JEEP XJ 1995 Service And Repair Manual

POWER STEERING SYSTEM DIAGNOSIS
JSTEERING 19 - 7

POWER STEERING SYSTEM DIAGNOSIS
19 - 8 STEERINGJ

POWER STEERING SYSTEM DIAGNOSIS
JSTEERING 19 - 9

PUMP LEAKAGE DIAGNOSISGEAR LEAKAGE DIAGNOSIS
19 - 10 STEERINGJ

POWER STEERING PUMP
INDEX
page page
Drive Pulley Replacement................... 13
Flow Control Valve Fitting O-Ring Seal......... 14
Power Steering PumpÐInitial Operation........ 15
Pressure and Return Hose Replacement........ 11Pump Replacement........................ 12
Reservoir Replacement..................... 14
Service Information........................ 11
SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an inter-
nal fluid leak occurs, the complete unit must be re-
placed. A reservoir, cap, and O-ring seal kit are the
only service components available.
PRESSURE AND RETURN HOSE REPLACEMENT
Cap hose open ends and pump/steering gear fit-
tings to prevent entry of foreign material.
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE HOSES TO TOUCH A
HOT EXHAUST MANIFOLD OR THE CATALYTIC
CONVERTER.
REMOVAL
(1) Remove fasteners from hose retaining brackets
at all locations.
(2) If applicable, remove pressure sensor from
pressure hose (Fig. 1, 2).
(3) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser-
voir (Fig. 1, 2, 3).
(4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2, 3).
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks.The
hose must be kept away from exhaust system
components.Do not distort hose tube ends by bend-
ing, kinking or over tightening.
(3) If applicable, install and tighten pressure sen-
sor to 28 Nzm (252 in. lbs.) torque (Fig. 1, 2).
(4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
Fig. 1 Power Steering HoseÐYJ
JSTEERING 19 - 11

(5) Tighten fittings at pump and gear to 35 Nzm
(25 ft. lbs.) torque.
(6) Install clamps on return hose on gear, pump
and reservoir.(7) After installation, inspect and test for fluid
leaks.
PUMP REPLACEMENT
REMOVAL
CAUTION: The drive belt tension must be released
before removing the pump. If the belt is not loos-
ened, the pump pulley could be damaged.
(1) Remove serpentine drive belt. Refer to Group 7,
Cooling for additional information.
(2) Place a drain pan under pump.
(3) Remove pressure and return hoses from pump.
Refer to Pressure and Return Hose Replacement in
this section.
(4) Remove 2 rear bracket-to-pump bolts (Fig. 4).
(5) Remove lower nut at adjustment bracket.
(6) Remove adjuster bolt.
(7) Remove upper pivot bolt.
(8) Tilt pump forward and remove pump and front
bracket assembly from engine bracket.
(9) Remove adjuster collar at lower stud on pump
bracket.
(10) Remove pulley from pump. Refer to Drive Pul-
ley Replacement in this section (Fig. 5).
(11) Remove 3 front bracket-to-pump bolts.
Fig. 2 Power Steering HoseÐXJ 4 Cylinder
Fig. 3 Power Steering HoseÐXJ 6 Cylinder
19 - 12 STEERINGJ

INSTALLATION
(1) Install 3 front bracket-to-pump bolts. Tighten
to 28 Nzm (21 ft. lbs.) torque.
(2) Install pulley on pump. Refer to Drive Pulley
Replacement in this section (Fig. 6).
(3) Install adjuster collar on adjuster bracket stud
(Fig. 4).
(4) Tilt pump forward and install pump onto en-
gine bracket.
(5) Install upper pivot bolt.
(6) Install lower adjuster bolt.
(7) Install lower adjuster stud nut.
(8) Install 2 rear engine bracket to pump bolts.
Tighten to 28 Nzm (21 ft. lbs.) torque.
(9) Install the serpentine drive belt. Refer to Group
7, Cooling for additional information.
(10) Install the pressure and return hoses to
pump. Refer to Pressure and Return Hose Replace-
ment in this section.
(11) Add power steering fluid. Refer to Power
Steering Pump Initial Operation in this section.
DRIVE PULLEY REPLACEMENT
REMOVAL
(1) Remove power steering pump. Refer to Pump
Replacement in this section.(2) Remove the drive pulley with Puller C-4333
(Fig. 5).
Do not hammer on any part of drive pulley,
damage will occur to the pump and pulley.
INSTALLATION
(1) Install the pulley with Installer C-4063-B (Fig.
6). Do not use the tool adapters.
Fig. 4 Pump MountingÐ6 Cylinder
Fig. 5 Remove Drive PulleyÐTypical
JSTEERING 19 - 13

(2) Be sure tool and pulley remain aligned and
NOT cocked with the pump shaft.
(3) Press the pulley on flush with end of pump
shaft (Fig. 7).
(4) Install power steering pump. Refer to Pump
Replacement in this section.
With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.).Be
careful that pulley does not contact mounting
bolts.
RESERVOIR REPLACEMENT
REMOVAL
(1) Remove power steering pump. Refer to Pump
Replacement in this section.
(2) Clean exterior of pump with solvent.
(3) Clamp the pump body in a soft jaw vice.
(4) Pry up tab and slide the retaining clip off (Fig.
8).
(5) Remove fluid reservoir from pump body. Re-
move and discard O-ring seal (Fig. 9).
INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent.
(2) Install O-ring seal in housing.
(3) Install reservoir onto housing.
(4) Slide and tap in reservoir retainer clips until
tab locks to housing.
(5) Install power steering pump. Refer to Pump
Replacement in this section.
FLOW CONTROL VALVE FITTING O-RING SEAL
REMOVAL
(1) Clean area around fitting to prevent dirt from
entering pump. Remove pressure hose from pump fit-
ting.
Fig. 6 Install Drive PulleyÐTypical
Fig. 7 Pump Shaft Location
Fig. 8 Remove Reservoir ClipsÐTypical
Fig. 9 Remove ReservoirÐTypical
19 - 14 STEERINGJ

(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 - 15

STEERING LINKAGEÐXJ
INDEX
page page
Drag Link............................... 16
Pitman Arm.............................. 17
Service Information........................ 16Steering Damper.......................... 17
TieRod ................................ 16
SERVICE INFORMATION
The steering linkage consists of a pitman arm, drag
link, tie rod, and steering damper. 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 C-3894-A 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 tie rod
ball studs and drag link (Fig. 2).
(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 ends from the tube.
INSTALLATION
(1) If necessary, install the tie rod ends in the tube
(Fig. 2). Position the tie rod clamp as shown (Fig. 3)
and tighten to 27 Nzm (20 ft. lbs.) torque.
(2) Install the tie rod on the drag link and steering
knuckle. Install the retaining nuts.
(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. Install new cotter pins.
DRAG LINK
REMOVAL
The drag link ball stud cannot be disassem-
bled for service.
(1) Remove the steering damper ball stud from the
drag link with a puller tool.
(2) Remove the drag link from the steering knuckle
with a puller tool. Remove the same for tie rod and
pitman arm.
(3) If necessary, loosen the end clamp bolts and re-
move the tie rod end from the link.
INSTALLATION
(1) Install the drag link adjustment sleeve and tie
rod end. Position clamp bolts as shown (Fig. 3).
(2) Position the drag link at the steering linkage
(Fig. 2).
Install the nut that attach the drag link to the
steering knuckle. Do the same for the tie rod and pit-
man arm.
(3) Tighten the nut at the steering knuckle to 47
Nzm (35 ft. lbs.) torque. Tighten the pitman and tie
rod ball stud nuts to 75 Nzm (55 ft. lbs.) torque. In-
stall new cotter pins.
(4) Install the steering damper onto the drag link.
Tighten the nut to 47 Nzm (35 ft. lbs.) torque. Install
a new cotter pin.
Fig. 1 Ball Stud Removal
19 - 16 STEERINGJ