JEEP XJ 1995 Service And Repair Manual

(3) Place the ignition key cylinder in the ACCES-
SORY position.
(4) Remove shipping pin from plastic base.
(5) Connect the cable eyelet to the bellcrank pin
(Fig. 4).
(6) Place gear selector in PARK.
(7) Push the spring-loaded cable adjuster forward
and snap cable into bracket (Fig. 4).
(8) Push the cable adjuster lock clamp downward
to lock it.(9) Install the center console and related trim. Re-
fer to Group 23, Body.
(10) Test the park-lock cable operation.
(11) Load the steering column up to the bracket.
Refer to Column Assembly Replacement in this
group.
TEST/INSPECTION
(1) Turn the ignition switch key to the LOCK posi-
tion.
(2) Press inward on the gear selector handle re-
lease button, the button should not move.
(3) Turn the ignition switch key to the ON posi-
tion.
(4) Press inward on the gear selector handle re-
lease button.
(5) Move the gear selector handle to the DRIVE or
NEUTRAL position.
(6) Attempt to turn the ignition switch key to the
LOCK position.
(7) If the park-lock cable is correctly adjusted, the
key will not turn to the LOCK position.
(8) Press inward on the gear selector handle re-
lease button and move the gear selector handle to the
PARK position.
(9) Turn the ignition switch key to the LOCK posi-
tion. If the park-lock cable is correctly adjusted, the
key will turn to the LOCK position.
(10) If additional cable adjustment is required,
slide the adjuster forward or rearward to obtain the
correct position. Refer to Group 21, Transmission for
additional information involving shift cable adjust-
ment.
Fig. 4 Cable and Shifter
JSTEERING 19 - 57

STEERING COLUMNÐYJ
INDEX
page page
Assembly............................... 63
Assembly............................... 71
Column Replacement...................... 58
Disassembly............................. 66DisassemblyÐColumn or Console Shift......... 60
Non-Tilt Steering Column................... 60
Steering Wheel........................... 58
Tilt Steering Column....................... 66
The column may be disassembled and reassembled.
Also most steering column components can be serviced
without removing the column from the vehicle. For ad-
ditional information, refer to Group 8H, Electrical.
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 damper, 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
(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.
COLUMN REPLACEMENT
REMOVAL
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
Fig. 1 Horn Pad Removal/Installation
Fig. 2 Steering Wheel Removal
19 - 58 STEERINGJ

(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. 3).
(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. 4).
(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)
(10) Remove the bolts that attach the toe plate to
the floor pan (Fig. 5).
(11) 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)
(4) Install the support bracket on the column (Fig.
4) and tighten the bolts to 30 Nzm (270 in. lbs.)
torque.
(5) Install and tighten the column to brake sled
bolts (Fig. 4) to 30 Nzm (270 in. lbs.) torque.
Fig. 3 Column Shaft Coupler
Fig. 4 Column Bracket
Fig. 5 Steering Column Mounting
JSTEERING 19 - 59

(6) Column shift vehicles, install the shift cable
grommet on the shift lever.
(7) Install and tighten the toe plate to floor pan
bolts/nuts to 21.5 Nzm (192 in. lbs.) torque (Fig. 5).
(8) Install the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(9) Install steering wheel on column, refer to Steer-
ing Wheel-Installation.
(10) Connect the negative (ground) cable to the
battery.
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 TOREMOVE THE STEERING SHAFT RETAINING SNAP
RING WITHOUT USING LOCKPLATE COMPRESSOR
C-4156.
(4) Compress the lockplate with Compressor
C-4156 and release the steering shaft retaining 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).
(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.
Fig. 1 Steering Column Support Fixture
Fig. 2 Retaining Snap Ring Removal
19 - 60 STEERINGJ

(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).
Fig. 3 Steering Column Disassembly
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 - 61

(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.
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.
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 - 62 STEERINGJ

(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.
(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.
ASSEMBLY
WARNING: USE ONLY THE ORIGINAL OR EXACT
REPLACEMENT SCREWS, BOLTS AND NUTS TO
ASSEMBLE THE STEERING COLUMN. INCORRECT
SCREW OR BOLT LENGTH COULD PREVENT THE
COLUMN FROM COMPRESSING WITH IMPACT
(FRONT-END COLLISION). ALL FASTENERS USED
FOR ASSEMBLY MUST BE TIGHTENED WITH THE
CORRECT TORQUE. THIS WILL ENSURE THE COL-
UMN WILL BREAKAWAY WITH IMPACT.
CAUTION: Apply chassis lubricant to all the bear-
ing, thrust and friction producing mating surfaces
before assembly.
COLUMN SHIFT ASSEMBLY
(1) Insert the lock sector through the key/lock cyl-
inder hole in the key/lock cylinder housing. Install
the lock sector on the lock sector shaft (Fig. 13). En-
sure that the lock sector turns freely after installa-
tion.
(2) Install the lock rack preload spring. The bowed
side of the spring must contact the lock rack when
the rack is installed.
(3) Assemble the lock bolt and the lock rack (Fig.
14).
(4) Install the assembled lock bolt and lock rack in
the key/lock cylinder housing (Fig. 15). Mate the lock
rack block tooth with the lock sector block tooth.
(5) Install the shift lever detent plate on the key/
lock cylinder housing (Fig. 16).
Fig. 11 Lock Sector Removal
Fig. 12 Lower Bearing, Adapter, Retainer & Clip
Fig. 13 Lock Sector Installation
JSTEERING 19 - 63

(6) Install the thrust cap on the key/lock cylinder
housing (Fig. 16).
(7) Install the ignition switch actuating rod and
rack on the key/lock cylinder housing.
(8) Insert and install the gear selector lever hous-
ing lower bearing the housing. Align the indentations
in the bearing shell with the projections on the hous-
ing jacket.
(9) Install the gear selector lever spring in the le-
ver housing.(10) Install the gear selector lever housing and
shroud on the upper end of the steering column
jacket. Rotate the housing and ensure that the bear-
ing is properly seated.
(11) Place the gear selector in the PARK position,
and the lock rack pulled downward. Position and cor-
rectly seat the key/lock cylinder housing on the steer-
ing column jacket. Install and tighten the four
attaching screws.
(12) Insert the shift tube in the lower end of the
steering column jacket. Rotate it until the shift tube
upper key slides into the gear selector housing key-
way.
COLUMN SHIFT FINAL ASSEMBLY
(1) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive shaft
(Fig. 17). Force it inward and move the ignition
switch actuator rod up and down to align the compo-
nents. When the components align, the key/lock cyl-
inder will move inward and lock in place.
(2) Install the key warning buzzer switch.
(3) Install the ignition switch, refer to Ignition
Switch ÐAll Models in Group 8D, Ignition.
(4) Install the lower bearing, the adapter, the re-
tainer and spring clip at the lower end of the steer-
ing column.
(5) Install the steering shaft through the lower end
of the steering column and insert it into the upper
bearing.
Fig. 14 Lock Bolt & Lock Rack
Fig. 15 Lock Bolt/Lock Rack Installation
Fig. 16 Key/Lock Cylinder Housing
19 - 64 STEERINGJ

(6) Position the turn signal switch and wire har-
ness in the cylinder housing. Fold the wires against
the connector. Route the connector down through the
steering column jacket.
(7) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
(8) Align the turn signal switch in the housing and
secure the switch with the attaching screws. Tighten
the screws to 4 Nzm (35 in. lbs.) torque.
(9) Install the dimmer switch actuator arm.
Tighten the attaching screws to 4 Nzm (35 in. lbs.)
torque.
(10) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(11) Position the thrust washer, the upper bearing
preload spring and the canceling cam on the steering
shaft (Fig. 18).
(12) Place the turn signal switch in the neutral
(OFF) position and install the hazard warning switch
knob.
(13) Position the lockplate on the steering shaft.
Install a replacement lockplate retaining snap ring
on the sleeve of the Lock Plate Compressor C-4156.
Install the tool on the steering shaft (Fig. 19).
(14) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(15) Ensure that the retaining snap ring is com-
pletely seated in the groove before removing the tool.
Remove the tool and install the lockplate cover.(16) Install the steering wheel. Refer to the instal-
lation procedure. Tighten the steering wheel retain-
ing nut to 34 Nzm (25 ft. lbs.) torque.
(17) If removed, install the steering column in the
vehicle. Refer to the installation procedure.
(18) If disconnected, connect the battery negative
cable and, if equipped, reset the clock
Fig. 17 Key/Lock Cylinder InstallationFig. 18 Canceling Cam Position
Fig. 19 Lockplate Snap Ring Installation
JSTEERING 19 - 65

TILT STEERING COLUMN
DISASSEMBLY
(1) Remove the steering column from the vehicle, if
necessary. Refer to the removal procedure.
(2) If the column is removed for service, fabricate a
support fixture to clamp it in a vise (Fig. 1).
(3) If the steering column has not been removed
from the vehicle, place the front wheels in the
straight-ahead position. Disconnect the battery nega-
tive cable.
(4) Protect the painted areas on the steering col-
umn.
(5) Remove the steering wheel. Refer to the re-
moval procedure.
(6) Column shift: Remove the gear selector lever
retaining pin and the lever from the housing.
(7) Remove the lockplate cover. Use two small pry
bars to pry the cover off the lockplate.
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.
(8) Compress the lockplate with Lock Plate Com-
pressor C-4156 and release the steering shaft retain-
ing snap ring (Fig. 2).
(9) Remove the lockplate compressor tool and the
retaining snap ring. Discard the snap ring.
(10) Remove the lockplate, canceling cam, upper
bearing preload spring, and the thrust washer from
the steering column/shaft.(11) Remove the hazard warning switch knob.
Press the knob inward and remove it from the steer-
ing column by turning it counterclockwise.
(12) If the steering column is the column shift
type, remove the two retaining screws and the gear
selector indicator cover.
(13) If the steering column is the column shift
type, remove the gear selector indicator lamp bracket
retaining screw. Do not remove the lamp and bracket
at this time.
(14) Remove the tilt-release lever.
(15) Disconnect the turn signal wire harness con-
nector from the bracket located at the lower end of
the steering column (Fig. 3).
CAUTION: Wrap tape around the turn signal switch
wire harness connector to prevent it from becoming
entangled during removal.
(16) Remove the plastic protector from the wire
harness.
(17) Remove the turn signal switch retaining
screws (Fig. 4), dimmer switch actuator arm, to re-
move the switch. Guide the switch straight up and
out of the steering column.
(18) Remove the windshield wiper switch wire har-
ness and all the other wire harnesses located within
the steering column.
(19) Insert the ignition switch key into the key/lock
cylinder. Turn the key 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.
Fig. 1 Steering Column Support Fixture
Fig. 2 Lockplate Snap Ring Removal
19 - 66 STEERINGJ