lock JEEP CHEROKEE 1994 Service Repair Manual

turning the stub shaft COUNTERCLOCKWISE.
²The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(7) Install the races and thrust bearing to worm
shaft (Fig. 35).
(8) Install worm shaft to housing.
(9) Install valve. Refer to Valve Replacement in
this section.
(10) Install rack piston to worm shaft from tool,
compress seals.
²Hold Arbor tightly against worm shaft and turn
stub shaft CLOCKWISE until rack piston is seated
on worm shaft.
WARNING: MAKE SURE ALL RACK PISTON BALLS
ARE REINSTALLED IN THE RACK PISTON. IM-
PROPER INSTALLATION MAY RESULT IN PER-
SONAL INJURY.
(11) Install rack piston plug and tighten to 150
Nzm (111 ft. lbs.) torque.
(12) Install housing end plug. Refer to Housing
End Plug Replacement in this section.
(13) Install pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
(14) Adjust steering gear. Refer to Steering Gear
Adjustments in this section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
PITMAN SHAFT SEALS AND BEARING
REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(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. 36).
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.
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove if
necessary.
(7) Remove needle bearing from side cover area of
housing (Fig. 37).
ASSEMBLE
(1) Install needle bearing into housing (Fig. 38).
(2) Install single lip seal with Installer or a suit-
able size socket (Fig. 39).
(3) Coat the double lip seal and washer with
grease.
(4) Install the backup washer.
(5) Install the double lip seal.
(6) Install the backup washer.
Fig. 36 Pitman Shaft Seals
Fig. 35 Worm Shaft and Bearing
19 - 32 STEERINGJ

(2) Wrap a single layer of plastic tape around the
pitman shaft threads and splines. This will protect
the replacement seals during installation.
(3) Install the seal with a suitable size socket.
(4) Remove the tape from the shaft.
(5) Center the steering gear.
(6) Align and install the pitman arm.
(7) Install the washer and retaining nut on the pit-
man shaft. Tighten the nut to 251 Nb1m (185 ft. lbs.)
torque.
GEAR ADJUSTMENTS IN VEHICLE
REMOVE
(1) Raise and support the vehicle.
(2) Mark the pitman shaft and pitman arm for in-
stallation reference. Remove the pitman arm from
the shaft.
(3) Loosen the adjuster lock nut then back the ad-
juster plug off 1/4 turn.
(4) Remove the steering wheel horn pad.
(5) Turn the steering wheel in one direction until
stopped by the gear. Then turn back 1/2 turn.
CAUTION: Do not turn the steering wheel hard
against the internal stops when the linkage is re-
moved. This could result in damage to the recircu-
lating ball guides.
MEASURE
Place a low calibration (50 in. lbs.) torque wrench
and socket on the steering wheel nut. Rotate the
wrench and nut through a 90 degree arc (1/4 turn).
This will measure the worm shaft bearing preload.
ADJUST WORMSHAFT BEARING PRELOAD
TORQUE
(1) Adjust the preload by tightening the adjuster
plug. The preload should be 0.6 to 1 Nzm(5to8in.
lbs.) torque.
Steering column/shaft misalignment or damage will
increase the amount of torque required to rotate the
steering wheel. If the rotating torque is exceptionally
high, inspect the steering column/shaft alignment. If
the alignment is correct, remove the steering gear,
determine the cause of the high preload torque, and
repair as necessary.
(2) Tighten the adjuster locknut to 68 Nzm (50 ft.
lbs.) torque. Measure the preload torque. If neces-
sary, adjust the preload torque again.
ADJUST OVERCENTER DRAG TORQUE
(1) Turn the steering wheel from one stop to the
other and count the total numbers of turns. Turn the
wheel back in reverse direction 1/2 the total number
of turns to center the steering gear.
(2) Turn the over center adjusting screw in to re-
move all lash between the ball nut and pitman shaftsector teeth. Hold the adjustment screw and tighten
the lock nut to 34 Nzm (25 ft. lbs.) torque.
(3) Check the torque at the steering wheel by tak-
ing the highest reading as the wheel is turned
through the center position.
(4) The overcenter drag torque should be 0.5 to 1
Nzm (4 to 10 in. lbs.).
(5) If necessary, loosen the lock nut and adjust the
over center adjuster screw to obtain the proper
torque. Re-tighten the lock nut to the lock nut.
(6) After tightening the locknut, measure the over-
center drag torque again and readjust the torque, if
necessary.
INSTALL
(1) Align the installation reference marks and in-
stall the pitman arm.
(2) Install and tighten the pitman shaft nut and
washer to 251 Nzm (185 ft. lbs.) torque.
(3) Install the horn button.
GEAR DISASSEMBLY
(1) Rotate the wormshaft from stop-to-stop and
count the number of rotations. Rotate the wormshaft
in the reverse direction 1/2 of the total number of ro-
tations to center it and the ball nut.
(2) Remove the pitman shaft adjustment screw
locknut. Remove the cover retaining bolts, cover, and
gasket (Fig. 3).
(3) Slide the adjustment screw head (Fig. 3) out of
the pitman shaft T-slot and remove it and the
shim(s).
(4) Retain the shim(s) for end-play measurement
during assembly.
(5) Remove the pitman shaft, the wormshaft bear-
ing preload torque adjustment cap locknut, and the
adjustment cap (Fig. 2).
(6) Remove the wormshaft and the ball nut (Fig.
2).
(7) Remove (pry) the pitman shaft and the worm-
shaft seals from the steering gear housing (Fig. 3).
WORMSHAFT AND BALL NUT DISASSEMBLY
(1) Remove the upper bearing from the wormshaft
(Fig. 2).
CAUTION: Do not allow the ball nut to rotate freely
and travel to either extreme end of the wormshaft.
This could damage the tangs at the ends of the re-
circulating ball guides (Fig. 3).
(2) Remove the recirculating ball guide clamp re-
taining screws, the clamp and the guides (Fig. 2).
Separate the half-guides and place the recirculating
balls aside in a container.
(3) Hold the ball nut over a cloth. Remove the re-
maining recirculating balls by rotating the worm-
shaft back and forth.
JSTEERING 19 - 37

(7) Install the locknut on the wormshaft bearing
adjustment cap but do not tighten it at this time.
(8) Pack the steering gear housing with as much
chassis lubricant as possible.
Rotate the wormshaft in one direction until
the ball nut ceases. Pack the end of the housing
full of lubricant, rotate the shaft in the opposite
direction and repeat the packing procedure.
(9) Place the ball nut (Fig. 12) in the centered po-
sition, rotate the wormshaft from stop-to-stop and
count the number of rotations. Rotate wormshaft in
the reverse direction 1/2 of the number of rotations to
center the ball nut.
(10) Lubricate the pitman shaft with chassis lubri-
cant and insert it in the steering gear housing. En-
gage the center tooth on the shaft with the center
groove on the ball nut.
(11) Apply chassis lubricant to the replacement
housing cover gasket. Position it so that it surrounds
the housing cover opening.
(12) Place the shim(s) on the adjustment screw
and thread the screw into the cover to a depth of 2 to
3 threads.
(13) Slide the head of the adjustment screw into
the pitman shaft T-slot. With the cover in place, ro-
tate the screw counterclockwise to thread it into the
cover. Rotate the screw until the cover almost comes
in contact with the gasket.
(14) Install the cover retaining bolts finger tight
only. Continue tightening the adjustment screw coun-
terclockwise until cover is tight against the gasket,
then loosen the screw 1/2 rotation.
(15) Tighten the cover bolts to 61 Nzm (45 ft. lbs.)
torque.(16) Install the pitman shaft seal, refer to the re-
placement procedure.
(17) Rotate the wormshaft and observe the steer-
ing gear operation. With the adjustment screw and
cap loose, the wormshaft should rotate freely and not
bind. If the steering gear binds, repair as necessary.
(18) Inspect for lubricant leakage from the shaft
seals. If there is a leak at either seal, replace the de-
fective seal(s).
GEAR ADJUSTMENTS ON BENCH
WORM BEARING PRELOAD
(1) Tighten the worm bearing adjuster plug until it
bottoms, then loosen 1/4 turn.
(2) Carefully turn the wormshaft all the way to the
end of travel, then turn back 1/2 turn.
(3) Tighten adjuster plug until torque wrench indi-
cates 0.6 to 1.0 Nzm (5 to 8 in. lbs.) torque (Fig. 13).
(4) Tighten the adjuster plug locknut to 68 Nzm (50
ft. lbs.) torque.
OVER-CENTER PRELOAD
(1) Back off preload adjuster until it stops, then
turn it in one full turn.
(2) With gear at center of travel, check torque to
turn stub shaft. This will be reading #1 (Fig. 14).
(3) Turn adjuster in until torque to turn stub shaft
is 0.5 to 1 Nzm (4 to 10 in. lbs.) more than reading
#1.
(4) Hold pitman shaft adjustment screw and
tighten adjuster lock nut to 34 Nzm (25 ft. lbs.)
torque.
Fig. 12 Pitman Shaft & Ball Nut Engagement
Fig. 13 Worm Bearing Preload Adjustment
19 - 42 STEERINGJ

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

(3) Remove the steering column mounting bracket
to instrument panel nuts. Lower the steering column.
Refer to Steering Column Removal .
(4) Disconnect the park-lock cable from the steer-
ing column and bracket.
(5) Remove the center console and related trim.
(6) Pull the carpet backward to expose the cable at
the gear selector lever bell-crank (Fig. 3).
(7) Disconnect the cable eyelet from the bell-crank
(Fig. 3).
(8) Remove the cable from the shift bracket (Fig.
3).
INSTALLATION
(1) Route and install the cable.
(2) Position the carpet and install the retaining
screws, the accelerator pedal bracket, the panels and
the moldings.
(3) Install the center console and related trim.
(4) Raise the steering column, refer to Steering
Column Removal.
(5) Install the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(6) Connect the battery negative cable.
ADJUSTMENT
(1) Pry up the park-lock cable adjuster lock (Fig.
3).
(2) Connect the park-lock cable eyelet to the bell-
crank pin (Fig. 3).
(3) Place the gear selector in park.
(4) Insert a .030 - .035 pin between the pawl and
the park gate (Fig. 4).
(5) Push the spring-loaded cable adjuster forward.(6) Lower the cable into the mounting bracket un-
til the tabs are fully engaged in the adjuster (Fig. 3).
(7) Push the cable adjuster lock clamp downward
to lock it (Fig. 3).
(8) Remove the pin from the park gate.
(9) Test the park-lock cable operation:
²Turn the ignition switch key to the LOCK position
²Press inward on the gear selector handle release
button, the button should not move
²Turn the ignition switch key to the ON position
²Press inward on the gear selector handle release
button
²Move the gear selector handle to the DRIVE or
NEUTRAL position
²Attempt to turn the ignition switch key to the
LOCK position
²If the park-lock cable is correctly adjusted, the key
will not turn to the LOCK position;
²Press inward on the gear selector handle release
button
²Move the gear selector handle to the PARK posi-
tion
²Turn the ignition switch key to the LOCK position
²If the park-lock cable is correctly adjusted, the key
will turn to the LOCK position.
(10) If additional cable adjustment is needed, slide
the adjuster forward or rearward to obtain the cor-
rect position (Fig. 3).
Refer to Group 21, Transmission for additional in-
formation.COLUMN REPLACEMENTÐXJ
REMOVAL
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
Fig. 3 Park-Lock Cable
Fig. 4 Park-Lock Adjustment
19 - 46 STEERINGJ

(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

NON-TILT STEERING COLUMN
DISASSEMBLYÐCOLUMN OR CONSOLE SHIFT
Steering column removal from the vehicle is not
necessary for;
²Lockplate cover
²Lockplate
²Steering shaft retaining ring
²Canceling cam
²Turn signal switch
²Upper bearing preload spring
²Ignition key/lock cylinder service
The steering column must be removed from
the vehicle to service any other component.
(1) If the column is removed for service, fabricate a
support fixture to clamp it in a vise (Fig. 1).
(2) Remove the steering wheel. Refer to the re-
moval procedure.
(3) Remove the lockplate cover.
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 (J23653-B).
(4) Compress the lockplate with Compressor
C-4156 (J-23653-B) and release the steering shaft re-
taining snap ring (Fig. 2).
(5) Remove the lockplate compressor tool and the
retaining snap ring. Discard the snap ring.CAUTION: When the steering shaft retaining snap
ring is removed, the steering shaft is no longer re-
tained within the column.
(6) Remove the lockplate, canceling cam, upper
bearing preload spring, and the thrust washer from
the steering column/shaft (Fig. 3).
Fig. 2 Retaining Snap Ring Removal
Fig. 3 Steering Column Disassembly
Fig. 1 Steering Column Support Fixture
19 - 50 STEERINGJ

(7) Remove the hazard warning switch knob. Press
the knob inward and remove it from the column by
turning it counterclockwise.
(8) Remove the turn signal/wiper/cruise control
stalk by pulling it out straight from the column.
Wiper must be in the off position.
(9) Disconnect the turn signal wire harness con-
nector from the bracket.
CAUTION: Wrap tape around the turn signal
switch wire harness connector (Fig. 4) to prevent it
from becoming entangled during removal.
(10) Remove the turn signal switch retaining
screws (Fig. 5), dimmer switch actuator arm, to re-
move the switch. Guide the switch straight up and
out of the steering column.
(11) Remove the wiper switch wire harness and all
the other wire harnesses located within the steering
column.
(12) Insert the ignition switch key into the key/
lock cylinder and turn to the ON position.
CAUTION: Do not attempt to remove the key warn-
ing buzzer switch and contacts separately. If sepa-
rated, the contacts can detach and drop into the
steering column.
(13) Remove the key warning buzzer switch and
contacts as a unit (Fig. 6). Use needle-nose pliers or
a paper clip bent at a right angle (90 degrees).
(14) 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 key/
lock cylinder. (Fig. 7).
(15) Remove the ignition switch and the dimmer
switch (Fig. 8) from the lower end of the steering col-
umn.
Proceed to Column Shift Disassembly Proce-
dure or Console Shift Disassembly Procedure.
Fig. 4 Taped Turn Signal Switch Wire Harness
Connector
Fig. 5 Turn Signal Switch Retaining Screw
Fig. 6 Key Warning Buzzer/Contacts Removal
JSTEERING 19 - 51

COLUMN SHIFT DISASSEMBLY
(1) Remove the gear selector lever upper pivot pin
and the selector lever.
(2) Remove the upper bearing thrust washer.
(3) Remove the four screws that attach the key/
lock cylinder housing to the steering column jacket.
Remove the housing (Fig. 9).
(4) Remove the thrust cap from the key/lock cylin-
der housing (Fig. 10).
(5) Remove the ignition switch actuating rod and
rack from the key/lock cylinder housing (Fig. 10).
(6) Remove the rack preload spring and the shaft
lock bolt and spring from the key/lock cylinder hous-
ing. Remove the shift lever detent plate from the
housing (Fig. 10).(7) Use a blunt punch to exert force on the block
tooth to disengage and remove the lock sector (Fig.
11).
(8) Remove the gear selector lever housing and the
shroud from the steering column jacket.
(9) Remove the gear selector lever spring from the
lever housing.
The steering column must be removed from
the vehicle to disassemble the remaining steer-
ing column components.
Fig. 7 Key/lock Cylinder Removal
Fig. 8 Ignition Switch & Dimmer Switch
Fig. 9 Key/Lock Cylinder Housing
Fig. 10 Key/Lock Cylinder Housing Components
19 - 52 STEERINGJ

(10) Remove the steering shaft (if not previously
removed).
(11) Remove the spring clip from the steering col-
umn lower bearing retainer. Remove the retainer,
the lower bearing and the adapter (Fig. 12).
(12) Slide out and remove the shift tube.
CONSOLE SHIFT DISASSEMBLY
(1) Remove the screws that attach the key/lock cyl-
inder housing and the shroud to the steering column
jacket (Fig. 13).
(2) Remove the dimmer switch actuator arm.
(3) Disengage the remote rod from the lock rack.(4) Remove the key/lock cylinder housing-to-shroud
attaching screws (Fig. 14). Separate the housing and
the shroud.
(5) Remove the wave washer from the key release
lever pivot. Remove the key release lever and the
pivot.
(6) Remove the lock rack and the lock bolt (Fig.
15).
(7) Remove the lock rack preload spring.
Fig. 11 Lock Sector Removal
Fig. 12 Lower Bearing, Adapter, Retainer & Clip
Fig. 13 Key/Lock Cylinder Housing Removal
Fig. 14 Housing/Shroud Attaching Screw
JSTEERING 19 - 53