JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is concealed within and
integral to the ignition switch, which is mounted on
the steering column. The key-in ignition switch is
actuated by the ignition lock cylinder mechanism,
and is hard wired between a body ground and the
Body Control Module (BCM) through the instrument
panel wire harness.
The key-in ignition switch cannot be adjusted or
repaired and, if faulty or damaged, the entire igni-
tion switch unit must be replaced,(Refer to 19 -
STEERING/COLUMN/LOCK CYLINDER HOUSING
- REMOVAL). For complete circuit diagrams, refer to
Body Control Modulein the Contents of Wiring
Diagrams.
OPERATION
The key-in ignition switch closes a path to ground
for the BCM when the ignition key is inserted in the
ignition lock cylinder, and opens the ground path
when the key is removed from the ignition lock cyl-
inder. The BCM monitors the key-in ignition switch
status through an internal pull-up, then sends the
proper switch status messages to other electronic
modules over the Programmable Communications
Interface (PCI) data bus network. The key-in ignition
switch status is also used by the BCM as an input
for chime warning system operation.
DIAGNOSIS AND TESTING
KEY-IN IGNITION SWITCH
For complete circuit diagrams, refer toBody Con-
trol Modulein the Contents of Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) Disconnect and isolate the battery negative
cable. Disconnect the instrument panel wire harness
connector from the key-in ignition switch connector
receptacle on the ignition switch. Check for continu-
ity between the key-in ignition switch sense and
ground terminals of the key-in ignition switch con-
nector receptacle. There should be continuity with
the key inserted in the ignition lock cylinder, and no
continuity with the key removed from the ignition
lock cylinder. If OK, go to Step 2. If not OK, replace
the faulty ignition switch unit.
(2) Check for continuity between the ground cir-
cuit cavity of the instrument panel wire harness con-
nector for the key-in ignition switch and a good
ground. There should be continuity. If OK, go to Step
3. If not OK, repair the open ground circuit to ground
as required.
(3) Disconnect the gray 26-way instrument panel
wire harness connector from the Body Control Mod-
ule (BCM) connector receptacle. Check for continuity
between the key-in ignition switch sense circuit cav-
ity of the instrument panel wire harness connector
for the key-in ignition switch and a good ground.
There should be no continuity. If OK, go to Step 4. If
not OK, repair the shorted key-in ignition switch
sense circuit as required.
(4) Check for continuity between the key-in igni-
tion switch sense circuit cavities of the instrument
panel wire harness connector for the key-in ignition
switch and the gray 26-way instrument panel wire
harness connector for the BCM. There should be con-
tinuity. If OK, use a DRB scan tool and the proper
Diagnostic Procedures manual to test the BCM. If
not OK, repair the open key-in ignition switch sense
circuit as required.
LOCK CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) Disconnect negative battery cable at battery.
(2) If equipped with an automatic transmission,
place shifter in PARK position.
(3) Rotate key to ON position.
19 - 14 COLUMNWJ

(4) A release tang is located on bottom of key cyl-
inder (Fig. 18).(5) Position a small screwdriver or pin punch into
tang access hole on bottom of steering column lower
cover (Fig. 19).
(6) Push the pin punch up while pulling key cylin-
der from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) If equipped with an automatic transmission,
place shifter in PARK position.
(2) Position key cylinder into steering column as it
would normally be in the ON position.
(3) Press key cylinder into column until it snaps
into position.
(4) Check mechanical operation of switch.Auto-
matic Transmission:Be sure transmission lever is
locked in PARK position after key removal. If key is
difficult to rotate or is difficult to remove, the shift
lever-to-steering column cable may be out of adjust-
ment or defective. Refer to Transmission for proce-
dures.Manual Transmission:Be sure key cannot
be removed until release lever is operated. If key can
be removed, release lever mechanism may be defec-
tive. Release lever mechanism is not serviced sepa-
rately. If repair is necessary, the steering column
must be replaced,(Refer to 19 - STEERING/COL-
UMN - REMOVAL).
(5) Connect negative cable to battery.
(6) Check electrical operation of switch.
STEERING WHEEL
REMOVAL
For steering wheel removal procedure,(Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
For steering wheel installation procedure,(Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
Fig. 18 Key Cylinder Release Tang
1 - KEY CYLINDER
2 - RELEASE TANG
Fig. 19 Key Cylinder and Cover Removal
1 - LOWER COVER
2 - ACCESS HOLE
3 - PIN PUNCH
4 - COVER SCREWS (3)
WJCOLUMN 19 - 15
LOCK CYLINDER (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
ADJUSTMENTS
STEERING GEAR.....................18
SPECIFICATIONS
POWER STEERING GEAR..............18
SPECIAL TOOLS
POWER STEERING GEAR..............19
PITMAN SHAFT
REMOVAL.............................20INSTALLATION.........................20
PITMAN SHAFT BEARING
REMOVAL.............................22
INSTALLATION.........................22
PITMAN SHAFT SEAL
REMOVAL.............................22
INSTALLATION.........................23
RACK PISTON/VALVE ASSEMBLY
REMOVAL.............................23
INSTALLATION.........................25
STUB SHAFT HOUSING
REMOVAL.............................25
INSTALLATION.........................25
GEAR
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1) .
The following gear components can be serviced:
²Pitman Shaft and Cover
²Pitman Shaft Bearings
²Pitman Shaft Oil Seal/Dust Seal
²Stud Shaft Housing with Seal
²O-Rings and Teflon Rings
NOTE: If rack piston assembly is damaged the gear
must be replaced.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned the rack piston moves. The rack pis-
ton teeth mesh with the pitman shaft. Turning the
worm shaft turns the pitman shaft, which turns the
steering linkage.
REMOVAL
(1) Place the front wheels in the straight ahead
position with the steering wheel centered and locked.
(2) Remove the air cleaner housing,(Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(3) Drain or siphon the power steering system.(4) Remove the pressure and return lines (Fig.
2)from the steering gear. Refer to hose removal in
this section.
(5) Remove the column coupler shaft bolt (Fig.
2)and remove the shaft from the gear.
(6) Raise and support the vehicle.
(7) Remove the left front wheel and tire assembly.
(8) Remove the pitman arm from gear with Puller
C-4150A.
(9) Remove the windshield washer reservoir,(Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - REMOVAL).
(10) Remove the steering gear mounting bolts.
Remove the steering gear out of the engine compart-
ment (Fig. 3).
INSTALLATION
(1) Position the steering gear on the frame rail and
install the bolts. Tighten the bolts to 108 N´m (80 ft.
lbs.) torque.
(2) Install the pitman arm and tighten nut to 251
N´m (185 ft. lbs.).
(3) Install windshield washer reservoir,(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WASHER RES-
ERVOIR - INSTALLATION).
(4) Install the wheel and tire assembly.
(5) Remove the support and lower the vehicle.
(6) Install the pressure and return hoses to the
steering gear and tighten to 20-38 N´m (14-28 ft.
lbs.).
(7) Install the column coupler shaft.
(8) Install the air cleaner housing,(Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
19 - 16 GEARWJ

(9) Fill the power steering pump (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 1 Recirculating Ball Type Gear
1 - ADJUSTER NUT
2 - COVER
3 - PITMAN SHAFT
4 - O-RING
5 - BEARING
6 - GEAR HOUSING
7 - RACK PISTON
8 - RETAINING RING
9 - O-RING
10 - BEARING
11 - STUB SHAFT HOUSING
12 - PITMAN SHAFT SEAL
13 - PLASTIC BACKUP WASHER
14 - METAL BACKUP WASHER
15 - RETAINING RING
16 - DUST SEAL
Fig. 2 Pressure And Return Lines
1 - PRESSURE LINE
2 - RETURN LINE
3 - COUPLER BOLT
4 - STEERING GEAR
Fig. 3 Steering Gear Mounting
1 - MOUNTING BOLTS
2 - PITMAN SHAFT
3 - STABILIZER BAR
WJGEAR 19 - 17
GEAR (Continued)

ADJUSTMENTS
STEERING GEAR
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
OVER-CENTER
(1) Rotate the stub shaft with Socket 8343 from
stop to stop and count the number of turns.
(2) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
(3) Place torque wrench and Socket 8343 in a ver-
tical position on the stub shaft. Rotate the wrench 45
degrees each side of the center and record the high-
est rotational torque in this range (Fig. 4) . This is
the Over-Center Rotating Torque.
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
(4) Rotate the stub shaft between 90É and 180É to
the left of center and record the left off-center pre-
load. Repeat this to the right of center and record the
right off-center preload. The average of these two
recorded readings is the Preload Rotating Torque.
(5) The Over-Center Rotating Torque should be
0.45-0.80 N´m (4-7 in. lbs.)higherthan the Preload
Rotating Torque.
(6) If an adjustment to the Over-Center Rotating
Torque is necessary, first loosen the adjuster lock
nut. Then turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until fully extended, then
turn back in (CLOCKWISE) one full turn.
(7) Remeasure Over-Center Rotating Torque. If
necessary turn the adjuster screw and repeat mea-
surement until correct Over-Center Rotating Torque
is reached.
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.(8) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 37-52 N´m (27-38 ft. lbs.).
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Steering Gear
TypeRecirculating Ball
Steering Gear
Overall Ratio12.7:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Pitman Shaft Overcenter Drag
New Gear (under 400 miles)0.45-0.80
+ Worm Shaft PreloadÐ 4-7
+ Worm Shaft Preload
Pitman Shaft Overcenter Drag
Used Gear (over 400 miles)0.5-0.6
+ Worm Shaft PreloadÐ 4-5
+ Worm Shaft Preload
Fig. 4 Checking Over-center Rotation Torque
1 - CENTER
19 - 18 GEARWJ
GEAR (Continued)

SPECIAL TOOLS
POWER STEERING GEAR
Puller Seal 7794-A
Slide Hammer C-637
Remover, Pitman Arm C-4150A
Handle C-4171
Driver 8277
Driver 8294
Scoket 8343
WJGEAR 19 - 19
GEAR (Continued)

PITMAN SHAFT
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing.
(9) Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig.
7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
Fig. 5 Center Stub
1 - WRENCH
2 - STUB SHAFT
Fig. 6 Cover and Pitman Shaft
1 - ADJUSTER NUT
2 - PITMAN SHAFT COVER
3 - O-RING
4 - GEAR HOUSING
5 - PITMAN SHAFT
Fig. 7 Oil Seal Removal
1 - PULLER
2 - STEERING GEAR
19 - 20 GEARWJ

(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
Fig. 8 Oil Seal Retaining Ring
1 - SNAP RING PLIERS
2 - RETAINING RING
Fig. 9 Bearing Driver
1 - UPPER BEARING
2 - LOWER BEARING
3 - DRIVER
Fig. 10 Upper Pitman Shaft Bearing
1 - DRIVER
2 - UPPER BEARING
Fig. 11 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
WJGEAR 19 - 21
PITMAN SHAFT (Continued)

PITMAN SHAFT BEARING
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing (Fig. 12).
(9)
Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig. 7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
PITMAN SHAFT SEAL
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing (Fig. 12).
Fig. 12 Backup Washers
1 - METAL BACK UP WASHER
2 - PLASTIC BACK UP WASHER
19 - 22 GEARWJ

(9) Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig.
7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
RACK PISTON/VALVE
ASSEMBLY
REMOVAL
(1) Remove the steering gear (Refer to 19 -
STEERING/GEAR - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(5) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(6) Remove the pitman shaft cover o-ring.
(7) Remove stub shaft housing bolts (Fig. 13).
(8) Remove the housing from the stub shaft (Fig.
14).
Fig. 13 Stub Shaft Housing
1 - STUB SHAFT HOUSING
2 - BOLTS
3 - STUB SHAFT
Fig. 14 Housing Removal
1 - STEERING GEAR
2 - STUB SHAFT HOUSING
WJGEAR 19 - 23
PITMAN SHAFT SEAL (Continued)