Turn the key to the ON position.
Fig. 1 Steering Column Support Fixture
Fig. 2 Lockplate Snap Ring Removal
JSTEERING 19 - 59

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.
COLUMN SHIFT 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 (J-23073-
01) in the shift tube. The spring-loaded lower foot of
the tool must 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.
(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.
Fig. 19 Retainer Plate Removal
Fig. 20 Key-Release Lever & Spring Removal
Fig. 21 Shift Tube Installation
19 - 64 STEERINGJ