1994 JEEP CHEROKEE service

SERVICE DIAGNOSIS/PROCEDURES
INDEX
page page
Runout................................. 4
Unbalance............................... 3Universal Joint Angle Measurement............ 4
Vibration................................ 3
VIBRATION
Tires that are out-of-round or wheels that are un-
balanced will cause a low frequency vibration. Refer
to Group 22, Wheels and Tires for additional infor-
mation.
Brake drums that are unbalanced will cause a
harsh, low frequency vibration. Refer to Group 5,
Brakes for additional information.
Driveline vibration can also result from loose or
damaged engine mounts. Refer to Group 21, Trans-
missions for additional information.
Propeller shaft vibration will increase as the vehi-
cle speed is increased. A vibration that occurs within
a specific speed range is not caused by propeller
shaft unbalance. Defective universal joints or an in-
correct propeller shaft angle are usually the cause.
UNBALANCE
If propeller shaft unbalance is suspected, it can be
verified with the following procedure.
Removing and re-indexing the propeller shaft
180É may eliminate some vibrations.
²Clean all the foreign material from the propeller
shaft and the universal joints.²Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas.If the pro-
peller shaft is bent, it must be replaced.
²Ensure the universal joints are not worn, are prop-
erly installed, and are correctly aligned with the
shaft.
²Check the universal joint clamp screws torque
(1) Raise the vehicle.
(2) Remove the wheel and tires assembly. Install
the wheel lug nuts to retain the brake drums.
(3) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.
(4) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration oc-
curred. Stop the engine.
(5) Install a screw clamp at position 1 (Fig. 1).
(6) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(7) If there is no difference in vibration at the
other positions, the vibration may not be propshaft
unbalance.
DRIVELINE VIBRATION
JPROPELLER SHAFTS 16 - 3

ADJUSTMENTÐXJ FRONT SHAFT
Adjust the pinion gear angle at the lower suspen-
sion arms with shims (Fig. 10). Adding shims will de-
crease the pinion gear shaft angle but will increase
the caster angle. The pinion gear shaft angle has pri-
ority over the caster angle.
PROPELLER SHAFT REPLACEMENT
PRECAUTIONS
Use exact replacement hardware for attaching the
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be ap-
plied when tightening the fasteners.
Put reference marks on the propshaft yoke and axle
or transmission yoke before service (Fig. 1). This will
assure correct phasing and eliminate possible vibration.
CAUTION: Do not allow the propeller shaft to drop
or hang from either universal joint during removal.
Attach it to the vehicle underside with wire to pre-
vent damage to the universal joints.CAUTION: It is very important to protect the ma-
chined, external surface of the slip yoke from dam-
age after propeller shaft removal. If damaged, the
transmission extension seal could be damaged and
cause a leak.
FRONTÐXJ VEHICLES
REMOVAL
(1) Raise the vehicle.
(2) Scribe alignment marks on the yokes at the
transfer case. Place marks at the pinion shaft and at
each end of the propeller shaft. These marks will be
used for installation reference (Fig. 2).
(3) Remove the U-joint strap bolts at the pinion
shaft yoke.
(4) Disconnect the propeller shaft at the transfer
case and remove the propeller shaft.
INSTALLATION
(1) Position the propeller shaft with the yoke refer-
ence marks aligned (Fig. 1). Install the propeller
shaft.
Replacement U-joint straps and bolts must be
installed.
(2) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 Nzm (14 ft. lbs.) torque.
(3) Tighten the flange to transfer case bolts to 27
Nzm (19.5 ft. lbs.) torque.
(4) Lower the vehicle.
Fig. 10 Angle AdjustmentÐXJ Vehicles
Fig. 1 Reference Marks on Yokes
JPROPELLER SHAFTS 16 - 7

UNIVERSAL JOINT REPLACEMENT
PRECAUTIONS
It is very important to put reference marks on the
yokes before removal or component service (Fig. 1).
This will assure correct phasing and eliminate possi-
ble vibration.
SINGLE CARDAN
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2)Paint or score alignment marks on the yokes
and propeller shaft for installation reference.
(3) Using a soft drift, tap the outside of the bear-
ing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke
(Fig. 2).
(5) Set the yoke in an arbor press or vise with a large
socket beneath it. Position the yoke with the lube fit-
ting pointing up (if equipped). Place a smaller socket on
the upper bearing assembly and press it through to re-
lease the lower bearing assembly (Fig. 3).
(6) If the bearing assembly will not pull out by
hand after pressing, tap the base of the lug near it to
dislodge.
(7) To remove the opposite bearing, turn the yoke
over and straighten the cross in the open hole. Then
carefully press the end of the cross until the remain-
ing bearing can be removed (Fig. 4).
CAUTION: If the cross or bearing assembly are cocked
when being pressed, the bearing assembly will score
the walls of the yoke bore and ruin the yoke.
CLEANING AND INSPECTION
(1) Clean all the universal joint yoke bores with
cleaning solvent and a wire brush.
(2) Inspect the yokes for distortion, cracks and
worn bearing assembly bores.
ASSEMBLY/INSTALLATION
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to aid in installation.
(2) Position the cross in the yoke with its lube fit-
ting (if equipped) pointing up (Fig. 5).
(3) Place a bearing assembly over the trunnion and
align it with the cross hole (Fig. 6). Keep the needle
bearings upright in the bearing assembly. A needle
roller lying at the bottom will prevent proper assembly.
Fig. 1 Reference Marks on Yokes
Fig. 2 Remove Snap Ring
Fig. 3 Press Out Bearing
JPROPELLER SHAFTS 16 - 9

(4) Press the bearing assembly into the cross hole
enough to install a snap ring. Install a snap ring.
(5) Repeat steps 3 and 4 to install the opposite
bearing assembly. If the joint is stiff, strike the yoke
with a soft hammer to seat the needle bearings. In-
stall a snap ring.
(6) Add grease to lube fitting (if equipped).
(7) Install the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
DOUBLE CARDAN (CV)
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2)Paint or score alignment marks on the yokes
and propeller shaft for installation reference.
(3) Remove all the bearing assembly snap rings (Fig.
7).
Fig. 4 Press Out Remaining Bearing
Fig. 5 Install Cross In Yoke
Fig. 6 Install Bearing On Trunnion
Fig. 7 Remove Snap Rings
16 - 10 PROPELLER SHAFTSJ

STEERING
CONTENTS
page page
GENERAL INFORMATION.................. 1
MANUAL STEERING GEAR............... 35
NON-TILT STEERING COLUMN............ 50
POWER STEERING PUMP................. 9
POWER STEERING SYSTEM DIAGNOSIS..... 3
RECIRCULATING BALL POWER STEERING GEAR.19STEERING COLUMN GENERAL SERVICE.... 45
STEERING LINKAGEÐXJ................. 14
STEERING LINKAGEÐYJ................. 17
STEERING RHD........................ 69
TILT STEERING COLUMN................ 59
TORQUE SPECIFICATIONS................ 73
GENERAL INFORMATION
STEERING SYSTEM COMPONENTS
Jeep vehicles can have either a manual or power
steering system (Fig. 1). A recirculating-ball type
steering gear is used for both systems.
Power steering systems use;
²Steering gear
²Pressure and return fluid hoses and fittings
²Belt driven steering pump
²Integral or remote body mounted pump reservoir
POWER STEERING GEAR
The steering gear is mounted on the left frame rail.
The gear is joined to the intermediate shaft by a uni-
versal joint coupling. The coupling helps isolate noise
and road shock from the interior.
The major internal components of the gear are the:
²Rotary valve assembly
²Steering worm shaft
²Rack piston assembly
²Pitman shaft
The movement of these parts, while turning or
parking, is aided by hydraulic pressure and flow sup-plied by the pump. Manual steering is always avail-
able at times when the engine is not running or in
the event of pump or belt failure. Steering effort is
higher under such conditions.
The steering stub shaft, rotary valve, worm shaft,
and rack piston assembly are all in line. The oil pas-
sages are internal within the gear housing except for
pressure and return hoses between the gear and
pump.
The power steering gear has a recirculating ball
system. This acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned right, the rack piston moves up in
gear. Turning the worm shaft left moves the rack
piston down in gear. The rack piston teeth mesh with
the sector, which is part of the pitman shaft. Turning
the worm shaft turns the pitman shaft, which turns
the wheels through the steering linkage.
The control valve in the steering gear directs the
power steering fluid to either side of the rack piston.
The rack piston is assisted by hydraulic pressure. If
the steering system loses hydraulic pressure, the ve-
hicle can be controlled manually, but with higher
steering effort.
An identification code located on the side cover des-
ignates the gear ratio (Fig. 2).
²Code BH designates 14:1 ratio used in XJ vehicles
²Code BF designates 13-16:1 ratio used in YJ vehi-
cles
A recirculating-ball steering gear is used with the
power (assisted) steering system (Fig. 1). The power
steering gear can be adjusted and internally serviced.
POWER STEERING PUMP
Hydraulic pressure is provided for operation of the
power steering gear by a belt driven power steering
Fig. 1 Steering Gears
JSTEERING 19 - 1

POWER STEERING PUMP
INDEX
page page
Drive Pulley Replacement.................. 11
Flow Control Valve Fitting O-Ring Seal........ 12
Power Steering PumpÐInitial Operation....... 13
Pressure and Return Hose Replacement........ 9Pump Replacement....................... 10
Reservoir Replacement.................... 12
Service Information........................ 9
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.
(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.
Fig. 1 Power Steering Hose YJ
JSTEERING 19 - 9

STEERING LINKAGEÐXJ
INDEX
page page
Drag Link.............................. 14
Pitman Arm............................. 15
Service Information....................... 14Steering Dampener....................... 15
Tie Rod ................................ 14
SERVICE INFORMATION
The steering linkage consists of a pitman arm, drag
link, tie rod, and steering dampener. 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 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 dampener 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.
Fig. 1 Ball Stud Removal
19 - 14 STEERINGJ

STEERING LINKAGEÐYJ
INDEX
page page
Drag Link.............................. 17
Pitman Arm............................. 18
Service Information....................... 17Steering Dampener....................... 18
Tie Rod ................................ 17
SERVICE INFORMATION
The steering linkage consists of a pitman arm, drag
link, tie rod, and steering dampener. 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 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 steering
knuckles and drag link (Fig. 2). Remove the steering
dampener from the tie rod.
(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 end from the tube.
INSTALLATION
(1) If necessary, install the tie rod end in the tube
(Fig. 2). Position the tie rod clamp as shown (Fig. 3).
Tighten the ball-stud end clamp bolts to 49 Nzm (36
ft. lbs.) torque.
(2) Install the tie rod on the drag link and steering
knuckles. Install the retaining nuts. Install the steer-
ing dampener to the tie rod.
(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. Tighten the steering dampener nut to 74 Nzm
(55 ft. lbs.) torque. Install new cotter pins.
DRAG LINK
REMOVAL
(1) Remove the cotter pins and nuts at the tie rod
and pitman arm (Fig. 2).
(2) Remove the drag link from the tie rod and pit-
man arm with a puller tool.
(3) If necessary, loosen the end clamp bolts and re-
move the tie rod ends from the tube.
INSTALLATION
(1) Install the drag link adjustment sleeve and tie
rod ends. Position clamp bolts as shown (Fig. 3).
(2) Position the drag link at the steering linkage
(Fig. 2).
Install the drag link to tie rod and pitman arm.
(3) Tighten the nut at the pitman arm to 74 Nzm
(55 ft. lbs.) torque. Tighten the tie rod ball stud nut
to 75 Nzm (55 ft. lbs.) torque. Install new cotter pins.
Fig. 1 Ball Stud Removal
JSTEERING 19 - 17