2002 JEEP GRAND CHEROKEE steering wheel

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
ADJUSTMENTS
STEERING GEAR.....................18
SPECIFICATIONS
POWER STEERING GEAR..............18
SPECIAL TOOLS
POWER STEERING GEAR..............19
PITMAN SHAFT
REMOVAL.............................20INSTALLATION.........................20
PITMAN SHAFT BEARING
REMOVAL.............................22
INSTALLATION.........................22
PITMAN SHAFT SEAL
REMOVAL.............................22
INSTALLATION.........................23
RACK PISTON/VALVE ASSEMBLY
REMOVAL.............................23
INSTALLATION.........................25
STUB SHAFT HOUSING
REMOVAL.............................25
INSTALLATION.........................25
GEAR
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1) .
The following gear components can be serviced:
²Pitman Shaft and Cover
²Pitman Shaft Bearings
²Pitman Shaft Oil Seal/Dust Seal
²Stud Shaft Housing with Seal
²O-Rings and Teflon Rings
NOTE: If rack piston assembly is damaged the gear
must be replaced.
OPERATION
The gear 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 the rack piston moves. The rack pis-
ton teeth mesh with the pitman shaft. Turning the
worm shaft turns the pitman shaft, which turns the
steering linkage.
REMOVAL
(1) Place the front wheels in the straight ahead
position with the steering wheel centered and locked.
(2) Remove the air cleaner housing,(Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(3) Drain or siphon the power steering system.(4) Remove the pressure and return lines (Fig.
2)from the steering gear. Refer to hose removal in
this section.
(5) Remove the column coupler shaft bolt (Fig.
2)and remove the shaft from the gear.
(6) Raise and support the vehicle.
(7) Remove the left front wheel and tire assembly.
(8) Remove the pitman arm from gear with Puller
C-4150A.
(9) Remove the windshield washer reservoir,(Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - REMOVAL).
(10) Remove the steering gear mounting bolts.
Remove the steering gear out of the engine compart-
ment (Fig. 3).
INSTALLATION
(1) Position the steering gear on the frame rail and
install the bolts. Tighten the bolts to 108 N´m (80 ft.
lbs.) torque.
(2) Install the pitman arm and tighten nut to 251
N´m (185 ft. lbs.).
(3) Install windshield washer reservoir,(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WASHER RES-
ERVOIR - INSTALLATION).
(4) Install the wheel and tire assembly.
(5) Remove the support and lower the vehicle.
(6) Install the pressure and return hoses to the
steering gear and tighten to 20-38 N´m (14-28 ft.
lbs.).
(7) Install the column coupler shaft.
(8) Install the air cleaner housing,(Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
19 - 16 GEARWJ

LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
DESCRIPTION
STEERING LINKAGE ± RIGHT HAND DRIVE
(RHD) VEHICLES......................26
DESCRIPTION........................26
SPECIFICATIONS
TORQUE CHART......................28
SPECIAL TOOLS
STEERING LINKAGE...................28
DAMPER
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................28
INSTALLATION.........................29
DRAG LINK
DESCRIPTION.........................29OPERATION...........................29
REMOVAL.............................29
INSTALLATION.........................29
PITMAN ARM
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................29
INSTALLATION.........................30
TIE ROD END
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................30
LINKAGE
DESCRIPTION
STEERING LINKAGE ± RIGHT HAND DRIVE
(RHD) VEHICLES
Vehicles equipped with right hand drive (RHD)
steering utilize the same components of left hand
drive vehicles. The RHD Steering linkage is designed
as a mirror image of left hand drive linkage with the
exception of the steering damper (Fig. 1), which is
mounted on the same side of the vehicle weather
RHD or LHD. See figure below for reference. All
specifications are the same as LHD. Refer to Group
19, Steering of the gasoline engine service manual for
additional information.
DESCRIPTION
The steering linkage consists of a pitman arm,
drag link, tie rod, and steering dampener (Fig. 2) .
An adjustment sleeve on the tie rod is used to set
wheel toe position. The sleeve on the drag link is
used for steering wheel centering.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
19 - 26 LINKAGEWJ

INSTALLATION
(1) Install the steering damper to the axle bracket
and tie rod.
(2) Install the steering damper bolt in the axle
bracket and tighten bolt to 88 N´m (65 ft. lbs.).
(3) Install the nut at the tie rod and tighten to 41
N´m (30 ft. lbs.).
DRAG LINK
DESCRIPTION
The drag link and ends are comprised of two forged
ends connected by a steel adjusting tube. The drag
link connects the steering gear pitman arm to the
steering knuckle. The larger offset end is attached to
the pitman arm.
OPERATION
The sleeve is used for steering wheel centering.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove right wheel and tire assembly.
(3) Remove the cotter pins and nuts at the right
steering knuckle and pitman arm (Fig. 4) .
(4) Remove the drag link from the steering
knuckle and pitman arm Puller C-3894-A.
(5) Loosen adjustment sleeve clamp bolts and
unscrew the tie rod ends from the adjustment sleeve.
INSTALLATION
(1) Screw the tie rod ends into the adjustment
sleeve.
(2) Install the drag link onto the right steering
knuckle and pitman arm.(3) Tighten the nut at the steering knuckle to 47
N´m (35 ft. lbs.). Tighten the pitman nut to 88 N´m
(65 ft. lbs.). Install new cotter pins.
(4) Position clamp bolts to their original position
and tighten to 41 N´m (30 ft. lbs.).
(5) Install right wheel and tire assembly.
(6) Remove support and lower the vehicle.
(7) Center the steering wheel.
PITMAN ARM
DESCRIPTION
The pitman arm is attached at one end of the
steering gear's sector shaft. The other end is con-
nected to the drag link.
OPERATION
The pitman arm transfers rotary motion into side
to side motion.
REMOVAL
(1) Remove the cotter pin and nut from the drag
link at the pitman arm (Fig. 5) .
(2) Remove the drag link ball stud from the pit-
man arm with a puller.
(3) Remove the nut and washer from the steering
gear shaft. Mark the pitman shaft and pitman arm
for installation reference. Remove the pitman arm
from steering gear with Puller C-4150A.
Fig. 3 Steering Damper
1 - DAMPER
2 - TIE ROD
Fig. 4 Drag Link
1 - STEERING GEAR
2 - PITMAN ARM
3 - CLAMP
4 - DRAG LINK
5 - CLAMP
WJLINKAGE 19 - 29
DAMPER (Continued)

INSTALLATION
(1) Align and install the pitman arm on steering
gear shaft.
(2) Install the washer and nut on the shaft and
tighten the nut to 251 N´m (185 ft. lbs.).
(3) Install drag link ball stud to pitman arm.
Install nut and tighten to 88 N´m (65 ft. lbs.). Install
a new cotter pin.
TIE ROD END
DESCRIPTION
The ends are forged, with a lubed for life ball
socket.
OPERATION
The tie rod ends connect the drag link to the wheel
assembly. The tie rod provides toe alignment and
transfers steering input from the drag link to the
wheels.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove the damper nut from the tie rod clamp
(Fig. 6).
(4) Remove the damper from the tie rod.
(5) Remove the cotter pins and nuts from the tie
rod ends at the steering knuckles (Fig. 6).(6) Remove the tie rod ends from the steering
knuckles with Puller C-3894-A..
(7) Loosen the adjustment sleeve clamp bolts and
unscrew the tie rod ends from the sleeve.
INSTALLATION
(1) Screw the tie rod ends into the adjustment
sleeve.
(2) Install the tie rod on the steering knuckles and
install the nuts.
(3) Tighten the nuts to 47 N´m (35 ft. lbs.). Install
new cotter pins and bend end 60É.
(4) Position the adjustment sleeve clamp bolts to
their original location and tighten to 41 N´m (30 ft.
lbs.).
(5) Install the damper on the tie rod and install
the nut.
(6) Tighten the nut to 41 N´m (30 ft. lbs.). Install
new cotter pins and bend end 60É.
(7) Install wheel and tire assemblies.
(8) Remove support and lower the vehicle.
(9) Perform toe position adjustment.
Fig. 5 Pitman Arm
1 - STEERING GEAR
2 - PITMAN ARM
Fig. 6 Tie Rod Assembly
1 - TIE ROD END
2 - CLAMP
3 - DAMPER
4 - TIE ROD
5 - CLAMP
6 - TIE ROD END
19 - 30 LINKAGEWJ
PITMAN ARM (Continued)

DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) Possible areas of pump leakage (Fig. 3).
STANDARD PROCEDURE
STANDARD PROCEDURE - INITIAL OPERATION
- 4.0L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - INITIAL OPERATION
- 4.7L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
NOTE: Remove as much of the old fluid out of the
system as possible with a suction tool or by remov-
ing a hose, When a component has failed. Then
refill it with fresh fluid until it is clean. This may
have to be done more than once.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine, and use
the DRB III to activate the hydraulic fan on full fan
operation.
(8)
Turn the steering wheel slowly from lock to lock.
(9) Stop the engine, check the fluid level and refill
as required and repeat the process
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(10) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
Fig. 3 4.0L Power Steering Pump
WJPUMP 19 - 33
PUMP (Continued)

STANDARD PROCEDURE - TIRE ROTATION
Tires on the front and rear operate at different
loads and perform different steering, driving, and
braking functions. For these reasons they wear at
unequal rates and tend to develop irregular wear
patterns. These effects can be reduced by rotating
the tires at regular intervals. The benefits of tire
rotation are:
²Increase tread life
²Maintain traction levels
²A smooth, quiet ride
The suggested method of tire rotation is (Fig. 10).
Other rotation methods can be used, but they will
not provide all the tire longevity benefits.
STANDARD PROCEDURE - WHEEL
INSTALLATION
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an
enlarged nose. This enlarged nose is necessary to
ensure proper retention of the aluminum wheels.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in
sequence to the proper torque specification (Fig. 11).
Never use oil or grease on studs or nuts.
Fig. 9 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
Fig. 10 Tire Rotation Pattern
Fig. 11 LUG NUT TIGHTENING PATTERN - TYPICAL
WJTIRES/WHEELS 22 - 5
TIRES/WHEELS (Continued)

²Unsatisfactory ride
²Vehicle drift
For proper tire pressure specification refer to the
Tire Inflation Pressure Chart provided with the vehi-
cles Owners Manual. A Certification Label on the
drivers side door pillar provides the minimum tire
and rim size for the vehicle. The label also list the
cold inflation pressure for these tires at full load
operation
Tire pressures have been chosen to provide safe
operation, vehicle stability, and a smooth ride. Tire
pressure should be checked cold once a month. Tire
pressure decreases as the ambient temperature
drops. Check tire pressure frequently when ambient
temperature varies widely.
Tire inflation pressures are cold inflation pressure.
The vehicle must sit for at least 3 hours to obtain the
correct cold inflation pressure reading. Or be drivenless than one mile after sitting for 3 hours. Tire
inflation pressures may increase from 2 to 6 pounds
per square inch (psi) during operation. Do not reduce
this normal pressure build-up.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DESCRIPTION - TIRE PRESSURE FOR HIGH
SPEED
Where speed limits allow the vehicle to be driven
at high speeds, correct tire inflation pressure is very
important. For speeds up to and including 120 km/h
(75 mph), tires must be inflated to the pressures
shown on the tire placard. For continuous speeds in
excess of 120 km/h (75 mph), tires must be inflated
to the maximum pressure specified on the tire side-
wall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
For emergency vehicles that are driven at speeds
over 90 mph (144 km/h), special high speed tires
must be used. Consult tire manufacturer for correct
inflation pressure recommendations.
DESCRIPTION - REPLACEMENT TIRES
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
Fig. 13 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 14 Over Inflation Wear
1 - THIN TIRE THREAD AREA
WJTIRES/WHEELS 22 - 7
TIRES (Continued)

INSTRUMENT PANEL SYSTEM
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the trim from the right and left A-pil-
lars. (Refer to 23 - BODY/INTERIOR/A-PILLAR
TRIM - REMOVAL).(3) Remove the top cover from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL TOP COVER - REMOVAL).
(4) Remove the four nuts that secure the instru-
ment panel to the studs on the dash panel near the
windshield fence line (Fig. 1).
(5) Remove the scuff plates from the right and left
front door sills. (Refer to 23 - BODY/INTERIOR/
DOOR SILL SCUFF PLATE - REMOVAL).
(6) Remove the trim panels from the right and left
inner cowl sides. (Refer to 23 - BODY/INTERIOR/
COWL TRIM - REMOVAL).
(7) Remove the console from the floor panel trans-
mission tunnel. (Refer to 23 - BODY/INTERIOR/
FLOOR CONSOLE - REMOVAL).
(8) Remove the fuse cover from the Junction Block
(JB). (Refer to 8 - ELECTRICAL/POWER DISTRIBU-
TION/FUSE COVER - REMOVAL).
(9) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(10) Remove the steering column opening cover
from the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(11) Remove the steering column bracket from the
instrument panel steering column support bracket.
(Refer to 23 - BODY/INSTRUMENT PANEL/IP
STEERING COLUMN BRACKET - REMOVAL).
Fig. 1 Instrument Panel to Dash Panel Mounting
1 - STUD (4)
2 - NUT (4)3 - INSTRUMENT PANEL
4 - DASH PANEL
WJINSTRUMENT PANEL SYSTEM 23 - 37