1995 JEEP YJ torque

(6) Install the wormshaft bearing adjustment cap
in the housing and tighten it only enough to remove
the wormshaft end-play.
(7) Install the locknut on the wormshaft bearing
adjustment cap but do not tighten it at this time.
(8) Pack the steering gear housing with as much
chassis lubricant as possible.
Rotate the wormshaft in one direction until
the ball nut ceases. Pack the end of the housing
full of lubricant, rotate the shaft in the opposite
direction and repeat the packing procedure.
(9) Place the ball nut (Fig. 12) in the centered po-
sition, rotate the wormshaft from stop-to-stop and
count the number of rotations. Rotate wormshaft in
the reverse direction 1/2 of the number of rotations to
center the ball nut.
(10) Lubricate the pitman shaft with chassis lubri-
cant and insert it in the steering gear housing. En-
gage the center tooth on the shaft with the center
groove on the ball nut.
(11) Apply chassis lubricant to the replacement
housing cover gasket. Position it so that it surrounds
the housing cover opening.
(12) Place the shim(s) on the adjustment screw
and thread the screw into the cover to a depth of 2 to
3 threads.
(13) Slide the head of the adjustment screw into
the pitman shaft T-slot. With the cover in place, ro-
tate the screw counterclockwise to thread it into the
cover. Rotate the screw until the cover almost comes
in contact with the gasket.
(14) Install the cover retaining bolts finger tight
only. Continue tightening the adjustment screw coun-terclockwise until cover is tight against the gasket,
then loosen the screw 1/2 rotation.
(15) Tighten the cover bolts to 61 Nzm (45 ft. lbs.)
torque.
(16) Install the pitman shaft seal, refer to the re-
placement procedure.
(17) Rotate the wormshaft and observe the steer-
ing gear operation. With the adjustment screw and
cap loose, the wormshaft should rotate freely and not
bind. If the steering gear binds, repair as necessary.
(18) Inspect for lubricant leakage from the shaft
seals. If there is a leak at either seal, replace the de-
fective seal(s).
GEAR ADJUSTMENTS ON BENCH
WORM BEARING PRELOAD
(1) Tighten the worm bearing adjuster plug until it
bottoms, then loosen 1/4 turn.
(2) Carefully turn the wormshaft all the way to the
end of travel, then turn back 1/2 turn.
(3) Tighten adjuster plug until torque wrench indi-
cates 0.6 to 1.0 Nzm (5 to 8 in. lbs.) torque (Fig. 13).
(4) Tighten the adjuster plug locknut to 68 Nzm (50
ft. lbs.) torque.
OVER-CENTER PRELOAD
(1) Back off preload adjuster until it stops, then
turn it in one full turn.
(2) With gear at center of travel, check torque to
turn stub shaft. This will be reading #1 (Fig. 14).
(3) Turn adjuster in until torque to turn stub shaft
is 0.5 to 1 Nzm (4 to 10 in. lbs.) more than reading
#1.
Fig. 12 Pitman Shaft & Ball Nut Engagement
Fig. 13 Worm Bearing Preload Adjustment
19 - 44 STEERINGJ

(4) Hold pitman shaft adjustment screw and
tighten adjuster lock nut to 34 Nzm (25 ft. lbs.)
torque.
INTERMEDIATE (COUPLER) SHAFT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition.
(2) Remove the shaft pinch bolt at the steering
gear and column (Fig. 15, 16). Un-bolt steering gear
from frame rail to remove shaft. Refer to Steering
Gear Replacement in this section.
INSTALLATION
(1) Align the intermediate (coupler) shaft to the
steering gear and column.
(2) Position the steering gear on the frame. Refer
to Steering Gear Replacement in this section.
(3) Install and tighten the pinch bolts to 34 Nzm
(25 ft. lbs.) torque.
STEERING GEAR REPLACEMENT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition with the steering wheel centered.
(2) Remove the column coupler shaft from the gear.
Refer to the removal procedures in this section.
(3) Remove pitman arm from gear. Refer to Pitman
Arm Removal in the Steering Linkage section.
Fig. 14 Over-center AdjustmentFig. 15 Coupler ShaftÐXJ
Fig. 16 Coupler ShaftÐYJ
JSTEERING 19 - 45

(4) Remove the steering gear retaining bolts and
nuts. Remove the steering gear from the vehicle (Fig.
17, 18).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.
Fig. 17 Steering Gear MountingÐXJ
Fig. 18 Steering Gear MountingÐYJ
MANUAL STEERING GEAR SPECIFICATIONS
19 - 46 STEERINGJ

AIRBAG MODULE REMOVEÐINSTALL
WARNING: THIS AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX MECHANICAL UNIT. BEFORE ATTEMPT-
ING TO REMOVE OR INSTALL THE AIRBAG SYS-
TEM OR RELATED STEERING WHEEL AND
STEERING COLUMN COMPONENTS YOU MUST
FIRST DISARM THE AIRBAG FIRING MECHANISM.
FAILURE TO DO SO COULD RESULT IN ACCIDEN-
TAL DEPLOYMENT AND POSSIBLE PERSONAL IN-
JURY.
When removing a deployed airbag module,
rubber gloves, eye protection and long-sleeved
shirt should be worn. There may be deposits on
the airbag module and other interior surfaces,
which can cause irritation to the skin and eyes
in large doses.
(1) Disconnect battery negative cable and isolate.
(2) Using a small screwdriver, remove plastic cover
plug from top outer surface of steering wheel hub
(Fig 2). Exit vehicle and disarm airbag by reaching
through driver's side window and turning arming
screw counter-clockwise to its travel limit (Fig 3 and
4 ). This is done using an 8mm socket and manual
drive. DO NOT USE POWER-DRIVEN TOOLS.
(3) From back side of steering wheel, remove 4
nuts attaching airbag module to steering wheel (Fig.
5). This is done using a 10mm socket and manual
drive. DO NOT USE POWER-DRIVEN TOOLS.
(4) Remove airbag module from steering wheel.
(5) Reverse removal procedures to install. Tighten
airbag module attaching nuts to 9 to 11 Nzm (80 to
100 in. lbs.). Exit vehicle and arm airbag by reaching
through driver's side window and turning arming
screw clockwise to its travel limit. Arming screw
torque should not exceed 1.1 to 1.7 Nzm (10-15 in.
lbs.). Reinstall plastic cover plug in steering wheel
hub.
STEERING WHEEL
WARNING: BEFORE ATTEMPTING TO REMOVE OR
INSTALL THE AIRBAG SYSTEM OR RELATED
STEERING WHEEL AND STEERING COLUMN COM-
PONENTS YOU MUST FIRST DISARM THE AIRBAG
FIRING MECHANISM. WHEN SERVICING AIR BAG
SYSTEM, REMOVE AND ISOLATE THE BATTERY
NEGATIVE (-) CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. YOU MUST DISARM THE AIRBAG
FIRING MECHANISM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT
AND POSSIBLE INJURY. WHEN AN UNDEPLOYED
AIR BAG ASSEMBLY IS TO BE REMOVED FROM
THE STEERING WHEEL, DISCONNECT THE BAT-
TERY GROUND CABLE AND ISOLATE. THE ARMING
SCREW MUST BE USED TO DISARM THE AIRBAG.
REMOVAL
(1) Make sure the front wheels are in thestraight
aheadposition and steering column locked in place.
Fig. 2 Plastic Cover Plug for Airbag Arming/
Disarming Bolt
Fig. 3 Arming/Disarming Bolt
Fig. 4 Airbag Bolt
JSTEERING 19 - 49

(2) Disconnect the battery negative (ground) cable
and isolate.
(3) Disarm the airbag (refer to group 8M, Electri-
cal for proper and safe procedures).
(4) Remove the air bag module and speed control
switch (if equipped) and disconnect the wire feeds
(Fig. 6).
(5) Disconnect the wire feed to the horn buttons.(6) Remove the steering wheel retaining nut. Score
or paint alignment marks on the column shaft and
steering wheel (if none exist) for installation refer-
ence.
(7) Remove the steering wheel with a universal
puller (Fig. 7).Do not hammer or jolt the steer-
ing column or shaft during removal of the
wheel.
INSTALLATION
(1) Install the steering wheel on column with the
scored marks or master splines aligned. Ensure the
wheel compresses the 2 lock tabs on the clockspring.
(2) Pull the speed control wires through the lower,
larger hole in the steering wheel. Pull the horn wire
through the smaller hole at the top.
(3) Install the retaining nut and tighten to 61 Nzm
(45 ft. lbs.) torque.Force the steering wheel down
on the shaft with the retaining nut only. Do not
hammer or shock the column with sudden im-
pact to install the wheel.
(4) Connect the wire feed to the horn buttons.
(5) Connect the wire feeds to the speed control
switch (Fig. 6). Tighten the air bag module nuts to 9
to 11 Nzm (80 to 100 in. lbs.) torque.
Fig. 5 Airbag Module Remove/Install
Fig. 6 Air Bag Module and Speed Control
19 - 50 STEERINGJ

CLOCKSPRING
WARNING: BEFORE SERVICING AIR BAG SYSTEM,
REMOVE AND ISOLATE BATTERY NEGATIVE (-) CA-
BLE (GROUND) FROM VEHICLE BATTERY. WHEN
AN UNDEPLOYED AIR BAG ASSEMBLY IS TO BE
REMOVED FROM THE STEERING WHEEL, DISCON-
NECT THE BATTERY GROUND CABLE AND ISO-
LATE.
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition before starting the repair.
(2) Disconnect battery negative cable and isolate.
(3) Remove the steering wheel and air bag, refer to
Steering Wheel Removal.
(4) Remove upper and lower steering column
shrouds to gain access to the clockspring wiring (Fig.
8).
(5) Release wire connector at clockspring.
(6) Pull clockspring assembly from column by lift-
ing locking fingers as necessary. The clockspring can-
not be repaired, and must be replaced if faulty.
INSTALLATION
(1) Snap clockspring assembly onto column. If
clockspring is not properly positioned, follow the cen-
tering procedures before installing steering wheel.
(2) Connect the wire connector to the clockspring.
(3) Install upper and lower steering column
shrouds. Be sure wiring is inside of shrouds and not
pinched.
(4) Install the steering wheel and air bag module,
refer to Steering Wheel Installation.
CENTERING PROCEDURE
If the rotating tape within the clockspring is not
positioned properly, the clockspring may fail during
use. The following procedures MUST BE USED to
center the clockspring;
²If it is not known to be properly positioned
²If the front wheels were moved from the straight
ahead position
(1) Place the front wheels in the straight ahead po-
sition before starting the procedure.
(2) Depress the 2 locking tabs to disengage the
locking mechanism (Fig. 9).
(3) Keeping the mechanism disengaged, rotate the
clockspring rotor in the CLOCKWISE DIRECTION
to the end of the travel. Do not apply excessive
torque.
Fig. 7 Steering Wheel Removal
Fig. 8 Upper and Lower Steering Column Shroud
Fig. 9 ClockspringÐAuto-Locking
JSTEERING 19 - 51

(14) Remove the Interlock cable from the steering
column. Refer to Automatic Transmission Shifter/Ig-
nition Interlock in this group.
(15) Remove the column. Use care to avoid damag-
ing the paint or trim.
INSTALLATION
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
(1) With the front wheels in the straight ahead po-
sition. Align and install the column to coupler.Do
not apply force at the top of the steering col-
umn shaft.(2) Ensure the ground clip is on the left spacer slot
(Fig. 17).
(3) Install the Interlock cable from the steering col-
umn. Refer to Automatic Transmission Shifter/Igni-
tion Interlock in this group.
(4) Install wiring harness connections to steering
column (Fig. 16).Ensure the wiring is not pinched
and all connections are correctly locked in
place.
(5) Install wiring harness connector onto multi
function switch (Fig. 18). Torque multi function
switch wiring harness connector retaining bolt to 2
Nzm (17 in. lbs.).
(6) Install wiring harness connector for key light
switch connection, onto the ignition switch (Fig. 19).
Fig. 15 Multi Function Switch Wiring Connection
Fig. 16 Steering Column Wiring Harness
J9519-57
Fig. 14 Halo Light And Key In Buzzer Wiring
Connection
JSTEERING 19 - 53

(7) Install wiring harness connectors onto clock
spring and ignition switch assembly (Fig. 20).
(8) Install shaft coupler pinch bolt loose, load col-
umn up to panel bracket.(9) Be sure both spacers are fully seated in the col-
umn support bracket. Tighten the column panel
bracket support nuts to 12 Nzm (105 in. lbs.) torque.
(10) Tighten the coupler pinch bolt to 47 Nzm (35
ft. lbs.) torque.
(11) Install the upper and lower shrouds. Install
the tilt lever (if equipped).
(12) Install rely box.
(13) Install the knee blocker.
(14) Install the steering wheel, refer to Steering
Wheel Installation and observe cautions.
(15) Remove the column shaft shipping lock pin
(installed in service column).
(16) Arm airbag, refer to Arming/Disarming Airbag
in this section.
(17) Connect the battery ground (negative) cable.
COLUMN COMPONENT SERVICE
The Acustar columns have been designed to be ser-
viced as an assembly; less wiring, switches, shrouds,
steering wheel, etc. Also most steering column com-
ponents can be serviced without removing the col-
umn from the vehicle. For additional information on
electrical components refer to Group 8, Electrical.
IGNITION SWITCH SERVICE
TEST AND REPAIR
If the ignition switch effort seems to be excessive
due to binding. Follow the procedure outlined below
to determine the cause.
When service procedures are performed on the
Acustar steering column there are certain areas of
the column that can not be tampered with. If a prob-
lem related to these areas of the steering column are
detected. The entire steering column (less the remov-
able components) should be replaced see (Fig. 1 and
2).
Fig. 17 Ground Clip & Spacer Installation
Fig. 18 Multi Function Switch Wiring Harness
Connector Installed
Fig. 19 Wiring Harness Connection For Key Light
Switch
Fig. 20 Wiring Harness Connection To Clock Spring
And Ignition Switch
19 - 54 STEERINGJ