2002 JEEP LIBERTY Rack and pinion

(16) Remove differential case from the fixture.
Remove side gear, clutch pack retainer and clutch
pack. Keep plates in order during removal.
CLEANING
Clean all components in cleaning solvent and dry
components with compressed air.
INSPECTION
Inspect clutch pack plates for wear, scoring or dam-
age. Replace both clutch packs if any one component
in either pack is damaged. Inspect side and pinion
gears for cracks chips or damage and replace as nec-
essary. Inspect differential case and pinion shaft and
replace if worn or damaged.
ASSEMBLY
Lubricate each component with gear lubricant
before assembly.
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 42).
(2) Install assembled clutch disc packs on the side
gear hubs.(3) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 43).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(4) Set differential case on Fixture 8138.
(5) Install lubricated Disc 8140 without the hole in
lower side gear (Fig. 44).
(6) Install the upper side gear and clutch disc pack
(Fig. 44).
(7) Hold assembly in position. Insert Disc 8140
with threaded hole into top side gear.
(8) Install Forcing Screw 6960-4 and tighten screw
to slightly compress clutch disc.
(9) Place pinion gears in position in side gears and
verify that the pinion mate shaft hole is aligned.
(10) Rotate case with Turning Bar 6960-2 until the
pinion mate shaft holes in pinion gears align with
holes in case. It may be necessary to slightly tighten
the forcing screw in order to install the pinion gears.
(11) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(12) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(13) Remove forcing screw and discs.
Fig. 42 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 43 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
KJREAR AXLE - 8 1/4 3 - 109
DIFFERENTIAL - TRAC-LOK (Continued)

²Vacuum Fluorescent Display Synchroniza-
tion (CMTC, EMIC, Radio)
²Vehicle Theft Security System Status (PCM,
ITM) - premium only
Refer to the appropriate diagnostic information for
additional details.
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE
The hard wired inputs to and outputs from the
Body Control Module (BCM), as well as other hard
wired circuits for this module may be diagnosed and
tested using conventional diagnostic tools and proce-
dures. However, conventional diagnostic methods
may not prove conclusive in the diagnosis of the
BCM, the Programmable Communications Interface
(PCI) data bus network, or the electronic messages
received and transmitted by the BCM over the PCI
data bus. The most reliable, efficient, and accurate
means to diagnose the BCM and the PCI data bus
network inputs to and outputs from this module
requires the use of a DRBIIItscan tool. Refer to the
appropriate diagnostic information.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
NOTE: Before replacing a Body Control Module
(BCM), use a DRBIIITscan tool to retrieve the cur-
rent settings for the BCM programmable features
and the axle ratio/tire size (electronic pinion factor).
Refer to the appropriate diagnostic information.
These settings should be duplicated in the replace-
ment BCM using the DRBIIITscan tool before
returning the vehicle to service.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Junction Block Module (JBM) from
the instrument panel end bracket on the driver side
of the vehicle. (Refer to 8 - ELECTRICAL/POWER
DISTRIBUTION/JUNCTION BLOCK - REMOVAL).
(3) Remove the four screws that secure the BCM
to the Junction Block (JB) (Fig. 3).
(4) Remove the BCM from the JB.
(5) If the vehicle is equipped with the optional
Remote Keyless Entry (RKE) system, remove the
RKE module from the receptacle on the BCM. (Refer
to 8 - ELECTRICAL/POWER LOCKS/REMOTE KEY-
LESS ENTRY MODULE - REMOVAL).
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
KJELECTRONIC CONTROL MODULES 8E - 7
BODY CONTROL MODULE (Continued)

NOTE: Before replacing a Body Control Module
(BCM), use a DRBIIITscan tool to retrieve the cur-
rent settings for the BCM programmable features
and the axle ratio/tire size (electronic pinion factor).
Refer to the appropriate diagnostic information.
These settings should be duplicated in the replace-
ment BCM using the DRBIIITscan tool before
returning the vehicle to service.
(1) If the vehicle is equipped with the optional
Remote Keyless Entry (RKE) system, reinstall the
RKE module into the receptacle on the BCM. (Refer
to 8 - ELECTRICAL/POWER LOCKS/REMOTE KEY-
LESS ENTRY MODULE - INSTALLATION).
(2) Position the BCM onto the Junction Block (JB)
(Fig. 3).
(3) Install and tighten the four screws that secure
the BCM to the JB. Tighten the screws to 2 N´m (18
in. lbs.).
(4) Reinstall the Junction Block Module (JBM)
onto the instrument panel end bracket on the driver
side of the vehicle. (Refer to 8 - ELECTRICAL/
POWER DISTRIBUTION/JUNCTION BLOCK -
INSTALLATION).
(5) Reconnect the battery negative cable.
COMMUNICATION
DESCRIPTION
The DaimlerChrysler Programmable Communica-
tion Interface (PCI) data bus system is a single wire
multiplex system used for vehicle communications on
many DaimlerChrysler Corporation vehicles. Multi-
plexing is a system that enables the transmission of
several messages over a single channel or circuit. All
DaimlerChrysler vehicles use this principle for com-
munication between various microprocessor-based
electronic control modules. The PCI data bus exceeds
the Society of Automotive Engineers (SAE) J1850
Standard for Class B Multiplexing.
Many of the electronic control modules in a vehicle
require information from the same sensing device. In
the past, if information from one sensing device was
required by several controllers, a wire from each con-
troller needed to be connected in parallel to that sen-
sor. In addition, each controller utilizing analog
sensors required an Analog/Digital (A/D) converter in
order to9read9these sensor inputs. Multiplexing
reduces wire harness complexity, sensor current
loads and controller hardware because each sensing
device is connected to only one controller, which
reads and distributes the sensor information to the
other controllers over the data bus. Also, because
each controller on the data bus can access the con-
troller sensor inputs to every other controller on the
data bus, more function and feature capabilities are
possible.
In addition to reducing wire harness complexity,
component sensor current loads and controller hard-
ware, multiplexing offers a diagnostic advantage. A
multiplex system allows the information flowing
between controllers to be monitored using a diagnos-
tic scan tool. The DaimlerChrysler system allows an
electronic control module to broadcast message data
out onto the bus where all other electronic control
modules can9hear9the messages that are being sent.
When a module hears a message on the data bus
that it requires, it relays that message to its micro-
processor. Each module ignores the messages on the
data bus that are being sent to other electronic con-
trol modules.
OPERATION
Data exchange between modules is achieved by
serial transmission of encoded data over a single wire
broadcast network. The wire colors used for the PCI
data bus circuits are yellow with a violet tracer, or
violet with a yellow tracer, depending upon the appli-
cation. The PCI data bus messages are carried over
the bus in the form of Variable Pulse Width Modu-
lated (VPWM) signals. The PCI data bus speed is an
average 10.4 Kilo-bits per second (Kbps). By compar-
Fig. 3 Body Control Module Remove/Install
1 - SCREW (4)
2 - RKE MODULE
3 - BODY CONTROL MODULE
4 - JUNCTION BLOCK
8E - 8 ELECTRONIC CONTROL MODULESKJ
BODY CONTROL MODULE (Continued)

in parallel with the IC where the two pigtail wire
leads connect to the IC pins.
The seat belt switch cannot be adjusted or repaired
and, if faulty or damaged, the entire seat belt buckle-
half unit must be replaced.
OPERATION
The seat belt switches are designed to provide a
status signal to the seat belt switch sense inputs of
the Airbag Control Module (ACM) indicating whether
the front seat belts are fastened. The ACM uses the
seat belt switch inputs as a factor in determining
what level of force with which it should deploy the
multistage driver and passenger airbags. In addition,
the ACM sends electronic messages to the ElectroMe-
chanical Instrument Cluster (EMIC) to control the
seat belt indicator based upon the status of the
driver side front seat belt switch. A spring-loaded
plastic slide with a small, enclosed permanent mag-
net is integral to the buckle latch mechanism. When
a seat belt tip-half is inserted and latched into the
seat belt buckle, the slide is pushed downward and
into close proximity of the Hall Effect Integrated Cir-
cuit (IC) chip within the buckle, which induces a cur-
rent within the chip. The chip provides this induced
current as an output to the ACM, which monitors the
current to determine the status of the front seat
belts. When the seat belt is unbuckled, the spring-
loaded slide and permanent magnet move upward
and away from the IC, causing the output current
from the seat belt switch to be reduced.
The seat belt switch receives a supply current from
the ACM, and the ACM senses the status of the front
seat belts through its pigtail wire connection to the
seat wire harness. The ACM also monitors the condi-
tion of the seat belt switch circuits through circuit
resistance created by the diagnostic resistor. The
ACM will illuminate the airbag indicator in the
EMIC and store a Diagnostic Trouble Code (DTC) for
any fault that is detected in either seat belt switch
circuit. For proper diagnosis of the seat belt switches,
a DRBIIItscan tool is required. Refer to the appro-
priate diagnostic information.
SEAT BELT TENSIONER
DESCRIPTION
A driver side seat belt tensioner supplements the
driver airbag system for all versions of this model
(Fig. 34). The seat belt tensioner is integral to the
driver side front seat belt and retractor unit, which is
secured to the B-pillar on the left side of the vehicle.
The retractor is concealed beneath the molded plastic
B-pillar trim. The seat belt tensioner consists prima-
rily of a molded plastic tensioner housing, a tubularmetal piston housing, a piston, a short rack gear, a
set of pinion gears, a pyrotechnically activated gas
generator, and a short pigtail wire. All of these com-
ponents are located on one side of the retractor spool
on the outside of the retractor housing. The seat belt
tensioner is controlled by the Airbag Control Module
(ACM) and is connected to the vehicle electrical sys-
tem through a dedicated take out of the body wire
harness by a keyed and latching molded plastic con-
nector insulator to ensure a secure connection.
The seat belt tensioner cannot be repaired and, if
faulty or damaged, the entire driver side front seat
belt and retractor unit must be replaced. The seat
belt tensioner is not intended for reuse and must be
replaced following a deployment. A locked retractor
that will not allow the seat belt webbing to be
retracted or extracted is a sure indication that the
seat belt tensioner has been deployed and requires
replacement. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/FRONT SEAT BELT & RETRACTOR -
REMOVAL).
OPERATION
The seat belt tensioner is deployed by a signal gen-
erated by the Airbag Control Module (ACM) through
the driver seat belt tensioner line 1 and line 2 (or
squib) circuits. When the ACM sends the proper elec-
trical signal to the tensioner, the electrical energy
generates enough heat to initiate a small pyrotechnic
gas generator. The gas generator is installed in one
end of the tubular metal piston housing, which con-
tains a piston and a small rack gear. As the gas
expands, it pushes the piston and the rack gear
Fig. 34 Seat Belt Tensioner
1 - RETRACTOR
2 - TENSIONER HOUSING
3 - PISTON HOUSING
4 - PIGTAIL WIRE
5 - GAS GENERATOR
8O - 36 RESTRAINTSKJ
SEAT BELT SWITCH (Continued)

through the tube. The rack gear engages a pinion
gear that drives a gear set in the tensioner housing,
which drives the seat belt retractor spool causing the
slack to be removed from the driver side front seat
belt. Removing excess slack from the driver side front
seat belt not only keeps the occupant properly posi-
tioned for an airbag deployment following a frontal
impact of the vehicle, but also helps to reduce inju-
ries that the occupant of the driver side front seat
might experience in these situations as a result of a
harmful contact with the steering wheel and/or steer-
ing column. Also, the seat belt tensioner has a tor-
sion bar mechanism that is designed to deform in
order to control the loading being applied to the occu-
pant of the driver side front seat by the seat belt dur-
ing a frontal impact, further reducing the potential
for occupant injuries.
The ACM monitors the condition of the seat belt
tensioner through circuit resistance, and will illumi-
nate the airbag indicator in the ElectroMechanical
Instrument Cluster (EMIC) and store a Diagnostic
Trouble Code (DTC) for any fault that is detected.
For proper diagnosis of the seat belt tensioner, a
DRBIIItscan tool is required. Refer to the appropri-
ate diagnostic information.
SEAT BELT TURNING LOOP
ADJUSTER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELTTHAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Unsnap and lift the trim cover to access the
nut that secures the front seat belt turning loop to
the height adjuster on the upper B-pillar.
(3) Remove the nut that secures the seat belt turn-
ing loop to the height adjuster stud on the upper
B-pillar.
(4) Remove the seat belt turning loop from the
height adjuster stud.
(5) Remove the upper trim from the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
UPPER TRIM - REMOVAL).
(6) Remove the screw that secures the seat belt
turning loop adjuster to the upper B-pillar (Fig. 35).
(7) Pull the upper end of the turning loop adjuster
away from the B-pillar far enough to disengage the
hooks on the lower end of the adjuster from the slots
in the B-pillar.
(8) Remove the seat belt turning loop adjuster
from the B-pillar.
Fig. 35 Seat Belt Turning Loop Adjuster Remove/
Install
1 - SCREW
2 - B-PILLAR
3 - ADJUSTER
KJRESTRAINTS 8O - 37
SEAT BELT TENSIONER (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................1DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE........3
COLUMN...............................5
GEAR.................................13
LINKAGE..............................16
PUMP.................................17
STEERING
DESCRIPTION
Power steering systems consist of:
²Steering column & Intermediate Shaft
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure, supply and return hoses
²Oil Cooler
OPERATION
The steering column intermediate shaft attaches
the steering column to the gear pinion. The rotation
of the pinion moves the gear rack from side-to-side.
This lateral action of the rack pushes and pulls the
tie rods to change the direction of the front wheels.
Power assist is provided by an engine mounted
hydraulic pump. The pump supplies hydraulic fluid
to the steering gear. All vehicles are equipped with
an oil cooler.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
STEERING NOISE
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill/parking, or when the steering is at the end of it's travel. Hiss is a high frequency noise similar to that
of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing through
an orifice. There is no relationship between this noise and steering performance.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash panel
seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Loose or damaged intermediate shaft or
column.4. Inspect and repair or replace.
MOAN Pressure hose in contact with other
components.Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
KJSTEERING 19 - 1

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL
REMOVAL - 4WD......................13
REMOVAL - 2WD......................14
INSTALLATION
INSTALLATION - 4WD..................14INSTALLATION - 2WD..................14
SPECIFICATIONS
TORQUE CHART......................15
SPECIAL TOOLS
OUTER TIE ROD END REMOVAL TOOL....15
GEAR
DESCRIPTION
A rack and pinion steering gear (Fig. 1) is made up
of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
OPERATION
The steering column intermediate shaft is attached
to the gear pinion. The rotation of the pinion moves
the gear rack from side-to-side. This lateral action of
the rack pushes and pulls the tie rods, which are
connected to the steering knuckles to change the
direction of the front wheels.
REMOVAL
REMOVAL - 4WD
(1) Siphon the power steering fluid from the power
steering reservoir.
(2) Lock the steering wheel to prevent spinning of
the clockspring.
(3) Raise and support the vehicle.
(4) Remove the skid plate from under the front
end to gain access to the gear (Refer to 13 - FRAME
& BUMPERS/FRAME/FRONT SKID PLATE -
REMOVAL).
(5) Remove the front tire and wheel assemblies.
NOTE: Mark the alignment adjusting cams for eas-
ier installation.
(6) Remove the lower control arms. (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(7) Remove the front axle. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/FRONT AXLE - REMOV-
AL).
(8) Remove the tie rod end nuts.
(9) Separate tie rod ends from the knuckles with
Puller C-3894-A.
(10) Remove the intermediate shaft lower coupler
bolt and slide the coupler off the gear (Fig. 2).
(11) Remove power steering pressure hose bracket
(Fig. 3).
(12) Remove the power steering lines from the
gear (Fig. 2).
(13) Remove the mounting bolts from the gear to
the front cradle (Fig. 3).
(14) Remove the steering gear from the vehicle.
Fig. 1 Rack & Pinion Steering Gear
1 - TIE ROD - INNER
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER LH
4 - BOOTS
5 - TIE ROD END - OUTER RH
KJGEAR 19 - 13

REMOVAL - 2WD
(1) Siphon the power steering fluid from the power
steering reservoir.
(2) Lock the steering wheel to prevent spinning of
the clockspring.
(3) Raise and support the vehicle.
(4) Remove the skid plate from under the front
end to gain access to the gear(Refer to 13 - FRAME
& BUMPERS/FRAME/FRONT SKID PLATE -
REMOVAL).
(5) Remove the tire and wheel assembly.
NOTE: Mark the alignment adjusting cams and tie
rod end jam nuts on the steering gear for easier
installation.
(6) Remove the tie rod end nuts.
(7) Separate tie rod ends from the knuckles with
Puller C-3894-A.
(8) Remove the lower intermediate shaft coupler
bolt and slide the coupler off the gear (Fig. 2).(9) Remove power steering pressure hose bracket
(Fig. 3).
(10) Remove the power steering lines from the
gear (Fig. 2).
(11) Remove the mounting bolts from the gear to
the front cradle (Fig. 3).
(12) Remove the steering gear from the vehicle.
INSTALLATION
INSTALLATION - 4WD
(1) Transfer the tie rod ends to the new steering
gear (if needed).
(2) Install the steering gear to the vehicle.
(3) Install the gear mounting bolts to the front cra-
dle. (Fig. 3). Tighten the gear mounting bolts to 162
N´m (120 ft.lbs.)
(4) Install the power steering lines to the gear
(Fig. 2).
(5) Install the power steering pressure hose
bracket (Fig. 3).
(6) Install the lower coupler bolt and slide the cou-
pler on to the gear (Fig. 2).
(7) Install the tie rod end to the knuckle and
tighten the nuts.
(8) Install the front axle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/FRONT AXLE - INSTALLA-
TION).
(9) Install the lower control arms. (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION).
(10) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Install the skid plate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE - INSTAL-
LATION).
(12) Lower the vehicle.
(13) Unlock the steering wheel.
(14) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(15) Reset the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
INSTALLATION - 2WD
(1) Transfer the outer tie rod ends to the new
steering gear (if needed).
(2) Install the steering gear to the vehicle.
(3) Install the gear mounting bolts to the front cra-
dle. (Fig. 3). Tighten the gear mounting bolts to 162
N´m (120 ft.lbs.)
(4) Install the power steering lines to the gear
(Fig. 2).
Fig. 2 COUPLER BOLT
Fig. 3 RACK & PINION
19 - 14 GEARKJ
GEAR (Continued)