JEEP XJ 1995 Service And Repair Manual

Fig. 14 Power Steering Gear
JSTEERING 19 - 27

PITMAN SHAFT AND SIDE COVER REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Pitman Arm Removal in the Steering Linkage sec-
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Clean exposed end of pitman shaft and housing.
²Clean pitman shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear.
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as
an assembly.
(4) Remove pitman shaft from the side cover (Fig.
15).
ASSEMBLE
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(2) Install preload adjuster nut.Do not tighten
nut until after pitman shaft adjustment has
been made.(3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 Nzm
(44 ft. lbs.).
(6) Adjust pitman shaft, refer to Over-Center Ad-
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
HOUSING END PLUG
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this Group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Rotate stub shaft back and forth to drain fluid
(1) Rotate retaining ring until one end is under the
hole in the housing. Unseat and force ring from
groove (Fig. 16).
(2) Rotate stub shaft slowly COUNTER-CLOCK-
WISE to remove end plug out from housing (Fig. 17).
Fig. 15 Side Cover and Pitman Shaft
Fig. 16 End Plug Retaining Ring
19 - 28 STEERINGJ

CAUTION: Do not turn stub shaft any farther than
necessary. The recirculating balls will drop out of
the rack piston circuit and fall inside the rack pis-
ton chamber.
(3) Remove O-ring seal (Fig. 17).
ASSEMBLE
²Lubricate O-ring seal with power steering fluid
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 mm (1
inch) from access hole (Fig. 18).
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
ADJUSTER PLUG ASSEMBLY REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span-
ner Wrench C-4381 (Fig. 19).
(3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 20).
Fig. 17 End Plug Components
Fig. 18 Installing The Retaining Ring
Fig. 19 Remove/Install Adjustment Plug
Fig. 20 Remove Retainer
JSTEERING 19 - 29

(4) Remove bearing spacer, races and thrust bear-
ing (Fig. 21).
(5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
with tool C-4177 and handle C-4171 (Fig. 22).
ASSEMBLE
CAUTION: Needle bearing must be installed with
identification on bearing facing tool to prevent dam-
age to bearing.(1) Install needle bearing into adjuster plug with
tool C-4177 and handle C-4171.
(2) Apply white petroleum grease on lip seal. In-
stall lip seal into adjuster plug with tool C-4177 and
handle C-4171.
(3) Apply white petroleum grease to dust seal cav-
ity and install dust seal into adjuster plug with tool
C-4177 and handle C-4171.
(4) Install retainer snap ring.
(5) Install O-ring seal to adjuster plug.
(6) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(7) Install thrust washer bearing retainer to ad-
juster plug (Fig. 23).
CAUTION: When installing adjuster plug, care
should be taken NOT to cut the seals.
(8) Install adjuster plug into housing with Spanner
Wrench C-4381.
(9) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(10) Install adjuster plug lock nut, and using a
punch (drift) in a notch, tighten securely (Fig. 24).
Hold adjuster plug to maintain alignment of the
marks.
(11) Adjust pitman shaft. Refer to Over-Center Ad-
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
VALVE REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
Fig. 21 Adjustment Plug Components
Fig. 22 Needle Bearing Removal
Fig. 23 Install Retainer
19 - 30 STEERINGJ

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

(5) Install the double lip seal.
(6) Install the backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Install the pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
CHECK VALVE REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
CAUTION: Use care not to damage the threads of
the housing when prying out check valve.
(1) Remove valve by prying from housing with a
small screwdriver.
ASSEMBLE
(1) Install the valve into the housing with a 3/8-
inch diameter piece of tubing 100 mm (4 inches) long.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
Fig. 37 Needle Bearing Removal
Fig. 38 Pitman Shaft Bearing Installation
Fig. 39 Pitman Shaft Seal Installation
JSTEERING 19 - 35

POWER STEERING GEAR SPECIFICATIONS
19 - 36 STEERINGJ