1995 JEEP YJ wheel bolt torque

PITMAN SHAFT SEALSÐIN CAR REPLACEMENT
REMOVAL
(1) Remove pitman arm from gear. Refer to Pitman
Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and hous-
ing. Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 2).
CAUTION: Use care not to score the housing bore
when prying out seals and washers.
(4) Remove backup washer and double lip seal
with screwdriver.
²Start the engine and turn the steering wheel fully
to the LEFT to force out the seals and washers.
²Stop the engine
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove if
necessary. Inspect the pitman shaft seal surface for
roughness and pitting. If pitted replace shaft.
INSTALLATION
(1) Install single lip seal with Installer or a suit-
able size deep socket (Fig. 3).
(2) Coat the double lip seal and washer with
grease.
(3) Install the backup washer.
(4) Install the double lip seal.
(5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
(7) Center the steering gear.
(8) Install the pitman arm. Refer to Pitman Arm
Installation in Steering Linkage.(9) Add power steering fluid. Refer to Power Steer-
ing Initial Operation.
INTERMEDIATEÐCOUPLING 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. 4, 5). Unbolt 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) Disconnect and cap the fluid hoses from steer-
ing gear. Refer to Pressure and Return Hose Replace-
ment in this Group.
(3) Remove the column coupler shaft from the gear.
Refer to the removal procedures in this section.
(4) Remove pitman arm from gear. Refer to Pitman
Arm Removal in the Steering Linkage section.
Fig. 2 Pitman Shaft Seals
Fig. 3 Pitman Shaft Seal Installation
JSTEERING 19 - 23

(2) Wrap a single layer of plastic tape around the
pitman shaft threads and splines. This will protect
the replacement seals during installation.
(3) Install the seal with a suitable size socket.
(4) Remove the tape from the shaft.
(5) Center the steering gear.
(6) Align and install the pitman arm.
(7) Install the washer and retaining nut on the pit-
man shaft. Tighten the nut to 251 Nzm (185 ft. lbs.)
torque.
GEAR ADJUSTMENTS IN VEHICLE
REMOVE
(1) Raise and support the vehicle.
(2) Mark the pitman shaft and pitman arm for in-
stallation reference. Remove the pitman arm from
the shaft.
(3) Loosen the adjuster lock nut then back the ad-
juster plug off 1/4 turn.
(4) Remove the steering wheel horn pad.
(5) Turn the steering wheel in one direction until
stopped by the gear. Then turn back 1/2 turn.
CAUTION: Do not turn the steering wheel hard
against the internal stops when the linkage is re-
moved. This could result in damage to the recircu-
lating ball guides.
MEASURE
Place a low calibration (50 in. lbs.) torque wrench
and socket on the steering wheel nut. Rotate the
wrench and nut through a 90 degree arc (1/4 turn).
This will measure the worm shaft bearing preload.
ADJUST WORMSHAFT BEARING PRELOAD
TORQUE
(1) Adjust the preload by tightening the adjuster
plug. The preload should be 0.6 to 1 Nzm(5to8in.
lbs.) torque.
Steering column/shaft misalignment or damage will
increase the amount of torque required to rotate the
steering wheel. If the rotating torque is exceptionally
high, inspect the steering column/shaft alignment. If
the alignment is correct, remove the steering gear,
determine the cause of the high preload torque, and
repair as necessary.
(2) Tighten the adjuster locknut to 68 Nzm (50 ft.
lbs.) torque. Measure the preload torque. If neces-
sary, adjust the preload torque again.
ADJUST OVERCENTER DRAG TORQUE
(1) Turn the steering wheel from one stop to the
other and count the total numbers of turns. Turn the
wheel back in reverse direction 1/2 the total number
of turns to center the steering gear.(2) Turn the over center adjusting screw in to re-
move all lash between the ball nut and pitman shaft
sector teeth. Hold the adjustment screw and tighten
the lock nut to 34 Nzm (25 ft. lbs.) torque.
(3) Check the torque at the steering wheel by tak-
ing the highest reading as the wheel is turned
through the center position.
(4) The overcenter drag torque should be 0.5 to 1
Nzm (4 to 10 in. lbs.).
(5) If necessary, loosen the lock nut and adjust the
over center adjuster screw to obtain the proper
torque. Re-tighten the lock nut to the lock nut.
(6) After tightening the locknut, measure the over-
center drag torque again and readjust the torque, if
necessary.
INSTALL
(1) Align the installation reference marks and in-
stall the pitman arm.
(2) Install and tighten the pitman shaft nut and
washer to 251 Nzm (185 ft. lbs.) torque.
(3) Install the horn button.
GEAR DISASSEMBLY
(1) Rotate the wormshaft from stop-to-stop and
count the number of rotations. Rotate the wormshaft
in the reverse direction 1/2 of the total number of ro-
tations to center it and the ball nut.
(2) Remove the pitman shaft adjustment screw
locknut. Remove the cover retaining bolts, cover, and
gasket (Fig. 3).
(3) Slide the adjustment screw head (Fig. 3) out of
the pitman shaft T-slot and remove it and the
shim(s).
(4) Retain the shim(s) for end-play measurement
during assembly.
(5) Remove the pitman shaft, the wormshaft bear-
ing preload torque adjustment cap locknut, and the
adjustment cap (Fig. 2).
(6) Remove the wormshaft and the ball nut (Fig.
2).
(7) Remove (pry) the pitman shaft and the worm-
shaft seals from the steering gear housing (Fig. 3).
WORMSHAFT AND BALL NUT DISASSEMBLY
(1) Remove the upper bearing from the wormshaft
(Fig. 2).
CAUTION: Do not allow the ball nut to rotate freely
and travel to either extreme end of the wormshaft.
This could damage the tangs at the ends of the re-
circulating ball guides (Fig. 3).
(2) Remove the recirculating ball guide clamp re-
taining screws, the clamp and the guides (Fig. 2).
Separate the half-guides and place the recirculating
balls aside in a container.
JSTEERING 19 - 39

(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

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

(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

(1) Make sure the front wheels are in thestraight
aheadposition.
(2) Disconnect the negative (ground) cable from the
battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) Column shift vehicles, disconnect the shift ca-
ble grommet by prying it from the shift lever.
(5) Disconnect the column shaft to steering gear
coupler upper bolt (Fig. 3).
(6) Remove the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(7) Remove two nuts holding steering column
bracket to brake sled (Fig. 4).
(8) Remove four bolts holding steering column
bracket to column.(9) Disconnect the following items from the steer-
ing column connectors:
²Ignition switch wire harness
²Dimmer switch wire harness
²Turn signal switch wire harness
²Windshield wiper wire harness
²Cruise control wire harness (if equipped)
(10) Remove the bolts that attach the toe plate to
the floor pan (Fig. 5).
(11) Carefully remove column from vehicle.
INSTALLATION
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
(1) Carefully position column in vehicle.
(2) Align the column shaft to steering gear cou-
pling. Install and tighten the bolt to 34 Nzm (25 ft.
lbs.) torque.
(3) As applicable, connect the following items to
the steering column connectors:
²Ignition switch wire harness
²Dimmer switch wire harness
²Turn signal switch wire harness
²Windshield wiper wire harness
²Cruise control wire harness (if equipped)
(4) Install the support bracket on the column (Fig.
4) and tighten the bolts to 30 Nzm (270 in. lbs.)
torque.
(5) Install and tighten the column to brake sled
bolts (Fig. 4) to 30 Nzm (270 in. lbs.) torque.
Fig. 3 Column Shaft Coupler
Fig. 4 Column Bracket
Fig. 5 Steering Column Mounting
JSTEERING 19 - 59

(6) Column shift vehicles, install the shift cable
grommet on the shift lever.
(7) Install and tighten the toe plate to floor pan
bolts/nuts to 21.5 Nzm (192 in. lbs.) torque (Fig. 5).
(8) Install the lower portion of the instrument
panel, refer to Group 8E, Instrument Panel.
(9) Install steering wheel on column, refer to Steer-
ing Wheel-Installation.
(10) Connect the negative (ground) cable to the
battery.
NON-TILT STEERING COLUMN
DISASSEMBLYÐCOLUMN OR CONSOLE SHIFT
Steering column removal from the vehicle is not
necessary for;
²Lockplate cover
²Lockplate
²Steering shaft retaining ring
²Canceling cam
²Turn signal switch
²Upper bearing preload spring
²Ignition key/lock cylinder service
The steering column must be removed from
the vehicle to service any other component.
(1) If the column is removed for service, fabricate a
support fixture to clamp it in a vise (Fig. 1).
(2) Remove the steering wheel. Refer to the re-
moval procedure.
(3) Remove the lockplate cover.
WARNING: THE LOCKPLATE RETAINS A VERY
STRONG, SPRING FORCE. DO NOT ATTEMPT TOREMOVE THE STEERING SHAFT RETAINING SNAP
RING WITHOUT USING LOCKPLATE COMPRESSOR
C-4156.
(4) Compress the lockplate with Compressor
C-4156 and release the steering shaft retaining snap
ring (Fig. 2).
(5) Remove the lockplate compressor tool and the
retaining snap ring. Discard the snap ring.
CAUTION: When the steering shaft retaining snap
ring is removed, the steering shaft is no longer re-
tained within the column.
(6) Remove the lockplate, canceling cam, upper
bearing preload spring, and the thrust washer from
the steering column/shaft (Fig. 3).
(7) Remove the hazard warning switch knob. Press
the knob inward and remove it from the column by
turning it counterclockwise.
(8) Remove the turn signal/wiper/cruise control
stalk by pulling it out straight from the column.
Wiper must be in the off position.
(9) Disconnect the turn signal wire harness con-
nector from the bracket.
CAUTION: Wrap tape around the turn signal
switch wire harness connector (Fig. 4) to prevent it
from becoming entangled during removal.
(10) Remove the turn signal switch retaining
screws (Fig. 5), dimmer switch actuator arm, to re-
move the switch. Guide the switch straight up and
out of the steering column.
Fig. 1 Steering Column Support Fixture
Fig. 2 Retaining Snap Ring Removal
19 - 60 STEERINGJ