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mechanical cable is not routed to the throttle body.
CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal, cables or APPS.
Fig.34CABLE/LEVER/THROTTLELINKAGECOVER 1 - CABLE/LEVER/LINKAGE COVER 2 - PUSH UP LOWER TAB 3 - SCREWS/CLIPS (2) 4 - TAB PUSH HERE
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 36). The plas- tic cable retainer snaps into pedal arm.
(3) Remove cable core wire at pedal arm. (4) Remove APPS. Refer to (Diesel) Accelerator Pedal Position Sensor (APPS) Removal / Installation. (5) From inside vehicle, remove cable clip (Fig. 36). (6) Remove cable housing from dash panel and
pull cable into engine compartment.
(7) Remove cable housing at APPS bracket by pressing on release tab with a small screwdriver. To prevent cable housing breakage, press on tab only enough to release cable from APPS bracket.
FUEL INJECTION - DIESEL
14 - 96
THROTTLE CONTROL CABLE (Continued)DR
(3) Install remaining cable housing end into and through dash panel opening (snaps into position). The two plastic pinch tabs should lock cable to dash panel.
(4) From inside vehicle, hold up accelerator pedal. Install throttle cable core wire and plastic cable retainer into and through upper end of pedal arm (the plastic retainer is snapped into pedal arm). When installing plastic retainer to accelerator pedal arm, note index tab on pedal arm (Fig. 33). Align index slot on plastic cable retainer to this index tab. (5) Connect negative battery cables to both batter-
ies.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) Install cable/lever cover.
Fig.36ACCELERATORPEDALMOUNTING
1 - ACCELERATOR CABLE 2 - PLASTIC RETAINER (CLIP) 3 - THROTTLE PEDAL ARM 4 - PEDAL / BRACKET ASSEMBLY 5 - CABLE CLIP
INSTALLATION
Early Diesel Engine
(1) Install cable through mounting hole on cable mounting bracket (Fig. 35). Cable snaps into bracket. Be sure 2 pinch tabs are secure.
(2) Using large pliers, connect cable end socket to
throttle lever ball (snaps on).
Late Diesel Engine
(1) Attach cable to Accelerator Pedal Position Sen- sor (APPS). Refer to APPS (Diesel) Removal / Instal- lation.
(2) Push cable housing into rubber grommet and
through opening in dash panel.
(3) From inside vehicle, install clip holding cable
to dashpanel (Fig. 36).
(4) From inside vehicle, slide throttle cable core
wire into opening in top of pedal arm.
(5) Push cable retainer (clip) into pedal arm open-
ing until it snaps in place.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) If necessary, use DRB IIIt Scan Tool to erase from
any APPS Diagnostic Trouble Codes (DTC’s) PCM.
DR
STEERING
19 - 1
STEERING
TABLE OF CONTENTS
page
page
STEERING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - POWER
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE . . . . . . . . 4
SPECIAL TOOLS
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING DESCRIPTION
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
Power steering systems consist of: † Steering column † Rack and pinion steering gear † Belt driven hydraulic steering pump † Pump pressure and return hoses † Oil Cooler OPERATION
The steering column 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 to change the direction of the front wheels (Fig. 1).
Power assist is provided by an engine mounted hydraulic pump which supplies hydraulic fluid pres- sure to the steering gear.
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GEAR - INDEPENDENT FRONT SUSPENSION . . 16
GEAR - LINK/COIL . . . . . . . . . . . . . . . . . . . . . . . 19
LINKAGE - INDEPENDENT FRONTSUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38LINKAGE - LINK/COIL PUMP
Fig.1STEERINGCOMPONENTS
1 - POWER STEERING PUMP ASSEMBLY 2 - RESERVOIR 3 - HOSES 4 - TIE ROD ENDS 5 - MOUNTING BOLTS 6 - RACK & PINION
STEERING
19 - 2
STEERING (Continued) DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - POWER STEERING SYSTEM
DR
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 wheel 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.
STEERING NOISE
CONDITION
POSSIBLE CAUSES
CORRECTION
OBJECTIONAL HISS OR WHISTLE
1. Steering intermediate shaft to dash panel seal.
1. Check and repair seal at dash panel.
RATTLE OR CLUNK
1. Gear mounting bolts loose.
1. Tighten bolts to specification.
2. Noisy valve in power steering gear.
2. Replace steering gear.
2. Loose or damaged suspension components. 3. Internal gear noise. 4. Pressure hose in contact with other components. 5. Loose or damaged intermediate shaft or column.
2. Inspect and repair suspension.
3. Replace steering gear. 4. Reposition hose.
5. Inspect and repair or replace.
CHIRP OR SQUEAL
1. Loose belt.
WHINE OR GROWL
1. Low fluid level.
2. Pressure hose in contact with other components. 3. Internal pump noise. 4. Air in fluid
SUCKING AIR SOUND
1. Loose return line clamp.
2. O-ring missing or damaged on hose fitting. 3. Low fluid level. 4. Air leak between pump and reservoir. 5. Reservoir cap not installed correctly.
1. Adjust or replace.
1. Fill to proper level.
2. Reposition hose.
3. Replace pump. 4. Check for lekas, Evacuate air from P/S system.
1. Replace clamp.
2. Replace o-ring.
3. Fill to proper level. 4. Repair as necessary. 5. Install reservoir cap correctly.
SCRUBBING OR KNOCKING
1. Wrong tire size.
1. Verify tire size.
DR STEERING (Continued)
STEERING
19 - 3
BINDING AND STICKING
CONDITION
POSSIBLE CAUSE
CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
1. Low fluid level. 2. Tire pressure. 3. Steering components (ball joints/tie rod ends). 4. Loose belt. 5. Low pump pressure.
6. Column shaft coupler binding. 7. Steering gear worn. 8. Pump seized / Stuck valve
1. Fill to proper level. 2. Adjust tire pressure. 3 Inspect and repair as necessary.
4. Adjust or replace. 5. Pressure test and replace if necessary. 6. Replace coupler. 7. Replace gear. 8. Replace pump.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION
POSSIBLE CAUSE
CORRECTION
HARD TURNING OR MOMENTARY INCREASE IN TURNING EFFORT
STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION
1. Tire pressure.
1. Adjust tire pressure.
2. Low fluid level. 3. Loose belt. 4. Low pump pressure.
5. Internal gear leak.
1. Tire pressure. 2. Wheel alignment. 3. Lack of lubrication.
4. High friction in steering gear.
2. Fill to proper level. 3. Adjust or replace. 4. Pressure test and repair as necessary. 5. Replace gear.
1. Adjust tire pressure. 2. Align front end. 3. Inspect and lubricate suspension compnents. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE PLAY IN STEERING WHEEL
1. Worn or loose suspension or steering components.
1. Inspect and repair as necessary.
2. Worn or loose wheel bearings.
3. Steering gear mounting.
4. Gear out of adjustment. 5. Worn or loose steering coupler.
VEHICLE PULLS OR LEADS TO ONE SIDE.
1. Tire Pressure. 2. Radial tire lead. 3. Brakes dragging. 4. Wheel alignment.
2. Inspect and repair or adjust bearings. 3. Tighten gear mounting bolts to specification. 4. Replace gear. 5. Inspect and replace as necessary.
1. Adjust tire pressure. 2. Rotate tires. 3. Repair as necessary. 4. Align front end.
STEERING
19 - 4
STEERING (Continued) DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSUREThe following procedure is used to test the opera- tion of the power steering system on the vehicle. This test will provide the gallons per minute (GPM) or flow rate of the power steering pump along with the maximum relief pressure. Perform test any time a power steering system problem is present. This test will determine if the power steering pump or power steering gear is not functioning properly. The follow- ing pressure and flow test is performed using Power Steering Analyzer Tool kit 6815 and (Fig. 2) Adapter Kit 6893.
Fig.2AnalyzerWithTubeandAdapter
1 - TUBE 2 - ADAPTER FITTINGS 3 - ANALYZER 4 - GAUGE HOSE
FLOW AND PRESSURE TEST
(1) Check the power steering belt to ensure it is in
good condition and adjusted properly.
(2) Connect pressure gauge hose from the Power
Steering Analyzer to adapter 6826.
(3) Connect tube 6825A to Power Steering Ana-
lyzer test valve end.
power steering pump.
(4) Disconnect the high pressure hose from the
(5) Connect the tube 6825A to the pump fitting. (6) Connect
the power steering hose from the
steering gear to the adapter 6826.
(7) Open the test valve completely. (8) Start engine and let idle long enough to circu- late power steering fluid through flow/pressure test gauge and to get air out of the fluid. Then shut off engine.
DR
(9) Check fluid level, add fluid as necessary. Start
engine again and let idle.
(10) Gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345-552 kPa (50-80 psi).
(11) Increase the engine speed to 1500 RPM and read the flow meter. If the flow rate (GPM) is below specification, (refer to pump specification chart for GPM) the pump should be replaced.
CAUTION: The following test procedure involves testing maximum pump pressure output and flow control valve operation. Do not leave valve closed for more than three seconds as the pump could be damaged.
(12) Close valve fully three times and record high- est pressure indicated each time. All three read- ings must be above specifications and within 345 kPa (50 psi) of each other. † Pressures above specifications but not within † Pressures within 345 kPa (50 psi) of each other
345 kPa (50 psi) of each other, replace pump.
but below specifications, replace pump.
(13) Open the test valve and turn the steering wheel to the extreme left and right positions three times against the stops. Record the highest pressure reading at each position. Compare readings to the pump specifications chart. If pressures readings are not within 50 psi of each other, the gear is leaking internally and must be replaced.
CAUTION: Do not force the pump to operate against the stops for more than 2 to 3 seconds at a time because, pump damage will result.
PUMP SPECIFICATION
ENGINE
RELIEF
PRESSURE ±
FLOW RATE (GPM) AT 1500
1500 series
2500 & 3500
series
65
11032 kPa
(1615 ± 65 psi)
12400 kPa
(1800 ± 50 psi)
RPM
3.1 - 3.5
3.5 - 4.0
DR STEERING (Continued) SPECIAL TOOLS
STEERING
STEERING
19 - 5
ADAPTER,POWERSTEERINGFLOW/PRESSURE-
6825A
PULLER-8677
ADAPTERS,POWERSTEERINGFLOW/PRESSURE
TESTER-6893
ANALYZERSET,POWERSTEERINGFLOW/
PRESSURE6815
19 - 6
COLUMN
COLUMN
TABLE OF CONTENTS
page
DR
page
COLUMN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - STEERINGCOLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - IGNITIONSWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11KEY-IN IGNITION SWITCH
DESCRIPTION DIAGNOSIS AND TESTING - IGNITION
. . . . . . . . . . . . . . . . . . . . . . . . . 11
SWITCH AND KEY LOCK CYLINDER . . . . . . . 11
KEY CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COLUMN DESCRIPTION
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
The tilt and standard column (Fig. 1) has been designed to be serviced as an assembly; less wiring, switches, shrouds, steering wheel, etc. Most steering column components can be serviced without remov- ing the steering column from the vehicle.
To service the steering wheel, switches or airbag, refer to Restraints and follow all WARNINGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS- CHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
GEAR SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12UPPER STEERING COUPLING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD REMOVAL - 4X4 HD
. 14
. . . . . . . . . . . . . . . . . . . 14INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION - 4X4 HD . . . . . . . . . . . . . . . . 15STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COAT- INGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS.
CAUTION: Do not hammer on steering column shaft. This may cause damage to the shaft or bear- ing.
CAUTION: Do not attempt to remove the pivot bolts to disassemble the tilting mechanism. Do not remove shaft lock plate or plate retainer. This will damage the column.
CAUTION: Do not attempt to remove or modify the park lock slider or link.
NOTE: When servicing the steering wheel after removing the old bolt a new bolt must be used when installing.
DR COLUMN (Continued)
NOTE: When servicing the coupler a new bolt must be used when installing.
Fig.1STEERINGCOLUMN
1 - LOCK CYLINDER 2 - GEAR SHIFT LEVER 3 - MOUNTING HOLES 4 - STEERING COLUMN 5 - TILT LEVER
DIAGNOSIS AND TESTING - STEERING COLUMN
If the vehicle is involved in a front end collision/the air bag has deployed the column must be inspected. This inspection will determine if the Column has col- lapsed. Inspect the column mounting capsules visu- ally and manually push and pull them to check for separation or fractures. If capsules are fractured or have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS- ARMED. REFER TO ELECTRICAL RESTRAINT SYS- TEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi- cation to ensure proper operation of the steering column.
COLUMN
19 - 7
(1) Position the front wheels straight ahead. (2) Disconnect the negative (ground) cable from
(3) Remove the two switches from the steering
the battery.
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98–1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged into the steering wheel and not into the clock- spring, before attempting to remove the wheel. Fail- ure to do so may damage the steering wheel/ clockspring.
(6) Remove the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever. (8) Remove the column shrouds (Fig. 2).
Fig.2UPPER&LOWERSHROUDS
1 - UPPER SHROUD 2 - LOWER SHROUD
(9) Remove the clock spring, (Refer to 8 - ELEC- TRICAL/RESTRAINTS/CLOCKSPRING - REMOV- AL).
(10) Disconnect the wiring harness to the column. (11) Remove the shift cable from the column shift to 21 - TRANSMISSION/ lever actuator TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT CABLE - REMOVAL). (Fig. 3).
(Refer
COLUMN
19 - 8
COLUMN (Continued)DR
Fig.3SHIFTCABLECONNECTOR
Fig.5UPPERSTEERINGCOUPLER
1 - Shift lever 2 - Cable Connection 3 - Overdrive Electrical Wiring 4 - Mounting Screws
(12) Release the shift cable from the column
bracket and remove it from the bracket.
(13) Remove the SKIM module in order to discon-
nect the electrical connector.
(14) Remove the upper steering shaft coupler bolt
and slide the shaft down (Fig. 4) & (Fig. 5)
1 - STEERING COUPLER 2 - PINCH BOLT HOLE
(15) Remove the brake light switch and discard (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(16) Remove the four steering column mounting
nuts (Fig. 6).
Fig.4COUPLERSHAFT
1 - MOUNTING HOLES 2 - COUPLER BOLT HOLE
Fig.6MOUNTINGHOLES
1 - MOUNTING HOLES
(17) Remove the steering column assembly from
the vehicle. (Fig. 7)
DR COLUMN (Continued)
COLUMN
19 - 9
(7) Install the shifter cable. (Refer to 21 - TRANS- MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column. (9) Install the SKIM module. (10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds. (12) Install
the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - INSTALLA- TION).
(13) Align the spline on the wheel hub to shaft. (14) Then install the steering wheel and install a
new bolt. Tighten the bolt to 61 N·m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/ RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches. (17) Install the tilt lever handle. (18) Install the negative battery terminal. (19) Test the operation of the horn, Electronic PRNDL Indicator, lights and any other functions that are steering column operated.
IGNITION SWITCH DESCRIPTION
The ignition switch is located on the steering col- umn. It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch.
OPERATION
Vehicles equipped with an automatic trans- mission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle with a automatic transmission first adjust the shift linkage, (Refer to 21 - TRANSMISSION/TRANS- AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE - ADJUSTMENTS).
If the ignition switch effort is excessive remove the ignition key cylinder from the steering column. (Refer to 19 - STEERING/COLUMN/LOCK CYLINDER HOUSING - REMOVAL). Check the turning effort of the key cylinder. If the ignition key cylinder effort is excessive replace the key cylinder.
Fig.7STEERINGCOLUMN
1 - Steering Wheel 2 - Key Cylinder 3 - Gear Shift Lever 4 - Steering Column 5 - Tilt Lever Cable
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS- ARMED. REFER TO ELECTRICAL RESTRAINT SYS- TEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi- cation to ensure proper operation of the steering column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward against the studs in dash panel and hand tighten the nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install a new bolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N·m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower right nut. Then torque the lower left nut then the upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N·m (42 ft. lbs.). (6) Install a new brake light switch (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL).
DR
THEY MUST NEVER BE AIRBAG SYSTEM. REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS.
CAUTION: Do not hammer on steering column shaft. This may cause damage to the shaft or bear- ing.
CAUTION: Do not attempt to remove the pivot bolts to disassemble the tilting mechanism.
The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before removing ignition switch.
(1) Remove the negative (ground) cable from the
battery.
(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(3) Remove the lower and upper shrouds. (4) Remove key cylinder. (Refer to 19 - STEER- ING/COLUMN/LOCK CYLINDER HOUSING - REMOVAL).
(5) Disconnect the lower clockspring connectors. (6) Remove the wire retainer from the tilt lever
bracket.
(7) Remove the tilt lever mounting screws to gain access to the ignition switch mounting screws. (Fig. 9)
COLUMN
19 - 10
IGNITION SWITCH (Continued) REMOVALSERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped with an automatic transmission is not equipped with an internal locking shaft with the ignition cyl- inder. Alternative methods of locking the steering wheel for service will have to be used.
The tilt and standard column (Fig. 8) have been designed to be serviced as an assembly; without wir- ing, switches, shrouds, steering wheel, etc. Most steering column components can be serviced without removing the steering column from the vehicle.
Fig.8STEERINGCOLUMN
1 - KEY CYLINDER 2 - GEAR SHIFT LEVER 3 - MOUNTING HOLES 4 - STEERING COLUMN 5 - IGNITION SWITCH
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag, Refer to Electrical Restraints and follow all WARN- INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS- CHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COAT- INGS AND ARE SPECIFICALLY DESIGNED FOR THE
Fig.9IGNITIONSWITCHWITHTILT
1 - IGNITION SWITCH 2 - TILT LEVER MECHANISM
(8) For columns without tilt remove the bracket to gain access to the ignition switch mounting screws. (Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
DR IGNITION SWITCH (Continued)
COLUMN
19 - 11
(3) Position switch to column and install
the mounting screw. Tighten screw to 3 N·m (26 in. lbs.). (4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N·m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N·m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
shrouds.
(7) Reconnect the lower clockspring connectors. (8) Install the key cylinder. (9) Install
steering column upper and lower
(10) Enable the airbag system. (Refer to 8 - ELEC- TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL- LATION).
Fig.10IGNITIONSWITCHWITHOUTTILT
1 - Ignition Switch Mounting Screws 2 - Non-Tilt Mounitng Bracket Screws
Fig.11IGNITIONSWITCH
1 - Ignition Switch 2 - Ignition Switch Mounting Screws
(10) Remove ignition switch mounting screw. (11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.
(2) Connect the electrical connector to rear of the ignition switch. Make sure that locking tabs are fully seated into wiring connector.
KEY-IN IGNITION SWITCH DESCRIPTION
The key-in ignition switch is integral to the igni- tion switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced, (Refer to 19 - STEERING/COLUMN/IG- NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to Ignition Switch in the appropriate section of Electri- cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
19 - 12
COLUMN
KEY CYLINDER REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
steering column.
(1) Disconnect negative cable from battery. (2) Remove upper and lower covers (shrouds) from
(3) Place shifter in PARK position. (4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.
Fig.12KEYCYLINDER
1 - KEY 2 - KEY CYLINDER 3 - RETAINING PIN HOLE
(a) Rotate key to RUN position. (b) Press in on retaining pin while pulling key
cylinder from ignition switch (Fig. 13).
DR
INSTALLATION
The ignition key must be in the key cylinder for
cylinder installation.
(1) Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch.
(2) Push the key cylinder in until it clicks. (3) Replace the upper and lower shrouds. (4) Reconnect the battery.
GEAR SHIFT LEVER REMOVAL
(1) Remove the kneeblocker. (Refer to 23 - BODY/ INSTRUMENT PANEL/KNEE BLOCKER - REMOV- AL).
(2) Remove the upper and lower column shroud. (3) Remove and discard the brake light switch. (4) Loosen the column bolts and lower the column enough to allow clearance for the gear shift lever removal.
(5) Disconnect
the overdrive switch harness (if
equipped).
(6) Disconnect the shift cable from the shift lever. (7) Remove the SKIM. (8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)
(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).
Fig.13KEYCYLINDER
1 - KEY CYLINDER 2 - PUNCH
Fig.14GEARSHIFTLEVER
1 - PARK INHIBIT BLOCKER SPRING 2 - GEAR SHIFT LEVER
INSTALLATION
(1) Install the lever assembly using care to install the pin in the blocker to slider slot (Fig. 15) and install the mounting screws and tighten to 12 N·m (105 in. lbs.).
DR GEAR SHIFT LEVER (Continued)
COLUMN
19 - 13
(2) Lock the steering wheel with the tire in the
straight position.
(3) Remove and discard the lower pinch bolt. (4) Lower the steering coupler shaft from the col-
umn.
(5) Remove the upper steering coupling shaft seal by pushing in the four tags securing it to the panel (Fig. 16).
Fig.15GEARSHIFTLEVERSPRING
1 - BLOCKER TO INHIBIT LINK SLOT 2 - GEAR SHIFT LEVER
(2) Cycle the key from ACC to RUN and ensure
that the blocker does not stick or bind.
(3) Turn the key to the OFF position and ensure that the shifter will not pull from the PARK position. the over drive switch harness (if
(4) Connect
equipped).
NOTE: Route and tie off harness to original loca- tion.
(5) Connect the shift cable to the lever. (6) Ensure the gear shift lever and transmission are in the PARK position and snap the cable adjust clip in place.
(7) Install a new brake light switch (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - INSTALLATION).
(8) Install the SKIM and halo. (9) Install the upper and lower column shroud. (10) Install
the column back into place and
tighten.
(11) Install the kneeblocker. (Refer to 23 - BODY/ INSTRUMENT PANEL/KNEE BLOCKER - INSTAL- LATION).
Fig.16RELEASETANGS
1 - RELEASE TANGS (4) 2 - UPPER STEERING COUPLER SHAFT
(6) Remove and discard the lower coupler pinch bolt from the lower steering coupling shaft (Fig. 17). (7) Remove the upper steering coupling shaft from
the vehicle (Fig. 17).
UPPER STEERING COUPLING REMOVAL
(1) Disconnect the negative battery cable.
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
Fig.17UPPERSTEERINGCOUPLERSHAFT
1 - LOWER STEERING COUPLER 2 - RELEASE TANGS (4) 3 - UPPER STEERING COUPLER SHAFT
COLUMN
19 - 14
UPPER STEERING COUPLING (Continued) INSTALLATIONDR
(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).
(2) Install the upper steering coupling shaft seal by pushing it in securing the four tangs to the panel (Fig. 16).
NOTE: Note: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used.
Fig.18LOWERSTEERINGCOUPLER
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly. (5) Remove and discard the upper coupler pinch
(6) Remove and discard the lower coupler pinch
bolt (Fig. 20).
bolt (Fig. 19).
(3) Install the steering coupler shaft to the column
(Fig. 17).
(4) Install the upper pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(5) Install the shaft to the lower coupler (Fig. 17). (6) Install the lower pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(7) Unlock the steering wheel. (8) Reconnect the negative battery cable.
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD
(1) Disconnect the negative battery cable. (2) Raise and support the vehicle.
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly. for proper (5) Mark both coupler
connections
installation.
(6) Remove and discard the upper coupler pinch
(7) Remove and discard the lower coupler pinch
(8) Remove the lower steering shaft coupler (Fig.
bolt.
bolt.
18).
REMOVAL - 4X4 HD
(1) Disconnect the negative battery cable. (2) Raise and support the vehicle.
Fig.19LOWERCOUPLERPINCHBOLT
1 - INTERMEDIATE STEERING SHAFT 2 - LOWER COUPLING BOLT 3 - STEERING GEAR
DR LOWER STEERING COUPLING (Continued)
(7) Remove the lower steering shaft coupler (Fig.
20).
COLUMN
19 - 15
(5) Install the left front tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STAN- DARD PROCEDURE).
(6) Lower the vehicle. (7) Reconnect the negative battery cable. (8) Unlock the steering wheel.
STEERING WHEEL REMOVAL
(1) Disable and remove the driver’s side air- - ELECTRICAL/RESTRAINTS/
bag.(Refer DRIVER AIRBAG - REMOVAL).
to
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
Fig.20INTERMEDIATESTEERINGSHAFT
1 - UPPER COUPLING BOOT AND BOLT 2 - INTERMEDIATE STEERING SHAFT 3 - LOWER COUPLING BOLT 4 - STEERING GEAR
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD(1) Install the coupler to the steering rack & pin-
ion using the marks made in the removal process.
(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla- tion.
(3) Install the lower pinch bolt and tighten to 57
(4) Install the upper pinch bolt and tighten to 57
N·m (42 ft. lbs.).
N·m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STAN- DARD PROCEDURE).
(6) Lower the vehicle. (7) Reconnect the negative battery cable. (8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear. (2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla- tion.
Fig.21STEERINGWHEELPULLER
1 - STEERING WHEEL 2 - SPECIAL TOOL CJ98-1
(4) Remove and discard the steering wheel bolt. (5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
(3) Install the driver’s side air bag. (Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(3) Install the lower pinch bolt and tighten to 28
bolt to 61 N·m (45 ft. lbs.).
N·m (250 in. lbs.).
N·m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
19 - 16
GEAR - INDEPENDENT FRONT SUSPENSION
GEAR - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page
GEAR - INDEPENDENT FRONT SUSPENSION
BUSHING
DR
page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 18
GEAR - INDEPENDENT FRONT SUSPENSION DESCRIPTION
A rack and pinion steering gears (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.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18(2) Drain and siphon the power steering fluid from
the reservoir.
bolt.
& pinion.
(3) Raise the vehicle. (4) Remove and discard the steering coupler pinch
(5) Remove the power steering hoses from the rack
(6) Remove the tire and wheel assembly. (7) Remove the tie rod end nuts and separate tie rod ends from the knuckles with Special tool 8677
(Refer to 19 - STEERING/LINKAGE/TIE ROD END - REMOVAL).(8) Remove the skid plate (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - REMOV- AL).
(9) Remove the rack & pinion mounting bolts. (Fig.
2) & (Fig. 3)
(10) Remove the rack & pinion from the vehicle.
Fig.1STEERINGGEAR
1 - OUTER TIE ROD ENDS 2 - MOUNTING BUSHINGS 3 - BELLOWS
REMOVAL
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(1) Lock the steering wheel.
Fig.2STEERINGGEARMOUNTINGBOLTS
1 - STEERING GEAR MOUNTING BOLTS 4X4
DR GEAR - INDEPENDENT FRONT SUSPENSION (Continued)
GEAR - INDEPENDENT FRONT SUSPENSION
19 - 17
an additional 90°. (Refer to 19 - STEERING/LINK- AGE/TIE ROD END - INSTALLATION).
(5) Install the pressure power steering hose to the steering gear and tighten to 32 N·m (23 ft. lbs.). (Refer to 19 - STEERING/PUMP/HOSES - INSTAL- LATION).
(6) Install the return power steering hose to the steering gear and tighten to 71 N·m (52 ft. lbs.). (Refer to 19 - STEERING/PUMP/HOSES - INSTAL- LATION).
(7) Install the front skid plate (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(9) Remove the support and lower the vehicle. (10) Fill the system with fluid,
(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(11) Adjust the toe position. (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- DURE).
Fig.4STEERINGGEAR4X4
1 - FRONT AXLE 2 - STEERING GEAR MOUNTING NUTS & BUSHINGS
Fig.3STEERINGGEAR4X2
1 - SWAY BAR 2 - STEERING GEAR 3 - LEFT OUTER TIE ROD END 4 - LOWER CONTROL ARMS 5 - LEFT INNER & RIGHT OUTER (TIE ROD ENDS)
INSTALLATION
NOTE: Before installing gear inspect bushings and replace if worn or damaged.
NOTE: In the frame there is two holes for the mounting of the steering gear one is slotted and one is round, When tightening the gear to specifi- cations make sure to tighten the mounting bolt with the hole first to avoided movement of the steering gear.
(1) Install the gear on the front crossmember and tighten the mounting bolts to 319 N·m (235 ft. lbs.). (Fig. 4) & (Fig. 3).
(2) Slide the shaft coupler onto the gear. Install
new pinch bolt and tighten to 49 N·m (36 ft. lbs.).
(3) Clean and dry the tie rod end studs and the
knuckle tapers.
(4) Install the tie rod ends into the steering knuck- les and tighten the nuts to 61 N·m (45 ft. lbs.) then
GEAR - INDEPENDENT FRONT SUSPENSION
19 - 18
GEAR - INDEPENDENT FRONT SUSPENSION (Continued) SPECIFICATIONSDR
TORQUE CHART
DESCRIPTION
Rack and Pinion Steering
Gear
Gear to Frame Bolts
Rack and Pinion Steering
Gear
Coupler Bolt Tie Rod End Knuckle Nut
Tie Rod End
Jam Nut
Power Steering Line
Pressure Line
Power Steering Line
Return Line
Power Steering Line
Pressure Line To Pump
BUSHING REMOVAL
TORQUE SPECIFICATIONS
N·m 319
49
61
Ft. Lbs.
235
36
45
Then tighten an additional
Then tighten an additional
90° 75
32
71
37
90° 55
23
52
27
In. Lbs.
—
—
—
—
—
—
—
(1) Remove the steering gear
STEERING/GEAR - REMOVAL).
(Refer
to 19 -
CAUTION: Do not overtighten the vise on the gear case.
(2) Mount the steering gear in a soft jawed vise.
NOTE: If the bushings are seized a brass punch can be used to remove the bushings from the gear using care not to strike the gear.
(3) Remove the front mounting bushings. (4) Remove the rear mounting bushings. (5) Remove the steering gear from the vise and
place it on the bench.
INSTALLATION
NOTE: Coat all bushings with a thin rubber lubri- cate oil prior to installation.
NOTE: A rubber mallet can be used to assist in the installation of the bushings once lubricated.
(1) Coat the rear bushings with a thin rubber lubricate oil then install the rear bushings using a rubber mallet to seat the bushings in the gear.
(2) Coat the front bushings with a thin rubber lubricate oil then install the front bushings using a rubber mallet to seat the bushings in the gear.
(3) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(4) Adjust the toe position (if necessary) (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - STAN- DARD PROCEDURE).DR
GEAR - LINK/COIL
19 - 19
GEAR - LINK/COIL
TABLE OF CONTENTS
page
page
GEAR - LINK/COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . 21
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 22SPECIAL TOOLS
REMOVAL - DIESEL
. . . . . . . . . . . . . . . . . . . 24
INSTALLATION
INSTALLATION - GAS ENGINE . . . . . . . . . . . 24
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . 25STEERING GEAR INPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28PITMAN SHAFT
REMOVAL
REMOVAL - GAS . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . 30
REMOVAL - DIESELPOWER STEERING GEAR . . . . . . . . . . . . . . 22
INSTALLATION
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE . . . . . . . . . . . . . . . 23
INSTALLATION - GAS . . . . . . . . . . . . . . . . . . 30
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . 30GEAR - LINK/COIL DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio’s used are 12.5:1.
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 from input from the steering column the rack piston moves. The rack piston 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 a straight-ahead posi-
tion.
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
(2) Lock the steering wheel. (3) Siphon out as much power steering fluid as
possible.
Fig.1STEERINGGEAR
1 - INPUT SHAFT 2 - OUTLET 3 - INLET 4 - VALVE ASSEMBLY HOUSING 5 - PITMAN SHAFT COVER BOLTS 6 - STEERING GEAR 7 - MESHLOAD ADJUSTER NUT 8 - PITMAN SHAFT
GEAR - LINK/COIL
19 - 20
GEAR - LINK/COIL (Continued)DR
(4) Disconnect and cap the fluid hoses from steer- ing gear (Refer to 19 - STEERING/PUMP/HOSES - REMOVAL).
(5) Remove coupler pinch bolt at the steering gear
and slide shaft off gear (Fig. 2).
Fig.4STEERINGGEARREMOVAL/INSTALLATION 1 - STEERING GEAR 2 - MOUNTING BOLTS (3)
INSTALLATION
Fig.2COLUMNSHAFT
1 - STEERING COUPLER 2 - STEERING GEAR INPUT SHAFT
(6) Mark the pitman shaft and pitman arm for installation reference. Remove the pitman arm from the shaft with Puller C-4150A (Refer to 19 - STEER- ING/LINKAGE/PITMAN ARM - REMOVAL), (Fig. 3).
(1) Position the steering gear on the frame rail and install the three mounting bolts (Fig. 4). Tighten the mounting bolts to 196 N·m (145 ft. lbs.).
(2) Align steering coupler on gear shaft. Install pinch bolt and tighten to 49 N·m (36 ft. lbs.) torque. (3) Align and install the pitman arm (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - INSTALLA- TION).
(4) Install the washer and retaining nut on the pit- man shaft. Tighten the nut to 305 N·m (225 ft. lbs.). (5) Connect fluid hoses to steering gear (Refer to 19 - STEERING/PUMP/HOSES - INSTALLATION), tighten to 31 N·m (23 ft. lbs.).
(6) Add fluid, (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE).
(7) Reset the toe and center the steering wheel (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
Fig.3PITMANARMREMOVAL
1 - PITMAN ARM 2 - C-4150A PULLER
(7) Remove steering gear three mounting bolts (Fig. 4). Remove the steering gear from the vehicle.
ADJUSTMENTS
ADJUSTMENT
CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result.
NOTE: Adjusting the steering gear in the vehicle is not recommended. Remove gear from the vehicle and drain the fluid. Then mount gear in a vise to perform adjustments.
DR GEAR - LINK/COIL (Continued)
GEAR - LINK/COIL
19 - 21
(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
(2) Mount the gear carefully into a soft-jawed vise.
CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment
(3) Hold the steering gear upside down over a drain pan and rotate the input shaft back and forth several times lock-to-lock to discharge the fluid from the steering gear
(4) Rotate the input shaft to the left stop and then back-off approximately 45 degrees. Using an inch- pound torque wrench on the input shaft, record the peak torque required to slowly and evenly rotate the input shaft clockwise 1⁄2 turn (180 degrees) starting from the 45 degree position. This peak torque read- ing is the preload torque. The preload torque must be within 2 - 10 in-lbs.
(5) Rotate the input shaft to its center of travel (approximately 1.5 turns from either stop). Place the torque wrench on the input shaft with the handle in the vertical position. Rotate the torque wrench slowly and evenly 1⁄4 turn (90 degrees) each side of center and record the peak torque measure on or near cen- ter. This total on-center torque reading must be 5 - 9
in-lbs higher than the previously measured preload torque without exceeding a total of 17 in-lbs. The value of the total on-center minus the preload torque is defined as the meshload torque(6) If required, adjust the on-center torque by loos- ening the adjuster screw lock nut and turning the adjuster screw until the total on-center and meshload torque readings fall within the specified values. Turn the adjuster screw clockwise to increase and counter- clockwise to decrease the torque reading. While hold- ing the adjuster screw in place, tighten the lock nut to 31 N·m (23 ft. lbs.).
(7) Re-check the preload and on-center torque
readings.
(8) Install pitman arm on the steering gear (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - INSTALLATION).
(9) Reinstall steering gear to the vehicle (Refer to
19 - STEERING/GEAR - INSTALLATION).
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Steering Gear Type Gear Code & Ratio
Recirculating Ball
12.5:1
TORQUE SPECIFICATIONS
DESCRIPTION
Preload Torque
Meshload Torque
N·m
0.23-1.13
0.56-1.02
Ft. Lbs.
—
—
In. Lbs.
2-10
5-9
+ Preload (17 Max)
GEAR - LINK/COIL
19 - 22
GEAR - LINK/COIL (Continued) TORQUE CHARTTORQUE SPECIFICATIONS
DR
N·m 196
32
71
37
31
305
68
54
2.26
97
DESCRIPTION
Steering Gear Mounting
Frame Bolts
Power Steering Line
Pressure
Power Steering Line
Return
Power Steering Line
Pressure Line To Pump
Steering Gear
Adjustment Screw Locknut
Steering Gear
Pitman Shaft Nut
Steering Gear
Pitman Shaft Cover Bolts
Steering Gear
Valve Housing to Gear
Bolts
Steering Gear
Retainer Ring Screw
Steering Gear Retainer Ring
SPECIAL TOOLS
POWER STEERING GEAR
Ft. Lbs.
145
23
52
27
23
225
50
40
—
72
In. Lbs.
—
—
—
—
—
—
—
—
20
—
HANDLEC-4171
INPUTSHAFTSEALINSTALLER-8987
DR GEAR - LINK/COIL (Continued)
GEAR - LINK/COIL
19 - 23
PULLER,SLIDEHAMMER-C-3752
PITMANSHAFTSEALPROTECTOR-8993
SEALREMOVERADAPTER-8990
PITMANSHAFTSEALINSTALLER-8989
INPUTSHAFTSEALPROTECTOR-8986
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE
(1) Seperate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the steering wheel from stop to stop and
count the number of turns.
(4) Center the steering wheel by rotating it from the stop back 1 1/2 turns to achieve center position.
(5) Remove the pitman shaft cover bolts.
RETAINERRINGWRENCH-8988
NOTE: The pitman shaft will not clear the housing if it is not centered.
(6) Remove the pitman shaft from the gear. (7) Remove dust seal from the housing with a spe-
cial tool (Fig. 5).
CAUTION: Use care not to score the housing bore when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
GEAR - LINK/COIL
19 - 24
PITMAN SHAFT SEAL (Continued)DR
Fig.5SLIDEHAMMER
Fig.6CENTERINGSTEERINGGEAR
1 - STEERING GEAR 2 - SLIDE HAMMER C-3752 USED WITH SPECIAL TOOL ADAPTER 8990
(9) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to remove.
(10) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752.
REMOVAL - DIESEL
(1) Seperate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
with a wire brush.
(4) Clean exposed end of pitman shaft and housing
(5) Rotate the input shaft with a 12 point socket from stop to stop and count the number of turns (Fig. 6).
(6) Center the input shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 6).
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if it is not centered.
(8) Remove the pitman shaft from the gear. (9) Remove dust seal from the housing with a spe-
cial tool 8990 (Fig. 5).
1 - STEERING GEAR 2 - 12 POINT SOCKET 3 - RATCHET 4 - INPUT SHAFT
CAUTION: Use care not to score the housing bore when prying out seals.
(10) Remove retaining ring with snap ring pliers. (11) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to
