1988 JEEP CHEROKEE clock

STEERING GEAR
Disassembly
1) Place steering gear in a holding fixture. Worm shaft
should be centered in steering gear. Remove sector shaft cover bolts.
Remove sector shaft and cover from housing.
2) Remove sector shaft adjusting screw lock nut. Rotate
adjusting screw clockwise to remove cover from shaft. DO NOT lose shim
located on adjusting screw.
3) Loosen worm bearing adjuster lock nut. Remove worm bearing
adjuster and worm shaft lower bearing. Remove worm shaft and ball nut
assembly from housing. Remove upper bearing.
CAUTION: DO NOT allow ball nut to rotate down worm shaft as ball
guides may be damaged.
4) If ball nut fails to rotate smoothly on worm shaft,
disassembly is required. Remove ball guide clamp and guides. Rotate
worm shaft in both directions to remove balls. Note and record number
of balls in each circuit area of the ball nut.
5) Note direction of ball nut on worm shaft prior to removal.
Remove ball nut from worm shaft.
CAUTION: Note and record number of balls removed from each circuit of
ball nut during disassembly. Determine location of ball nut
on worm shaft prior to removal. Ball nut must be installed
on worm shaft with shallow teeth in proper direction.
6) Use slide hammer and puller attachment to remove worm
bearing adjuster bearing cup. See Fig. 2. Using a bearing driver or
socket, remove bearing cup from housing.
7) Remove bearings from housing. Pry out all seals from
housing. Note direction of seals.
Fig. 2: Removing Worm Adjuster Bearing Cup
Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect bearings and races for signs of wear. Inspect ball nut and

replacing shims as necessary.
4) Install ball nut on worm shaft. Ensure ball nut is
installed so shallow end of teeth are to the left as viewed from
steering wheel end of worm shaft. Align grooves in worm and nut by
sighting through ball guide holes.
5) There are 2 types of ball guides used. One type contains a
hole in the middle, while the other does not. If ball guides contain
the middle hole, install ball guides in the ball nut.
6) Divide balls into 2 equal groups. Insert each group into a
ball guide, while slowly turning worm shaft away from the hole. Repeat
procedure for remaining circuit.
7) On guides with no holes, separate guide halves and fill
each one half of each circuit with balls. Install remaining guide
half. Hold guides and plug ends with grease to prevent the balls from
falling out.
8) Fill each circuit of ball nut with half of remaining balls
in one circuit, and half in other. DO NOT turn worm shaft while
installing. It may be necessary to use small punch to aid in ball
installation. Install ball guides. On both types, install ball guide
clamp.
9) To install, reverse removal procedure. Lubricate all
seals, bearings and sector shaft prior to installation. Coat worm
bearing adjuster, sector shaft adjuster screw and sector shaft cover
bolts with non-hardening sealant prior to installation.
10) Screw worm bearing adjuster down until nearly all end
play has been removed. Lubricate steering gear by rotating worm shaft
until ball nut is at end of its travel.
11) Pack as much grease as possible into steering gear
housing without losing it out sector shaft opening. Rotate ball nut to
other end of its travel and pack more grease into housing.
12) Rotate ball nut until it is in center of its travel.
Insert sector shaft assembly, containing adjusting screw and shim into
housing. Center tooth of sector gear must engage center rack tooth
space in ball nut.
13) Pack housing with grease. Apply a thin bead of sealant to
sector shaft cover on models which do not use gasket. Install cover
and gasket on housing. Engage sector adjuster screw with tapped hole
in center of sector cover by turning screw counterclockwise.
14) Turn adjusting screw until sector cover is flush with
housing. Install sector cover bolts but do not tighten unless there is
a lash between sector shaft and worm shaft.
15) Tighten sector cover bolts to specification. Adjust
steering gear preload and meshload. See ADJUSTMENTS in this article.
Fig. 4: Exploded View of Saginaw Model 525 Steering Gear (Typical)
TORQUE SPECIFICATIONS

Fig. 1: Exploded View of Saginaw Rotary Valve Power Steering Gear
ADJUSTMENTS
THRUST BEARING PRELOAD ADJUSTMENT
1) Remove steering gear from vehicle. Remove adjuster plug
lock nut. Turn adjuster plug clockwise with a spanner wrench until
plug is seated in housing. This will require 20-30 ft. lbs. (27-41 N.
m) of torque.
2) Place an index mark on housing opposite one spanner wrench
hole in adjuster plug. Measure 1/2" (13 mm) counterclockwise from mark\
and again mark housing. Rotate plug counterclockwise until hole in
adjuster lines up with second mark.
3) Tighten lock nut. Ensure adjuster remains in position.
Attach an INCH lb. torque wrench to end of input shaft. Turn input
shaft to right stop, then back 1/4 turn.
4) Using torque wrench measure rotational torque required to
turn shaft. Reading should be taken with beam of torque wrench near
vertical while turning it counterclockwise at an even rate. Torque
reading should be 4-10 INCH lbs. (.4-1.1 N.m). See. Fig. 2.

Cleaning & Inspection
1) Clean all pump components in solvent, and blow dry.
Inspect flow control valve assembly for wear, scoring, burrs and other
damage. Inspect seal bore for burrs, nicks and score marks.
2) Inspect machined surfaces of body for scratches and burrs.
Check "O" ring mating surfaces. Inspect drive shaft and sleeve for
wear.
3) Inspect pump ring for roughness. Check thrust plate and
pressure plate for scoring and wear. Ensure vanes slide freely but fit
snugly into slots. If vanes are loose in slots, replace rotor and/or
vanes.
Reassembly
1) Lubricate all "O" rings, seals, pump ring, rotor and vanes
with petroleum jelly. Install sleeve. Ensure sleeve is fully seated.
2) Install "O" ring in sleeve seat. Install small dowel pin
in pump housing. Install pressure plate spring and "O" ring. Install
pressure plate with dowel pin hole aligned with dowel pin holes.
Install dowel pins.
3) Install pump ring with identification marks located
adjacent to one dowel pin. Install rotor with counterbore toward drive
shaft end of housing.
4) Install vanes with rounded edges toward pump ring. Install
thrust plate "O" ring. Install thrust plate with indentations aligned
with bolt holes of housing. Install retaining ring.
CAUTION: Pump ring must be installed with identification marks
located adjacent to dowel pins. Thrust plate must be
installed so indentations in thrust plate align with bolt
holes of housing and thrust plate engages with pump ring
dowel pins.
5) Using a socket, install drive shaft seal in housing until
seal bottoms. Support drive shaft bearing on inner race, and press
drive shaft into bearing. Install drive shaft and bearing in pump
housing.
6) Rotate drive shaft during installation to align with rotor
serrations. Ensure bearing is fully seated in pump housing. Snap ring
should be installed with large lug area (near snap ring pliers hole)
positioned right of small lug (near snap ring pliers hole), ensuring
beveled area of snap ring is properly positioned.
7) Install spring, flow control valve and "O" rings. Install
return tube with new "O" ring. Install pulley.
STEERING GEAR
Disassembly
1) Cap all openings in gear. Clean gear exterior thoroughly.
Mount gear in vise so that pitman shaft points downward. Rotate
housing end plug retainer ring until one end of plug is over the hole
in the housing.
2) Force end of ring from groove in housing and remove.
Rotate input shaft counterclockwise to force housing end plug out of
housing. Rotate input shaft clockwise 1/2 turn to draw rack/piston
inward. Remove piston end plug.
CAUTION: DO NOT rotate shaft more than is necessary to remove plug as
ball bearings will fall out of worm and rack piston assembly.
3) Remove lock nut from sector shaft adjuster. Remove sector
shaft cover. Remove and discard "O" ring from cover. Turn input shaft
until sector shaft teeth are centered in housing.

4) Tap end of sector shaft with a soft-faced hammer to free
shaft from housing, then remove sector shaft. Remove adjuster plug
lock nut. Remove adjuster plug with a spanner wrench.
5) Insert a rack/piston arbor into end of rack/piston until
arbor just contacts worm shaft. Turn stub shaft counterclockwise to
force rack/piston onto arbor. Remove rack/piston and arbor as an
assembly.
6) Take care to keep arbor fully inserted so ball bearings
will not fall out. Remove input shaft and control valve assembly from
housing. Remove worm, wormshaft lower thrust bearing, and races from
housing.
Reassembly
1) Lubricate all parts with clean power steering fluid before
reassembly. Install the lower thrust bearing and races onto the worm.
Cupped side of thrust washers must face toward stub shaft. See Fig. 8.
Fig. 8: Reassembly of Valve Body & Worm Shaft Assembly
NOTE: If conical thrust races are used, ensure tapered surfaces
are parallel to each other and that cupped sides face toward
stub shaft.

2) Install stub shaft cap "O" ring in valve body. Align valve
body drive pin on worm with narrow pin slot in valve body. Worm drive
lugs must engage in stub shaft cap.
3) Install valve body and worm assembly into housing. Perform
installation by pressing directly on valve body only. This will
prevent stub shaft "O" ring from disengaging from valve body.
4) Valve body is correctly seated when fluid return port in
housing is fully visible. Ensure worm locating pin is fully engaged in
valve body. Place seal protector over input shaft, install a new
adjuster plug "O" ring, then install adjuster plug.
5) Remove seal protector from housing and loosely install
adjuster plug lock nut. Insert arbor and rack/piston into housing.
Align worm and rack/piston and turn stub shaft clockwise to engage
worm. Maintain pressure on arbor until worm is fully engaged.
6) Turn input shaft clockwise until middle rack groove in
rack/piston is aligned with center of sector shaft roller bearing.
Remove arbor. Install a new sector shaft cover gasket.
7) Thread sector shaft cover onto adjuster screw until
bottomed. Back off 1 1/2 turns. Install sector shaft so that center
gear tooth meshes with center groove in rack/piston. Install cover
attaching bolts.
8) Install adjuster lock nut halfway onto sector shaft.
Install piston and plug in rack/piston. Install housing end plug "O"
ring, end plug and retainer ring. Adjust worm bearing preload and
over-center preload at this time.
ADJUSTER PLUG
Disassembly
1) Remove thrust bearing retainer ring with a screwdriver,
taking care not to score needle bearing bore. Discard retainer ring.
Remove thrust bearing spacer, thrust bearing and bearing races.
2) Remove and discard adjuster plug "O" ring, then remove
input shaft seal retainer. Remove and discard dust seal. Pry input
shaft seal from adjuster plug.
3) Inspect needle bearing in adjuster plug. If necessary,
remove bearing by pressing out from spacer end. See Fig. 9.
Inspection
Inspect thrust bearing for cracks and rollers for pitting,
scoring, or cracking. Check thrust races and spacer for damage or
damage. Replace parts as necessary.
Fig. 9: Exploded View of Adjuster Plug Assembly
Reassembly
1) Press roller bearing into adjuster plug (identification
end facing arbor) until bearing bottoms on input shaft seal bore.

Install input shaft seal with spring in seal facing adjuster plug.
2) Install dust seal into adjuster plug. Rubber face of seal
must face away from plug. Install retainer ring. Install adjuster plug
"O" ring.
3) Assemble thrust bearing, thrust bearing race, and thrust
bearing spacer on adjuster plug. Using a brass or wooden dowel, press
bearing retainer into needle bearing bore.
RACK/PISTON & WORM
Disassembly
Remove worm, lower thrust bearing and bearing races from rack
piston. Remove piston ring and back-up "O" ring from rack/piston.
Remove ball return guide clamp, ball return guide and all ball
bearings from rack/piston.
Inspection
1) Clean and dry all parts. Inspect worm and rack/piston
grooves for scoring. Inspect ball bearings for damage. If any ball
bearings are damaged, replace entire set. Check ball guides for
pinching of ends.
2) Inspect lower thrust bearing races for cracking, scoring,
or pitting. Replace wormshaft and rack/piston as an assembly if either
part is damaged. Inspect rack/piston teeth for chips, cracks, dents or
scoring.
Reassembly
1) Install "O" ring and piston ring onto rack/piston using
care not to twist them. Install worm into rack/piston until worm is
against piston shoulder. Install ball bearings into rack/piston while
slowly rotating worm counterclockwise.
NOTE: See RACK PISTON & WORM ASSEMBLY BALL BEARINGS table for
number of balls to be installed. BE SURE to install light
and dark colored balls alternately, as Black balls are
.0005" smaller than Silver balls.
2) Install correct number of balls in ball guide. Bearings in
guide must be in sequence with bearings in rack/piston. Hold balls in
place with chassis lubricant and install return ball guide assembly
into position.
3) Install clamp and tighten attaching bolts. Alternate light
and dark colored balls when installing. See Fig. 10. Insert
rack/piston arbor into rack/piston until it contacts worm. Maintain
pressure on arbor, and back worm out of rack/piston. DO NOT allow ball
bearings to drop out of circuits.
RACK PISTON & WORM ASSEMBLY BALL BEARINGS TABLE









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Application Rack/Piston Guide
Jeep ...................... 18 ....................... 6









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Will Not Shift Or Difficult To Shift Into Gear
Vehicle speed too high; slow vehicle to 2-3 MPH to shift.
Vehicle operated too long on dry paved surface; stop vehicle and place
in Reverse or Neutral to relieve driveline torque. Ensure transfer
case external linkage is not binding. Ensure correct fluid is used.
Internal parts may be worn or damaged.
Noisy In All Gears
Check fluid level. Ensure correct fluid is used. If fluid is
okay, locate possible internal mechanical problem.
Jumps Out Of Gear Or Noisy In 4WD
Transfer case not completely in gear; check shift linkage.
Range fork damaged. Shift fork pads are worn or shift fork binding.
Low range gear worn.
Fluid Leaking From Vent Or Seals
Transfer case overfilled. Vent plugged. Output shaft seals
are damaged or not installed properly.
ON-VEHICLE SERVICE
FRONT OIL SEAL
Removal & Installation
1) Mark front drive shaft and flange for installation
alignment reference. Remove front drive shaft. Remove flange. Discard
washer and nut. Using a screwdriver, carefully remove oil seal. Ensure
seal contact surface is clean.
2) Apply ATF to seal lip and flange seal surface. Install NEW
oil seal. Install flange and NEW washer and nut. Tighten nut to
specifications. See TORQUE SPECIFICATIONS . Install front drive shaft
using alignment marks. Check transfer case fluid.
EXTENSION HOUSING OIL SEAL & BUSHING
Removal & Installation
1) Mark rear drive shaft and flange for installation
alignment reference. Remove rear drive shaft. Tap extension housing in
a clockwise direction and remove extension housing. DO NOT pry on
extension housing. Using a screwdriver, remove oil seal from extension
housing.
2) Using bushing driver, replace bushing in extension
housing. Install NEW extension housing oil seal. Apply silicone
sealant to extension housing mating surface. Install extension
housing. To complete installation, reverse removal procedure.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1) Shift transfer case into 4H and disconnect battery
negative cable. Raise vehicle, remove skid plate and drain fluid.
2) Mark front and rear output shaft yokes to drive shafts for
reassembly reference. Support transfer case and remove rear
crossmember. Remove drive shafts.
3) Disconnect vehicle speed sensor electrical connector and
vacuum (hoses) harness at transfer case. Remove shift lever or linkage\
rod from case. Remove transfer case attaching bolts. Remove transfer
case from vehicle.