
o
STEERING
SYSTEM
10
FIG.
0-7—STEERING
CONNECTING
ROD
(DRAG
LINK)
10696
1—Cotter Pin
2>—Large
Plug
3—
Ball
Seat
4—
Ball
Seat Spring 5—
Spring
Plug
shaft,
tightness
of the steering gear in the frame,
tightness
of steering gear arm, adjustment of the
steering connecting rod and condition of the steer ing tie rod
ball
joint ends. Adjust the steering con
necting rod (drag
link)
to maximum safe
tightness
at both ends. Examine the steering beilcrank bearings, the shaft in the mounting bracket, and
the mounting bracket on the frame cross member,
k.
Check
front axle caster.
This
should be the same
on both sides, otherwise a locking brake may be
indicated
causing a twisting action of the axle.
Correct
caster is shown in specifications at the end
of this section.
I.
Check
the front wheel toe-in. See Specifications,
m.
Check
wheel
toe-out
on turns.
This
gives
you
an
indication of the proper angularity of the steer
ing knuckle arms and tells whether or not they have been bent and require replacing. These may be checked by comparing them with new parts. If
an
arm is bent, check for a bent tie rod.
n.
Check
wheel camber.
This
should be the same
on both wheels as shown on the Specifications,
o.
Check
the king pin inclination. See Specifica tions.
p.
Check
the tracking of the front axle and frame
alignment, which may be incorrect due to an accident.
0-14.
STEERING
LINKAGE
SERVICE
The
steering linkage must maintain constant toe-
in
and
good
steering control under all driving
conditions.
This
requires
ball
joints at each end
of the tie rods and steering connecting rod. All
joints in the steering linkage must be kept well
lubricated
for easy operation and long life. Should
the joints be worn, allowing excessive free motion
in
the linkage, the joints must be replaced. When
ever
ball
joints are replaced, toe-in must be reset. Because
some
members of the steering system may
have
become
bent or distorted, a periodic inspection
should be made.
0-15.
Steering Connecting
Rod
(Drag
Link)
The
steering connecting rod is of the
ball
and socket
type. All
ball
seat springs and adjusting plugs are 6—
-Dust
Cover
7—
Dust
Shield
8—
Small
Adjusting Plug
9—
Lubrication
Fitting
10—Connecting Rod
identical,
the only difference
between
front and
rear
end being the relative location of the springs.
The
correct assembly of the steering connecting
rod
is shown in Fig. 0-7. At the front or axle end,
the spring and spacer are assembled
between
the
rod
and
ball
seat, while at the steering gear end,
spring
and spacer are
between
the
ball
seat and the
end plug. In the illustration the front end is to the left.
When
removing springs and
seats
for any reason,
make
sure they are reassembled as shown in the
illustration
because this method of assembly re
lieves road shock from the steering gear in both di
rections. To adjust the
ball
joint, screw in the plug
firmly
against the
ball,
approximately 20 ft. lb. [2,8 kg-m.] then back off one quarter
turn
and lock
with
a new cotter pin inserted through
holes
in the
tube and the slot in the adjusting plug. To adjust the
ball
joint at the steering gear arm, screw in the end plug firmly against the
ball,
then back off one
full
turn
and lock with a new cotter pin inserted
through
holes
in the tube and the slot in the ad
justing
plug.
The
above adjustments
will
give
the proper spring
tension and avoid any
tightness
when swinging
the wheel from maximum left to right
turn.
The
ball
joints must be tight enough to prevent end
play
and yet
loose
enough to allow free movement.
0-16. Tie Rod
The
tie rods are of three piece construction consisting of the rod and two
ball
and socket end as semblies.
Ball
and socket end assemblies are
threaded into each rod and locked with clamps,
around
each end of the rod. Right and left hand threads on tie rod end assemblies provide toe-in adjustments without removing the tie rod ends from
the steering arm.
'Jeep'
Universal models are equipped with a
divided
tie rod connected to a bell-crank mounted
on the frame cross member.
With
this type con
struction
the toe-in of each wheel is adjusted in
dependently. See heading "Toe-in adjustment".
When
wear takes place in the tie rod end
ball
and socket, it
will
be necessary to replace the
ball
and socket assembly and also the rubber seal. 318

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL
D
©—P3
10789
FIG.
0-8—STEERING TIE ROD
1—
Cotter
Pin 6—Lockwasher
2—
Nut 7—Left Tie Rod
3—
Dust
Cover
8—Lubrication
Fitting
4—
Left
Socket 9—Left Socket (For Right Tie Rod) 5— Nut 10—Right Tie Rod 11—
Right
Socket
12—
Bolt
13— Tie
Rod
Clamp
0-17.
Tie Rod
Removal
First
disconnect and remove the steering tie rod
from
the bellcrank. Refer to Fig. O-l. The tie
rod
can then be removed by removing the cotter
pins and
nuts
at the
ends.
To remove the tie rod
from
the steering knuckle arms, use a puller or
expansion
fork.
Then
separate
the
joint
seals
and
fittings,
if
necessary.
The tie rod
sockets
can be
removed by loosening the
nuts
on the clamp bolts
and unscrewing the
sockets
from
the tie rod
tubes.
Refer to Fig. 0-8. When installing the
components
of
the steering linkage, new
seals
should be in stalled as
necessary.
All
nuts
should be torqued 38
to 42
lb-ft.
{5,2 a 5,8
kg-m.],
and new cotter pins
installed.
If the bellcrank was removed, the
steer
ing
bellcrank nut should be torqued 70 to 90
lb-ft.
[9,7
a 12,4
kg-m.].
0-18.
Steering
Bellcrank
Service
Refer to Fig. 0-9.
The
assembly
and adjustment of this unit is ex
tremely important; the information outlined below must be
followed
carefully whenever servicing the
bellcrank
assembly
on late model vehicles.
A
service kit
Part
No. 991381 containing the
bell
crank shaft, bearings,
seals,
bolt, nuts, and
washer
is
available for servicing this
assembly.
Be certain that all
parts
are installed in their proper position.
When assembling the parts, be
sure
the new
bear
ings in the bellcrank are positioned
Y%"
[3,175 mm.]
below the
surface
of the bellcrank
face
as shown. The
bearings
have
a
light
press"
fit that
will
hold
them in
place
after locating them in the proper
position.
Finally, when installing
washers,
the
chamfer on the
washer
must be installed toward
the bellcrank.
After
completing the
assembly,
and before attach
ing
the connecting
rods
to the bellcrank levers,
make
your
final
adjustment to the
assembly
as
follows:
a.
With
the W [11,113 mm.] diameter clamp bolt
loosened, adjust the locknut on the end of the
bell
crank shaft
until
the bellcrank just
rotates
freely
without
a bind.
Note:
On early model vehicles using bellcrank kit
Part
No. 920556, torque the bellcrank shaft nut
(Fig.
O-l #14) 70 - 90
lb-ft.
[9,7 a 12,4
kg-m.].
319

STEERING
SYSTEM
FIG.
0-9—STEERING
BELLCRANK
ASSEMBLY
1— 5s'-18
Stollock
Lockout
2—
Plain
Washer
3— 7 us"-20
x
2 l2' Bolt
4—
71«
*-20
Stollock
Locknut
5—
Beilcrank
Support
6—
Special
Ground
Washer
7— Seal
8—
Bearing
9— Beilcrank
10— Beilcrank
Shaft
11—
Seals
12—
Bearings
13— } s *
b.
Torque the
Vfc"
[11,113
mm.] diameter elamp
bolt to
50-70
lb-ft. [6,9 a 9,7 kg-m.].
c.
Assemble the tie rod to the beilcrank lever,
making
sure to tighten the nut to the proper
torque value of 38 to 45 lb-ft. [5,2 a 6,2 kg-m.].
d.
Connect the drag
link
to the beilcrank arm,
adjust
the
ball
joint by screwing in the plug firmly against the
ball,
approximately 20 lb-ft. [2,8 kg-m.], then back off one quarter
turn
and lock
with
a new cotter pin.
0-19.
Beilcrank
Support
Bracket
Rivet
Replacement
The
procedure for replacing a rivet with a bolt
is as follows:
a.
Drill
a [4,76 mm.] pilot
hole
up through
the front rivet.
b.
Enlarge
the [4,76 mm.]
hole
with a %"
[8,73 mm.]
drill.
c.
Chisel
off the
bottom
rivet head and drive the
remainder
of the rivet upward and out, using
a
punch and hammer.
d.
Install
a %" [9,53 mm.] bolt and lock nut,
torque to
30-45
lb-ft. [4,1 a 6,2 kg-m] and stake
the nut.
e.
Clamp
a metal plate to the frame to protect
the radiator, then
drill
and remove the remaining two rivets, install bolts, lock nuts and torque as
specified.
O-20.
STEERING
COLUMN
AND
WHEEL SERVICE
Jeep
Universal
Series vehicles use a
one-piece
steer
ing
shaft that is integral with the steering gear
assembly, as shown in Fig. 0-2. Alignment in
structions in paragraph 0-4 apply.
0-21.
Steering
Wheel Removal •
Refer to Fig. 0-2.
a.
Carefully
pry the rubber horn cap from the housing slot.
b.
Remove steering shaft nut.
c.
Remove steering wheel and spring.
0-22.
STEERING GEAR SERVICE
Note:
The steering gear can be adjusted when the
gear is mounted in the vehicle by first disconnecting
the drag
link
from the steering arm. Refer to Par.
Q-5.
0-23.
Removal
of
Steering Gear
•
F4-Engine.
a.
Remove the directional signal unit from the steering column.
b.
Remove the steering column bracket attached
at the instrument panel.
c.
Remove upper section of the floor pan.
d.
Disconnect shift rods from the shift levers at
lower end of the steering column if applicable.
e.
Disconnect the horn wire at lower end of steer
ing
gear assembly.
f.
Remove steering gear arm from the steering gear assembly.
g.
Remove
bolts
attaching the steering gear hous
ing
to the frame.
h.
Remove the steering gear assembly by bringing
it
up through the floor pan opening.
•
V6 Engine.
a.
Remove oil pan
skid
plate.
b.
Remove
left
exhaust pipe.
c.
Disconnect connecting rod (drag
link)
from
steering gear arm.
d.
Disconnect steering gear assembly from frame.
e.
Remove steering wheel from steering column.
f. Disconnect accelerator linkage.
g.
Remove upper floor pan assembly.
h.
Disconnect directional signal switch.
i.
Jack-up
vehicle, and remove steering gear and
320

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL
O
column assembly down through the floor pan open
ing and out from under vehicle.
0-24.
Disassembly
of
Steering
Gear
Refer
to Fig. 0-2.
When
the steering gear arm is installed on early
production vehicles, the line across the face of the
arm
and the end of the shaft should be in align ment. On later production vehicles, blind splines
on the lever shaft and in the steering gear arm en
sure
correct positioning of the arm.
a.
Remove the steering gear arm with a puller
C-3646.
Caution:
Do not use a hammer or
wedge
to re
move
the steering arm from the shaft and lever.
This
can cause damage to the shaft assembly.
b.
Loosen the lock nut and unscrew the adjusting
screw
two turns.
c.
Remove the side cover screws and washers. Re
move
the side cover and gasket.
d.
Remove lever shaft.
e.
Remove upper cover plate screws. Remove cam,
wheel tube, and bearing assembly from the housing.
f.
Clean
all parts with suitable cleaning solvent and wipe dry.
g.
After dismantling as outlined above is com
pleted, inspect cam
grooves
for wear, chipping and
scoring,
also the
ball
races on the cam ends and the
separate
ball
cups. Existence of any of
these
condi tions indicates the necessity for parts replacement.
h.
Inspect the tapered stud mounted on the lever
shaft for flat
spots
and chipping. In the case of
either, replacement is usually advisable. Inspect the
lever shaft for wear and
test
the fit of the shaft in
the bushings.
i.
Inspect condition of the oil seal at outer end of
lever shaft and the bearing at top end of steering
column.
0-25.
Reassembly
of
Steering
Gear
e Refer to Fig. 0-2.
Reassemble all parts to wheel tube in reverse order
of dismantling. Assemble cam, wheel tube and
bearing
assembly in housing, seating the lower
bearing
ball
cup in the housing.
Note:
New plastic retainer type cam bearings are
now available for the Ross steering gears. The new
bearings replace, and are interchangeable with,
the lock ring type cam bearings on gears equipped
with
early type cams.
With
adjusting shims in place, assemble upper
cover and adjust the cam bearings.
Assemble lever shaft in housing and with gasket
in
place assemble the side cover and set adjusting
screw
for a minimum backlash of the studs in the
cam
groove, with the steering gear at the center
point of travel.
When
assembling upper bearing spring and spring
seat in jacket tube make sure that the spring seat
is positioned correctly. It must be installed with
the lengthwise flange down against the bearing and
not up inside of spring coil.
0-26.
Installation
of
Steering
Gear
a.
After the gear has been properly adjusted, as
outlined in Par. 0-5, install steering gear assembly
in
chassis in the reverse order in which it was re
moved.
b.
After installing the assembly in the vehicle,
jack
up front of vehicle and place the front wheels
in
the straight ahead position.
c.
Temporarily install the steering wheel to locate
the mid-position of the steering gear. To locate the mid-position,
turn
the steering wheel as far to the
right
as possible and then
turn
in the
opposite
di
rection
as far as possible, noting the total number
of turns.
Turn
the wheel back just ^ of the total movement to place the gear in mid-position.
d.
With
the steering gear in mid-position and the
wheels in the straight ahead position install steer ing gear arm on lever shaft with the
ball
end down.
When
installed the line across the face of the arm
and
end of shaft should be in alignment.
0-27.
Steering
Wheel
Installation
•
Refer to Fig. 0-2.
a.
Install
steering wheel and spring on shaft.
Align
scribe marks on shaft and hub of wheel.
b.
Install
steering shaft nut and torque 20 to 25
lb-ft. [2,8 a 3,4 kg-m.].
c.
Install
horn cap. Test horn.
321

o
STEERING
SYSTEM 0-28.
SBKF1CE
DIAGNOSIS
SYMPTOMS PROBABLE REMEDY
Hard Steering
Lack
of Lubrication Lubricate all Connections
Tie
Rod
Ends
Worn.
Replace
Connecting Rod
Ball
Joints
Tight. Adjust
Cross
Shaft Improperly Adjusted Adjust Steering
Gear
Parts
Worn...................
Replace
Steering
Loose
Tie
Rod
Ends
Worn
Replace
Connecting Rod
Ball
Sockets
Worn
Replace
Steering
Gear
Parts
Worn.
Replace
Steering
Gear
Improperly Adjusted.
......
Adjust
Road Shook; Steering Connecting Rod too Tight;
Axle
Spring
Clip
Loose; Wheel Bearings Loose;
Poor
Shock Absorber
Control,
Turning Radius
Short One
Side
Center
Bolt
in Spring
Sheered
Off,
Axle
Shifted, Steering Arm Bent, Steering Arm not Properly Located
on
Steering
Gear.
0-29.
STEERING
SPECIFICATIONS
F4
ENGINE
V6
ENGINE
STEERING
GEAR:
Make.
Ross
Ross
Type
Cam
and Lever
Cam
and Lever
Ratio..
17.9 to 1
19 to 1
Bearings:
Ball
Cam-Upper
Ball Ball
Cam-Lower
Ball Ball
Lever
Shaft Bushing
Bushing
Steering Column-Upper
Ball
Ball
Lever
Shaft:
.0005*
to
.0025"
[0,0127
a
0,0635
mm.]
Clearance
to Bushing
.0005"
to
.0025"
[0,0127
a
0,0635
mm.j
.0005*
to
.0025"
[0,0127
a
0,0635
mm.]
End
Play .000'
.000"
Lash
at Cam (Straight Ahead) Slight Drag
Slight Drag
Wheel Diameter.
17M*
(438 mm.]
17M*
[438 mm.]
Wheel
Turns.
2.58
2.58
STEERING
GEOMETRY:
King
Pin Inclination
m°
I
72
Toe-In.
W to W U,2 a 2,3 mm.] W to W [1,2 a 2,3 mm.]
Camber
1°
30'
1°
30'
Caster
3°
3°
Turning
Angle:
27K°
DJ,
CJ Models
27K° 273^°
Turning
Radius with 27^° Angle: 17' 6" [5,3 mm.]
CJ-3B,
CJ-5, CJ-5A.
17' 6" [5,3 mm.]
17' 6" [5,3 mm.]
CJ-6,
CJ-6A
22' 10" [7,0 mm.]
22' 10" [7,0 mm.]
Outside Wheel Angle with Inside Wheel at 20°:
20° 20°
322

p
BRAKES
13264
FIG- P-2—DOUBLE
SAFETY BRAKE
MASTER
CYLINDER
With
the Double-Safety brake system type master
cylinder,
failure
in one part of the brake system
does
not result in
failure
of the entire hydraulic
brake system. Failure in the
front
brake system
will
leave the rear brake system
still
operative or
failure
in
the rear system
will
leave the
front
brake system
operative.
A
double hydraulic
cylinder
with
two outlets, two
residual
check valves, two
fluid
reservoirs, and
two
hydraulic pistons (a
primary
and secondary)
are operated in tandem by a single hydraulic push
rod.
The
primary
outlet is connected to the
front
brakes
with
the secondary outlet connected to the rear brakes.
With
the master
cylinder
fluid
reservoirs
filled
and the
front
and rear brake system
bled,
there is a
solid
column
of
fluid
on the
forward
side of both the
primary
and the secondary pistons.
Upon
application
of the brakes, through movement
of
the brake pedal,
fluid
is displaced by the pistons
into
the wheel cylinders to activate both
front
and
rear brakes.
Upon
release
of the brakes,
fluid
re
turns
from
the rear wheel cylinders through the secondary residual check valve to the secondary
portion
of the master
cylinder
bore.
Fluid
also
returns
from
the
front
wheel cylinders through the
primary
residual check valve to the
primary
portion
of the master
cylinder
bore.
P-3.
Parking
Brakes
— DJ-5, DJ-6
a.
The parking brake is operated by a T-handle
lever
mounted to the
left
of the steering
column
and
suspended
from
the instrument panel. When
the brake lever is
pulled
outward, tension is exerted
on
the parking brake cable leading to the brake.
The
amount of brake
grip
depends
on the number
of
notches the lever is
pulled
out. To set the park
ing
brake,
pull
out on the parking brake
control
T-handle.
To
release
the brake,
turn
the handle
slightly
and push it
forward.
0
FIG.
P-3—PARKING
BRAKE LINKAGE
—
DJ-5,
DJ-6
1—
Cable
and
Conduit
(Front)
7—Retracting
Spring
Link
13—Brake
Lever
Bracket
2—
Clip
8—Nut
14—Clevis
Pin
3—
Grommet
9—Nut
15—Cotter
Pin
4—
Hand
Brake
Handle
Assembly
10—Equalizer
16—Clevis
Pin
5—
Cable
and
Conduit
(Rear)
11—Adjusting
Rod
17—Cotter
Pin
6—
Retracting
Spring
12—Hand
Brake
Lever
324

Q
WHEELS
FIG.
Q-2—FRONT
WHEEL
ATTACHING
PARTS —
2-WHEEL-DRIVE
1—
Steering
Knuckle
2—
Brake
3— Hub
Grease
Seal
4—
Inner
Bearing
Cone
5—
Inner
Bearing
Cup
6—
Hub
and
Drum
7—
Outer
Bearing
Cup
8—
Outer
Bearing
Cone
9—
Tongued
Washer
10— Nut
11—
Cotter
Pin
12—
Grease
Cap
13— Nut
14—
Lockwasher
15—
Bolt
j
10703
is ir 10730
FIG.
Q-3—REAR
WHEEL
ATTACHING PARTS —
4-WHEEL-DRIVE
TAPERED
AXLE
1—
Oil
Seal
2—
Cone
and
Rollers
3— Cup
4—
Shims
5—
Bearing
Retainer
6—
Brake
Backing
Plate
7—
Gasket
8—
Grease
Retainer
9—
Grease
Protector
10—Bolt
11— Hub
and
Drum
12—
Shaft
Key
13—
Washer
14—
Nut
15—
Cotter
Pin
Ifi—Hub
Cap
17—Nut
18—
Ixick
Washer
19—Bolt
FIG.
Q-4—REAR
WHEEL
ATTACHING
PARTS —
2-WHEEL-
DRIVE-TAPERED
AXLE
1—
Oil
Seal
2—
Bearing
Cone
3—
Bearing
Cup
4—
Shim
Set
5—
Retainer
and
Seal
6—
Brake
7—
Nut
8—
Hub
and
Drum
9—
Axle
Shaft Key
10—
Washer
11— Nut
12—
Cotter
Pin
13—
Lockwasher
14—
Bolt
recommended with the exception that
rear
wheels
on vehicles having
Trac-Lok
or
Powr-Lok
axles
should always be removed for balancing.
Q-3. WHEEL
BEARING
SERVICE
Adjustment
of the wheel bearings is
critical
be cause it establishes the running clearance of the wheel bearings. Wheel bearing adjustment that is
too
tight
preloads the bearings and causes them
to run hot. Loose wheel bearings permit the drum hub to shift its position on the bearings as thrust loads
vary
with acceleration,
braking,
and cornering.
Loose
bearings also cause
erratic
braking.
To check
the wheel bearings for adjustment, brakes must
be free and in fully released position. 336

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL
FIG.
Q-5—REAR
WHEEL
ATTACHING
PARTS —
FLANGED
AXLE
1—
Brake
Backing Plate
2—
Retainer
Ring
3—
Unit-Bearing
4—
Oil
Seal
5—
Retainer
Plate 6—
Brake
Drum
7—
Cup
Plug
8—
Flanged
Axle Shaft
14284
Q-4. Checking
Front
Wheel Bearings
Raise
the front end of the vehicle with a
jack
so that the tires clear the floor.
Grip
the tire and
test
sidewise shake of the wheel.
If
bearings are correctly adjusted, shake of the
wheel
will
be just perceptible and wheel
will
turn
freely with no drag.
If
bearing adjustment is too tight, the rollers may
break
or
become
overheated. Loose bearings may cause
excessive
wear and noise.
If
this
test
indicates bearing adjustment is neces
sary,
follow
the procedure given in Par. Q-5. Loose
bearings
will
cause sidewise shake that is evident
around
the entire circumference of the wheel. A shake that is evident only when gripping the
wheels
in
a plane parallel to the ground, but not evident
around
the entire circumference, probably indicates
looseness
in the steering linkage.
Q-5.
Front Wheel Bearing Adjustment
With
the vehicle on the
jack,
the following proce
dure
should be followed to adjust the front wheel
bearings on four wheel-drive vehicles.
a. Remove the hub cap, snap
ring,
capscrews, and
washers that attach the driving
flange
to the hub.
b.
Using the
Front
Axle Shaft Drive Flange Puller
W-163,
pull
the driving flange.
c. Bend the lip of the nut lock washer so that the
locknut
and lock washer may be removed.
d.
Rotate the wheel and tighten the adjustment nut until the wheel binds.
Note:
Front
tire and wheel must be rotated by
hand
as the adjusting nut is
tightened
to ensure positive seating of the bearing.
Then
back off the adjusting nut about one-sixth
turn
making sure that wheel rotates freely without
sidewise shake.
e. Replace the lock washers and locknut. Bend
over the lock washer lip.
f.
Check
the adjustment (Par. Q-4). Reassemble the driving
flange
and hub cap. Make certain the
gasket is properly installed
between
the hub and
the flange.
•
Model DJ-5, DJ-6
On
two-wheel drive vehicles, remove the hub cap
and
the wheel retaining nut cotter pin. Rotate the
wheel and tighten the wheel retaining nut until the wheel binds.
Then
back off nut about one-sixth
turn
or more if necessary making sure wheel ro
tates
freely without sidewise shake. Replace the cotter pin and hub cap.
Q-6.
Rear
Wheel Bearing Adjustment —
Flanged
Axle Shaft
Vehicles
equipped with the
flange
type
rear
axle
shaft require no wheel bearing adjustment. The flanged axle shaft is equipped with a single row,
pre-adjusted,
tapered roller unit-bearing capable of
accepting thrust in either direction. The unit-
bearing
adjustment is built in at the factory mak
ing shimming or bearing adjustment unnecessary.
Refer
to Fig. Q-6.
Q-7.
Checking
Rear
Wheel Bearings —
Tapered
Axle
Raise
wheel on which adjustment is to be made
by placing a
jack
under the axle housing.
With
hands,
test
sidewise shake and in and out play
of the wheel. If bearings are correctly adjusted,
shake of wheel
will
be just perceptible and the 337