lock JEEP CHEROKEE 1995 Service Repair Manual

DISASSEMBLE
(1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement.
(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 seal²Remove 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.
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 - 31

(6) Lubricate O-ring seals and teflon rings with
power steering fluid.
(7) Install stub shaft and valve assembly to worm
shaft, fitting on worm shaft to slot in the valve as-
sembly.
(8) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment. Refer to Steering Gear Ad-
justments in this section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
RACK PISTON AND WORM SHAFT REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 30).
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 31). Hold tool tightly against worm shaft while
turning the stub shaft COUNTERCLOCKWISE.
²The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(6) Remove the rack piston, rack balls, and tool to-
gether from housing.
(7) Remove valve. Refer to Valve Replacement in
this section.
(8) Remove worm shaft.
(9) Remove thrust bearing and races.
(10) Remove tool from rack piston.
(11) Remove rack piston balls.
(12) Remove screws, clamp and ball guide.
(13) Remove teflon ring and O-ring seal (Fig. 32).
Fig. 28 Remove and Install Valve Seals
Fig. 29 Stub Shaft Installation
Fig. 30 Remove and Install Rack Piston End Plug
19 - 32 STEERINGJ

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 into bore of rack piston.
Hold tool tightly against worm shaft while turning
Fig. 31 Remove and Install Rack Piston
Fig. 32 Remove and Install Seal on Rack Piston
Fig. 33 Installing Balls in Rack Piston
Fig. 34 Balls in the Return Guide
JSTEERING 19 - 33

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 Pitman
Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and hous-
ing. 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 using tool C-4177 and handle C-4171 (Fig.
37).
ASSEMBLE
(1) Install needle bearing into housing using tool
C-4178 and handle C-4171 (Fig. 38).
(2) Install single lip seal with tool C-4178 and han-
dle C-4171 or a suitable size socket (Fig. 39).
(3) Coat the double lip seal and washer with
grease.
(4) Install the backup washer.
Fig. 35 Worm Shaft and Bearing
Fig. 36 Pitman Shaft Seals
19 - 34 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 Nzm (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 shaft
sector 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.
JSTEERING 19 - 39

(6) Install the wormshaft bearing adjustment cap
in the housing and tighten it only enough to remove
the wormshaft end-play.
(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.
Fig. 12 Pitman Shaft & Ball Nut Engagement
Fig. 13 Worm Bearing Preload Adjustment
19 - 44 STEERINGJ

(4) Hold pitman shaft adjustment screw and
tighten adjuster lock nut to 34 Nzm (25 ft. lbs.)
torque.
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.
Fig. 14 Over-center AdjustmentFig. 15 Coupler ShaftÐXJ
Fig. 16 Coupler ShaftÐYJ
JSTEERING 19 - 45

GENERAL INFORMATION
The airbag system is a standard equipment safety
device on XJ (Cherokee) models. It is designed to pro-
tect the driver from serious injury, caused by a fron-
tal impact of the vehicle. If the airbag module
assembly is defective and non-deployed, refer to
Chrysler Corporation current return list for proper
handling procedures.
ARMING/DISARMING MECHANISM
BEFORE SERVICING A COLUMN EQUIPPED
WITH AIR BAG, REFER TO GROUP 8M, ELEC-
TRICAL FOR PROPER AND SAFE PROCE-
DURES.
The steering wheel hub incorporates an airbag
Arming/Disarming mechanism and a specially de-
signed nut-blocker. The nut-blocker serves as a safety
to prevent removal of the airbag module until the
unit has been disarmed. A removable plastic cover
plug on the top, outer hub of the steering wheel al-
lows access to the arming screw.
When the airbag module is disarmed, the arming
screw extends upward from the steering wheel hub.
This will prevent installation of the plastic cover
plug. Also, the nut-blocker is retracted to allow ac-
cess to the two upper airbag module mounting nuts.
When the airbag module is armed, the plastic cover
plug will install flush with the outer surface of the
steering wheel hub. In addition, the nut-blocker will
prevent access to the two upper airbag module
mounting nuts.THE FASTENERS, SCREWS, AND BOLTS, ORIG-
INALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS. THIS HARDWARE IS
SPECIFICALLY DESIGNED FOR THE AIR BAG
SYSTEM. THEY MUST NEVER BE REPLACED
WITH ANY SUBSTITUTES. REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SER-
VICE PACKAGE OR FASTENERS IN THE PARTS
BOOK.
The Acustar columns (Fig. 1) have been designed to
be serviced as an assembly; less wiring, switches,
shrouds, steering wheel, etc. Most steering column
components can be serviced without removing the
column from the vehicle. For additional information
on electrical components refer to Group 8, Electrical.
CAUTION: Bumping, jolting and hammering on the
steering column shaft 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.
Fig. 1 Acustar Steering Column
19 - 48 STEERINGJ

AIRBAG MODULE REMOVEÐINSTALL
WARNING: THIS AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX MECHANICAL UNIT. BEFORE ATTEMPT-
ING TO REMOVE OR INSTALL THE AIRBAG SYS-
TEM OR RELATED STEERING WHEEL AND
STEERING COLUMN COMPONENTS YOU MUST
FIRST DISARM THE AIRBAG FIRING MECHANISM.
FAILURE TO DO SO COULD RESULT IN ACCIDEN-
TAL DEPLOYMENT AND POSSIBLE PERSONAL IN-
JURY.
When removing a deployed airbag module,
rubber gloves, eye protection and long-sleeved
shirt should be worn. There may be deposits on
the airbag module and other interior surfaces,
which can cause irritation to the skin and eyes
in large doses.
(1) Disconnect battery negative cable and isolate.
(2) Using a small screwdriver, remove plastic cover
plug from top outer surface of steering wheel hub
(Fig 2). Exit vehicle and disarm airbag by reaching
through driver's side window and turning arming
screw counter-clockwise to its travel limit (Fig 3 and
4 ). This is done using an 8mm socket and manual
drive. DO NOT USE POWER-DRIVEN TOOLS.
(3) From back side of steering wheel, remove 4
nuts attaching airbag module to steering wheel (Fig.
5). This is done using a 10mm socket and manual
drive. DO NOT USE POWER-DRIVEN TOOLS.
(4) Remove airbag module from steering wheel.
(5) Reverse removal procedures to install. Tighten
airbag module attaching nuts to 9 to 11 Nzm (80 to
100 in. lbs.). Exit vehicle and arm airbag by reaching
through driver's side window and turning arming
screw clockwise to its travel limit. Arming screw
torque should not exceed 1.1 to 1.7 Nzm (10-15 in.
lbs.). Reinstall plastic cover plug in steering wheel
hub.
STEERING WHEEL
WARNING: BEFORE ATTEMPTING TO REMOVE OR
INSTALL THE AIRBAG SYSTEM OR RELATED
STEERING WHEEL AND STEERING COLUMN COM-
PONENTS YOU MUST FIRST DISARM THE AIRBAG
FIRING MECHANISM. WHEN SERVICING AIR BAG
SYSTEM, REMOVE AND ISOLATE THE BATTERY
NEGATIVE (-) CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. YOU MUST DISARM THE AIRBAG
FIRING MECHANISM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT
AND POSSIBLE INJURY. WHEN AN UNDEPLOYED
AIR BAG ASSEMBLY IS TO BE REMOVED FROM
THE STEERING WHEEL, DISCONNECT THE BAT-
TERY GROUND CABLE AND ISOLATE. THE ARMING
SCREW MUST BE USED TO DISARM THE AIRBAG.
REMOVAL
(1) Make sure the front wheels are in thestraight
aheadposition and steering column locked in place.
Fig. 2 Plastic Cover Plug for Airbag Arming/
Disarming Bolt
Fig. 3 Arming/Disarming Bolt
Fig. 4 Airbag Bolt
JSTEERING 19 - 49

(2) Disconnect the battery negative (ground) cable
and isolate.
(3) Disarm the airbag (refer to group 8M, Electri-
cal for proper and safe procedures).
(4) Remove the air bag module and speed control
switch (if equipped) and disconnect the wire feeds
(Fig. 6).
(5) Disconnect the wire feed to the horn buttons.(6) Remove the steering wheel retaining nut. Score
or paint alignment marks on the column shaft and
steering wheel (if none exist) for installation refer-
ence.
(7) Remove the steering wheel with a universal
puller (Fig. 7).Do not hammer or jolt the steer-
ing column or shaft during removal of the
wheel.
INSTALLATION
(1) Install the steering wheel on column with the
scored marks or master splines aligned. Ensure the
wheel compresses the 2 lock tabs on the clockspring.
(2) Pull the speed control wires through the lower,
larger hole in the steering wheel. Pull the horn wire
through the smaller hole at the top.
(3) Install the retaining nut and tighten to 61 Nzm
(45 ft. lbs.) torque.Force the steering wheel down
on the shaft with the retaining nut only. Do not
hammer or shock the column with sudden im-
pact to install the wheel.
(4) Connect the wire feed to the horn buttons.
(5) Connect the wire feeds to the speed control
switch (Fig. 6). Tighten the air bag module nuts to 9
to 11 Nzm (80 to 100 in. lbs.) torque.
Fig. 5 Airbag Module Remove/Install
Fig. 6 Air Bag Module and Speed Control
19 - 50 STEERINGJ