1994 JEEP CHEROKEE power steering fluid

(5) Remove the steering gear retaining bolts and
nuts. Remove the steering gear from the vehicle (Fig.
6, 7).
INSTALLATION
(1) Align the column coupler shaft to steering gear.
Refer to Column Coupler installation in this section.
(2) Position the steering gear (and bracket) on the
frame rail and install the bolts.
²XJÐTighten the bolts to 95 Nzm (70 ft. lbs.) torque
²YJÐTighten the bolts to 105 Nzm (78 ft. lbs.)
torque
(3) Align and install the pitman arm. Refer to Pit-
man Arm Installation in the Steering Linkage sec-
tion.(4) Connect fluid hoses to steering gear. Refer to
Pressure and Return Hose Replacement in this
Group.
STEERING GEAR ADJUSTMENTS
SERVICE INFORMATION
Adjusting the steering gear in the vehicle isNOT
recommended. Remove the gear from the vehicle and
mount in a vise. Drain the power steering fluid and
make the following adjustments in this order:
²FIRST - worm thrust bearing preload
Fig. 6 Steering Gear MountingÐXJ
Fig. 7 Steering Gear MountingÐYJ
Fig. 4 Coupler ShaftÐXJ
Fig. 5 Coupler ShaftÐYJ
19 - 22 STEERINGJ

(2) Starting at either stop turn the stub shaft back
1/2 the total number of turns. This is the center of
the gear travel (Fig. 12).
(3) Turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until extended, then turn
back in (CLOCKWISE) one full turn.
(4) Place the torque wrench in the vertical position
on the stub shaft. Rotate the wrench 45 degrees each
side of the center and record the highest rotational
torque on center (Fig. 13).
(5) Turn the adjuster in until torque to turn stub
shaft is 0.6 to 1.2 Nzm (6.0 to 10.0 in. lbs.) more than
reading in Step 4.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 49 Nzm (36 ft. lbs.).
GEAR DISASSEMBLY INFORMATION
CAUTION: Cleanliness is extremely important when
repairing a power steering gear. Keep the bench,
tools and components clean at all times. Thor-
oughly clean the exterior of the gear with cleaning
solvent before disassembly. Drain as much of the
fluid as possible. Use protective vise jaws at all
times when clamping components. During assem-bly, lubricate all components with power steering
fluid except where noted (Fig. 14).
Fig. 13 Checking Over-center Rotation Torque
Fig. 12 Steering Gear Centered
19 - 24 STEERINGJ

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. 16 End Plug Retaining Ring
Fig. 15 Side Cover and Pitman Shaft
19 - 26 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 (J7624) (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 - 27

(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 seal
²Remove 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.
(6) Lubricate O-ring seals and teflon rings with
power steering fluid.
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 - 29

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 (J-21552) into bore of rack
piston. Hold tool tightly against worm shaft while
Fig. 34 Balls in the Return Guide
Fig. 31 Remove and Install Rack Piston
Fig. 32 Remove and Install Seal on Rack Piston
Fig. 33 Installing Balls in Rack Piston
JSTEERING 19 - 31

STEERING RHD
GENERAL SERVICE PROCEDURE INFORMATION
Right hand drive service procedures and torque
specifications involving steering; linkage, gear and
column are the same as left hand drive vehicles ex-
cept where shown. Refer to appropriate service proce-
dures regarding each component in the system.
The steering linkage consists of a pitman arm,
drag link, and tie rod. Adjustment sleeves are used
on the tie rod and drag link for toe and steering
wheel alignment (Fig. 1).
RECIRCULATING-BALL POWER STEERING GEARS
The steering gears can be adjusted and internally
serviced. The components CANNOT be interchanged
with those of a left hand drive vehicle.
The steering gear has a 17.5:1 ratio.
POWER STEERING PUMP
PRESSURE AND RETURN LINE
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 LINES TO TOUCH A
HOT EXHAUST MANIFOLD.REMOVAL
(1) Place a drain pan under the pump and gear.
(2) Disconnect the pressure and return line from
the steering gear (Fig. 2, 3).
(3) Disconnect the pressure and return line from
the pump (Fig. 4). Drain the fluid from pump and
reservoir.
(4) Remove pressure and return line bracket at
belt tensioner (Fig. 5).
Fig. 1 RHD Steering Linkage
Fig. 2 Fluid Lines On Steering Gear
JSTEERING 19 - 69

INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Install pressure and return line on the pump
and gear (Fig. 2, 3, 4).
(3) Align the pressure and return line bracket to
the tensioner bracket. Install the screw. Tighten thescrew to 28 Nzm (21 ft. lbs.) torque.
(4) Tighten fittings at pump and gear to 28 Nzm
(21 ft. lbs.) torque.
(5) After installation, add power steering fluid, in-
spect and test for fluid leaks.
Fig. 4 Fluid Lines At Pump
Fig. 5 Pressure And Return Line Routing
Fig. 3 Pressure And Return Lines
19 - 70 STEERINGJ