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    Exj 19 Exj 19 Document Transcript

    • STEERING GEAR PRESSURE RESERVOIR HOSE RETURN HOSE 4.0 L PUMPXJ STEERING 19 - 1 STEERING CONTENTS page pagePOWER STEERING GEAR . . . . . . . . . . . . . . . . 10 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 21POWER STEERING PUMP . . . . . . . . . . . . . . . . . 4 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 24POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . 1 POWER STEERING INDEX page pageGENERAL INFORMATION DIAGNOSIS AND TESTING STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . 1 POWER STEERING SYSTEM DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . . . 2GENERAL INFORMATIONSTEERING SYSTEM The power steering system has a hydraulic pump.The pump is a constant flow rate and displacement,vane-type pump. The pump on the 4.0L engine has areservoir mounted to it (Fig. 1). The 2.5L engine hasa remote mounted reservoir. The steering gear used is a recirculating ball typegear. The gear acts as a rolling thread between theworm shaft and the rack piston. When the steeringwheel is turned the worm shaft turns which movesthe rack piston. The rack piston movement turns thepitman shaft which is connected to the steering link-age by the pitman arm. This gear is used on all mod-els. The power steering system consists of: Fig. 1 Power Steering Gear & Pump—4.0L • Hydraulic pump • Recirculating ball steering gear • Steering column • Steering linkageNOTE: Right hand drive (RHD) and left hand drive(LHD) service procedures and torque specificationsfor steering linkage, gear and column are the same.The power steering pump procedures are different.Refer to appropriate service procedures regardingeach component in the system.
    • 19 - 2 STEERING XJDIAGNOSIS AND TESTINGPOWER STEERING SYSTEM DIAGNOSIS CHARTS STEERING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound evident at astandstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similarto that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passingthrough an orifice. There is no relationship between this noise and steering performance. CONDITION POSSIBLE CAUSES CORRECTIONOBJECTIONAL HISS OR 1. Steering intermediate shaft to dash 1. Check and repair seal at dashWHISTLE panel seal. panel. 2. Noisy valve in power steering gear. 2. Replace steering gear.RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification. 2. Loose or damaged suspension 2. Inspect and repair suspension. components. 3. Loose or damaged steering linkage. 3. Inspect and repair steering linkage. 4. Internal gear noise. 4. Replace gear. 5. Pressure hose in contact with other 5. Reposition hose. components.CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level. 2. Pressure hose in contact with other 2. Reposition hose. components. 3. Internal pump noise. 3. Replace pump.SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp. 2. O-ring missing or damaged on hose 2. Replace o-ring. fitting. 3. Low fluid level. 3. Fill to proper level. 4. Air leak between pump and reservoir. 4. Repair as necessary.SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.KNOCKING 2. Wrong gear. 2. Verify gear. BINDING AND STICKING CONDITION POSSIBLE CAUSE CORRECTIONDIFFICULT TO TURN WHEEL 1. Low fluid level. 1. Fill to proper level.STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure. 3. Steering components. 3. Inspect and lube. 4. Loose belt. 4. Adjust or replace. 5. Low pump pressure. 5. Pressure test and replace if necessary. 6. Column shaft coupler binding. 6. Replace coupler. 7. Steering gear worn or out of 7. Repair or replace gear. adjustment.
    • XJ STEERING 19 - 3DIAGNOSIS AND TESTING (Continued) INSUFFICIENT ASST. OR POOR RETURN TO CENTER CONDITION POSSIBLE CAUSE CORRECTIONHARD TURNING OR MOMENTARY 1. Tire pressure. 1. Adjust tire pressure.INCREASE IN TURNING EFFORT 2. Low fluid level. 2. Fill to proper level. 3. Loose belt. 3. Adjust or replace. 4. Lack of lubrication. 4. Inspect and lubricate steering and suspension compnents. 5. Low pump pressure. 5. Pressure test and repair as necessary. 6. Internal gear leak. 6. Pressure and flow test, and repair as necessary.STEERING WHEEL 1. Tire pressure. 1. Adjust tire pressure.DOES NOT WANT TO RETURN TO 2. Wheel alignment. 2. Align front end.CENTER POSITION 3. Lack of lubrication. 3. Inspect and lubricate steering and suspension compnents. 4. High friction in steering gear. 4. Test and adjust as necessary. LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTIONEXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Inspect and repair as necessary.WHEEL steering components. 2. Worn or loose wheel bearings. 2. Inspect and repair or adjust bearings. 3. Steering gear mounting. 3. Tighten gear mounting bolts to specification. 4. Gear out of adjustment. 4. Adjust gear to specification. 5. Worn or loose steering coupler. 5. Inspect and replace as necessary.VEHICLE PULLS OR LEADS TO 1. Tire Pressure. 1. Adjust tire pressure.ONE SIDE. 2. Radial tire lead. 2. Rotate tires. 3. Brakes dragging. 3. Repair as necessary. 4. Wheel alignment. 4. Align front end.
    • RESERVOIRCLIP CAP BODY PUMP FLUID (TYPICAL) VOIR RESER- HIGH-PRESSURE PULLEY DRIVE FITTING19 - 4 STEERING XJ POWER STEERING PUMP INDEX page pageDESCRIPTION AND OPERATION PUMP RESERVOIR–2.5L . . . . .............. 6 POWER STEERING PUMP . . . . . . . . . . . . . . .. 4 DISASSEMBLY AND ASSEMBLYDIAGNOSIS AND TESTING FLOW CONTROL VALVE . . . . .............. 8 POWER STEERING PUMP PRESSURE TEST .. 4 PUMP PULLEY . . . . . . . . . . . .............. 8 PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . .. 5 PUMP RESERVOIR . . . . . . . . .............. 8SERVICE PROCEDURES SPECIFICATIONS POWER STEERING PUMP—INITIAL TORQUE CHART . . . . . . . . . . .............. 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .. 5 SPECIAL TOOLSREMOVAL AND INSTALLATION POWER STEERING PUMP . . .............. 9 POWER STEERING PUMP . . . . . . . . . . . . . . .. 6DESCRIPTION AND OPERATIONPOWER STEERING PUMP Hydraulic pressure is provided for operation of thepower steering gear by a belt driven power steeringpump. The power steering pump is a constant flowrate and displacement, vane-type pump. The internalparts in the housing operate submerged in fluid. Theflow control orifice is part of the high pressure linefitting. The pressure relief valve inside the flow con-trol valve limits the pump pressure. The reservoir isattached to the pump body with spring clips on the4.0L engine. On the 2.5L engine the reservoir is sep-arate from the pump. The power steering pump is connected to the steer-ing gear by the pressure and return hoses. The pumpshaft has a pressed-on drive pulley that is belt drivenby the crankshaft pulley (Fig. 1).NOTE: Power steering pumps have different pres-sure rates and are not interchangeable with otherpumps. Fig. 1 Pump With Integral Reservoir PUMP PRESSURE TESTDIAGNOSIS AND TESTING (1) Check belt tension and adjust as necessary. (2) Disconnect high pressure hose at gear or pump.POWER STEERING PUMP PRESSURE TEST Use a container for dripping fluid. The following procedure is used to test the opera- (3) Connect pressure gauge from Power Steeringtion of the power steering system on the vehicle. This Analyzer Tool Kit 6815 to both hoses using appropri-test will provide the flow rate of the power steering ate adapter from Adapter Kit 6893. Connect sparepump along with the maximum relief pressure. Per- pressure hose to gear or pump.form test any time a power steering system problem (4) Open the test valve completely.is present. This test will determine if the power (5) Start engine and let idle long enough to circu-steering pump or power steering gear is not function- late power steering fluid through flow/pressure testing properly. The following pressure and flow test is gauge and to get air out of the fluid. Then shut offperformed using Power Steering Analyzer Tool Kit engine.6815 (Fig. 2) and Adapter Kit 6893.
    • ADAPTER TINGS FIT- SPECIAL TOOL 6815 CAP TIGHT, (BEARING) O-RING 6. 5. O-RING SEAL. 4. CHECK OIL LEVEL: THE CAP. SEAL. REPLACE O-RING FITTING NUT TO SPECIFICATIONS. IF LEVEL 3. REPLACE REPLACE IF LEAKAGE PERSISTS WITH THE LEAKAGE PERSISTS, 2. BUSHING FITTING TO SPECIFICATIONS. IF REPLACE PUMP. CORRECT AND 1. TORQUE HOSE SEAL.WORN, SEAL WORN. LEAKAGE PERSISTS, REPLACE PUMP. RESERVOIRXJ STEERING 19 - 5DIAGNOSIS AND TESTING (Continued) RELIEF PRESSURE CHART ENGINE RELIEF PRESSURE Ϯ 50 2.5L 9653 kPa (1400 psi) 4.0L 9653 kPa (1400 psi) PUMP LEAKAGE DIAGNOSIS Fig. 2 Pressure Test Gauge (6) Check fluid level, add fluid as necessary. Startengine again and let idle. (7) Gauge should read below 862 kPa (125 psi), ifabove, inspect the hoses for restrictions and repair asnecessary. The initial pressure reading should be inthe range of 345-552 kPa (50-80 psi).CAUTION: The following test procedure involvestesting maximum pump pressure output and flowcontrol valve operation. Do not leave valve closedfor more than three seconds as the pump could bedamaged. (8) Close valve fully three times and record high-est pressure indicated each time. All three read-ings must be above specifications and within345 kPa (50 psi) of each other. • Pressures above specifications but not within SERVICE PROCEDURES345 kPa (50 psi) of each other, replace pump. • Pressures within 345 kPa (50 psi) of each other POWER STEERING PUMP—INITIAL OPERATIONbut below specifications, replace pump. WARNING: THE FLUID LEVEL SHOULD BENOTE: Refer to pump relief pressure chart. CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS.CAUTION: Do not force the pump to operateagainst the stops for more than 2 to 3 seconds at a CAUTION: Use MOPAR Power Steering Fluid ortime because, pump damage will result. equivalent. Do not use automatic transmission fluid and do not overfill. (9) Open the test valve, turn steering wheelextreme left and right positions against the stops. Wipe filler cap clean, then check the fluid level.Record the highest indicated pressure at each posi- The dipstick should indicate COLD when the fluid istion. Compare readings to specifications. If highest at normal temperature.output pressures are not the same against either (1) Fill the pump fluid reservoir to the proper levelstop, the gear is leaking internally and must be and let the fluid settle for at least two (2) minutes.repaired. (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.
    • PUMP ASSEMBLY 4.0L PUMP ASSEMBLY 2.5L PUMP BRACKET19 - 6 STEERING XJSERVICE PROCEDURES (Continued) (5) Slowly turn the steering wheel right and left, (2) Remove pressure and return hoses from pump,lightly contacting the wheel stops at least 20 times. and drain pump. (6) Check the fluid level add if necessary. (3) Remove 3 pump mounting bolts through pulley (7) Lower the vehicle, start the engine and turn access holes.the steering wheel slowly from lock to lock. (4) Loosen the 3 pump bracket bolts (Fig. 3) and (8) Stop the engine and check the fluid level and (Fig. 4).refill as required. (5) Tilt pump downward and remove from engine. (9) If the fluid is extremely foamy or milky look- (6) Remove pulley from pump.ing, allow the vehicle to stand a few minutes andrepeat the procedure. INSTALLATION (1) Install pulley on pump.CAUTION: Do not run a vehicle with foamy fluid for (2) Install pump on engine.an extended period. This may cause pump damage. (3) Tighten pump bracket bolts to 47 N·m (35 ft. lbs.). (4) Install 3 pump mounting bolts and tighten toREMOVAL AND INSTALLATION 27 N·m (20 ft. lbs.). (5) Install the pressure and return hoses to pump.POWER STEERING PUMP (6) Install drive belt, refer to Group 7 Cooling. (7) Add power steering fluid and perform PowerNOTE: The power steering pump is mounted in the Steering Pump Initial Operation.same position on LHD and RHD vehicles. On 4.0LRHD vehicles the front bracket is difference. The PUMP RESERVOIR–2.5Lservice procedures are the same. REMOVALREMOVAL (1) Remove the pump return hoses from the reser- (1) Remove serpentine drive belt, refer to Group 7 voir and drain the reservoir.Cooling. Fig. 3 Pump Mounting
    • RETURN HOSE MOUNTING BOLT RETURN HOSE BRACKET RESERVOIR RETURN HOSE MOUNTING NUT PUMP ASSEMBLY RETURN HOSE RESERVOIRXJ STEERING 19 - 7REMOVAL AND INSTALLATION (Continued) Fig. 4 Pump Mounting 4.0L RHD (2) Remove the reservoir top mounting bolt (RHD)(Fig. 5) or nut (LHD) (Fig. 6). (3) Loosen lower mounting bolt (RHD) or nut(LHD). (4) Slide reservoir up off the lower bolt (RHD) orstud (LHD). Fig. 6 Pump Reservoir-LHD INSTALLATION (1) Slide reservoir down onto lower bolt (RHD) or stud (LHD). (2) Install the reservoir top mounting bolt (RHD) (Fig. 5) or nut (LHD) (Fig. 6). Fig. 5 Pump Reservoir-RHD (3) Tighten lower mounting bolt (RHD) or nut (LHD). (4) Install the pump return hoses. (5) Fill reservoir to proper level. Refer to Power Steering Pump Initial Operation.
    • POWER STEERINGTOOL C-4333 SPECIAL PULLEY DRIVE PUMP SPECIAL TOOLSTEERING POWER DRIVE PULLEY PUMP C-4063–B RETAINING CLIPS RESERVOIR19 - 8 STEERING XJDISASSEMBLY AND ASSEMBLY PUMP RESERVOIRPUMP PULLEY DISASSEMBLY (1) Remove power steering pump.DISASSEMBLY (2) Clean exterior of pump. (1) Remove pump assembly. (3) Clamp the pump body in a soft jaw vice. (2) Remove pulley from pump with Puller C-4333 (4) Pry up tab and slide the retaining clips off (Fig.(Fig. 7). 9). Fig. 7 Pulley RemovalASSEMBLY (1) Replace pulley if bent, cracked, or loose. (2) Install pulley on pump with Installer C-4063-B(Fig. 8) flush with the end of the shaft. Ensure thetool and pulley remain aligned with the pump shaft. Fig. 9 Pump Reservoir Clips (5) Remove fluid reservoir from pump body. Remove and discard O-ring seal. ASSEMBLY (1) Lubricate new O-ring Seal with Mopar Power Steering Fluid or equivalent. (2) Install O-ring seal in housing. (3) Install reservoir onto housing. (4) Slide and tap in reservoir retainer clips until tab locks to housing. (5) Install power steering pump. Refer to Pump Replacement in this section. FLOW CONTROL VALVE DISASSEMBLY Fig. 8 Pulley Installation (1) Clean area around fitting to prevent dirt from (3) Install pump assembly. entering pump. Remove pressure hose from pump fit- (4) With Serpentine Belts; Run engine until warm ting.(5 min.) and note any belt chirp. If chirp exists, move (2) Remove fitting from pump housing (Fig. 10).pulley outward approximately 0.5 mm (0.020 in.). If Prevent flow control valve and spring fromnoise increases, press on 1.0 mm (0.040 in.). Be sliding out of housing bore.careful that pulley does not contact mounting (3) Remove and discard O-ring seal.bolts.
    • TIGHTEN TO 75 N·mFITTING CONTROL VALVE ASSEMBLYSEAL FLOW FT (55 CONTROL SPRING LBS.) O-RINGXJ STEERING 19 - 9DISASSEMBLY AND ASSEMBLY (Continued) SPECIAL TOOLS POWER STEERING PUMP Analyzer Set, Power Steering Flow/Pressure 6815 Fig. 10 Flow Control ValveASSEMBLY (1) Install spring and flow control valve into pumphousing bore. Be sure the hex nut end of thevalve is facing in toward pump. (2) Install O-ring seal onto fitting. (3) Install flow control valve in pump housing andtighten to 75 N·m (55 ft. lbs.). (4) Install pressure hose to valve. Adapters, Power Steering Flow/Pressure Tester 6893SPECIFICATIONSTORQUE CHARTDESCRIPTION TORQUEPower Steering Pump Bracket to Pump . . . . . . . . . . . 28 N·m (21 ft. lbs.) Bracket to Engine . . . . . . . . . . 47 N·m (35 ft. lbs.) Flow Control Valve . . . . . . . . . 75 N·m (55 ft. lbs.) Pressure Line . . . . . . . . . . . . . 28 N·m (21 ft. lbs.) Puller C-4333 Installer, Power Steering Pulley C-4063–B
    • 19 - 10 STEERING XJ POWER STEERING GEAR INDEX page pageDESCRIPTION AND OPERATION RACK PISTON AND WORM SHAFT . . . . . . . . . 16 POWER STEERING GEAR . . . . . . . . . . . . . . . . 10 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 14DIAGNOSIS AND TESTING ADJUSTMENTS POWER STEERING GEAR LEAKAGE STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . 18 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 12 SPECIFICATIONSREMOVAL AND INSTALLATION POWER STEERING GEAR . . . . . . . . . . . . . . . . 20 STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . 12 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 20DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS HOUSING END PLUG . . . . . . . . . . . . . . . . . . . 12 POWER STEERING GEAR . . . . . . . . . . . . . . . . 20 PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . 13DESCRIPTION AND OPERATION rack piston teeth mesh with the pitman shaft. Turn- ing the worm shaft turns the pitman shaft, whichPOWER STEERING GEAR turns the steering linkage. The power steering gear is a recirculating ball typegear (Fig. 1). The gear acts as a rolling thread CAUTION: Components attached with a nut andbetween the worm shaft and rack piston. The worm cotter pin must be torqued to specification. Then ifshaft is supported by a thrust bearing at the lower the slot in the nut does not line up with the cotterend and a bearing assembly at the upper end. When pin hole, tighten nut until it is aligned. Never loosenthe worm shaft is turned the rack piston moves. The the nut to align the cotter pin hole.
    • RING, RETAININGPLUGSEAL, O-RINGXJ TEFLON STEERING 19 - 11RING,COVER, SIDEDIAGNOSIS AND TESTINGNUT, ADJUSTER LOCK (Continued)GASKETSHAFT, PITMANSHAFT, WORMRACEBEARING, THRUSTVALVE, CHECKHOUSINGSCREWCLAMPGUIDE, BALLBALLSPISTON, RACKPLUGBEARING, NEEDLEWASHER, BACKUPRING, RETAININGSHAFT, STUBSPOOL, VALVEBODY, VALVENUT, COUPLING SHIELD RET. AND LOCKTHRUST SUPPORT ASSEMBLYSEAL, PITMAN SHAFTSEAL, DUSTNUT, ADJUSTER Fig. 1 Recirculating Ball Type Gear
    • 19 - 12 STEERING XJ2. SIDE COVER LEAK — TORQUETHE ADJUSTERTO SPECIFICATION.IFREPLACE THE PERSISTS.COVER BOLTS SIDE COVER REPLACE1. ADJUSTER PLUG SEAL — SEAL SIDE LEAKAGE PLUG SEALS. 3. TOP COVERLINE FITTING — TORQUE SEAL. 5. PITMAN FITTING 4. PRESSURE SEAL — — SPECIFICA- REPLACE SHAFT SEALS TO REPLACE TIONS. IF THE SEAL.PERSISTS, THE HOSELEAKAGE NUTREPLACE THE SEALS.DIAGNOSIS AND TESTINGPOWER STEERING GEAR LEAKAGE DIAGNOSIS Fig. 2 Steering Gear Mounting (LHD) DISASSEMBLY AND ASSEMBLY HOUSING END PLUG RETAININGING R DISASSEMBLYREMOVAL AND INSTALLATION (1) Unseat and remove retaining ring from groove with a punch through the hole in the end of theSTEERING GEAR housing (Fig. 3).REMOVAL (1) Place the front wheels in the straight aheadposition with the steering wheel centered. (2) Disconnect and cap the fluid hoses from steer-ing gear. (3) Remove the column coupler shaft from thegear. (4) Remove pitman arm from gear. (5) Remove the steering gear retaining bolts andremove the gear (Fig. 2).INSTALLATION (1) Align the column coupler shaft to steering gear. (2) Install steering gear (and bracket) on the framerail and tighten bolts to 95 N·m (70 ft. lbs.) (3) Align and install the pitman arm and tightennut to 251 N·m (185 ft. lbs.). (4) Connect fluid hoses to steering gear andtighten to 28 N·m (21 ft. lbs.). (5) Fill power steering system to proper level. Fig. 3 End Plug Retaining Ring (2) Rotate stub shaft slowly COUNTER-CLOCK- WISE to force the end plug out from housing.
    • HOUSING HOUSING ASSEMBLY END O-RING PLUG SEAL HOUSING END PUNCHRETAINER PLUG RING CAP RETAININGHOLE ACCESS RING RING PRELOAD ADJUSTER NUT SIDEGASKETSHAFT GEAR PITMAN SIDE COVER COVER BOLTS BLY HOUSING SEAL ASSEM-XJ STEERING 19 - 13DISASSEMBLY AND ASSEMBLY (Continued)CAUTION: Do not turn stub shaft any further than PITMAN SHAFT/SEALS/BEARINGnecessary. The rack piston balls will drop out of therack piston circuit if the stub shaft is turned too far. DISASSEMBLY (3) Remove O-ring from the housing (Fig. 4). (1) Clean exposed end of pitman shaft and housing with a wire brush. (2) Remove preload adjuster nut (Fig. 6). (3) Rotate stub shaft to center the gear. (4) Remove side cover bolts and remove side cover, gasket and pitman shaft as an assembly (Fig. 6). Fig. 4 End Plug ComponentsASSEMBLY (1) Lubricate O-ring with power steering fluid andinstall into the housing. (2) Install end plug by tapping the plug lightlywith a plastic mallet into the housing. (3) Install retaining ring so one end of the ringcovers the housing access hole (Fig. 5). Fig. 6 Side Cover and Pitman Shaft (5) Remove pitman shaft from the side cover. (6) Remove dust seal from the housing with a seal pick (Fig. 7). CAUTION: Use care not to score the housing bore when prying out seals and washer. (7) Remove retaining ring with snap ring pliers. (8) Remove washer from the housing. (9) Remove oil seal from the housing with a seal pick. (10) Remove pitman shaft bearing from housing with a bearing driver and handle (Fig. 8). ASSEMBLY (1) Install pitman shaft bearing into housing with Fig. 5 Installing The Retaining Ring a bearing driver and handle. (2) Coat the oil seals and washer with grease. (3) Install the oil seal with a driver and handle. (4) Install backup washer. (5) Install the retainer ring with snap ring pliers.
    • 19 - 14 STEERING XJDISASSEMBLY AND ASSEMBLY (Continued) SPOOL VALVE DISASSEMBLY (1) Remove lock nut (Fig. 9) and. (2) Remove adjuster nut with Spanner Wrench C-4381. LOCK NUT SUPPORT ASSEM- PUNCH THRUST BLY ADJUSTERHOUSING STUB SHAFT NUT STEERING GEAR (3) Remove thrust support assembly out of the housing (Fig. 10). (4) Pull stub shaft and valve assembly from the housing (Fig. 11). REMOVER SIDE COVER AREA Fig. 7 Pitman Shaft Seals & Bearing Fig. 9 Fig. 8 Needle Bearing Removal (6) Install dust seal with a driver and handle. (7) Install pitman shaft to side cover by screwingshaft in until it fully seats to side cover. (8) Install preload adjuster nut. Do not tighten Fig. 10 Thrust Support Assemblynut until after Over-Center Rotation Torqueadjustment has been made. (5) Remove stub shaft from valve assembly by (9) Install gasket to side cover and bend tabs lightly tapping on a block of wood to loosen shaft.around edges of side cover. Then disengage stub shaft pin from hole in spool (10) Install pitman shaft assembly and side cover valve and separate the valve assembly from stubto housing. shaft (Fig. 12). (11) Install side cover bolts and tighten to 60 N·m (6) Remove spool valve from valve body by pulling(44 ft. lbs.). and rotating the spool valve from the valve body (Fig. (12) Adjust Over-Center Rotation Torque. 13). (7) Remove spool valve O-ring and valve body teflon rings and O-rings underneath the teflon rings (Fig. 14).
    • STUBSHAFT PIN 6mm (1/4”) SHAFT IN SPOOL GEAR HOLE THRUST SUPPORT VALVE ASSEMBLYSTUB SHAFT ADJUSTER NUTNUT VALVE BODY LOCK VALVE BODY ROTATE SEALS O-RING VALVE SPOOL VALVE TO REMOVEXJ STEERING 19 - 15DISASSEMBLY AND ASSEMBLY (Continued) Fig. 11 Valve Assembly With Stub Shaft Fig. 13 Spool Valve Fig. 12 Stub Shaft Fig. 14 Valve Seals (8) Remove the O-ring between the worm shaft NOTE: Notch in stub shaft cap must fully engageand the stub shaft. valve body pin and seat against valve body shoul- der.ASSEMBLY (4) Install O-rings and teflon rings over theNOTE: Clean and dry all components, then lubri- O-rings on valve body.cate with power steering fluid. (5) Install O-ring into the back of the stub shaft (Fig. 16). (1) Install spool valve spool O-ring. (6) Install stub shaft and valve assembly in the (2) Install spool valve in valve body by pushing housing. Line up worm shaft to slots in the valveand rotating. Hole in spool valve for stub shaft pin assembly.must be accessible from opposite end of valve body. (7) Install thrust support assembly. (3) Install stub shaft in valve spool and engagelocating pin on stub shaft into spool valve hole (Fig. NOTE: If any component of the thrust support15). assembly are damaged (Fig. 17) the assembly must be replaced.
    • VALVEBODYSPOOL VALVE NOTCHPIN CAP BODY IN STUB O-RING SHAFT RACK PISTON SEAL RATCHET SUPPORT BEARING SUPPORT LARGE THRUST WASHERTHRUST BEARING END PLUG O-RING SMALL THRUSTRETAINER WASHER EXTENSION19 - 16 STEERING XJDISASSEMBLY AND ASSEMBLY (Continued) Fig. 17 Thrust Support Assembly Fig. 15 Stub Shaft Installation Fig. 16 Stub Shaft O-Ring Fig. 18 Rack Piston End Plug (8) Install adjuster nut and lock nut. (6) Turn the stub shaft COUNTERCLOCKWISE, (9) Adjust Thrust Bearing Preload and Over-Cen- this will force the rack piston onto the tool and holdter Rotating Torque. the rack piston balls in place. (7) Remove the rack piston and tool together fromRACK PISTON AND WORM SHAFT housing. (8) Remove tool from rack piston.DISASSEMBLY (9) Remove rack piston balls. (1) Remove side cover and pitman shaft. (10) Remove clamp bolts, clamp and ball guide (2) Remove housing end plug. (Fig. 20). (3) Remove rack piston plug (Fig. 18). (11) Remove teflon ring and O-ring from the rack (4) Turn stub shaft COUNTERCLOCKWISE until piston (Fig. 21).the rack piston begins to come out of the housing. (12) Remove the adjuster lock nut and adjuster (5) Insert Arbor C-4175 into bore of rack piston nut.(Fig. 19) and hold tool tightly against worm shaft. (13) Pull the stub shaft with the spool valve and thrust support assembly out of the housing.
    • TEFLONBE INSTALLED GUIDE MUST SEAL O-RING BACK-UPPISTON BALL UNDER RACK PISTON SPECIAL TOOL C-4175 RING RACK BALLS NUT RACK PISTON CLAMP PISTON GEAR HOUSING INSTALL BALLS WORM COUNTER RACE WORM FLANGE ROTATING IN THIS BEARING CLOCKWISE SHAFT HOLE WHILE SLOWLY BEARINGXJ STEERING 19 - 17DISASSEMBLY AND ASSEMBLY (Continued) (14) Remove the worm shaft from the housing (Fig. 22). Fig. 19 Rack Piston with Arbor Fig. 22 Worm Shaft ASSEMBLY NOTE: Clean and dry all components and lubricate with power steering fluid. (1) Check for scores, nicks or burrs on the rack piston finished surface. Slight wear is normal on the worm gear surfaces. (2) Install O-ring and teflon ring on the rack pis- ton. (3) Install worm shaft in the rack piston and align worm shaft spiral groove with rack piston ball guide hole (Fig. 23). Fig. 20 Rack Piston Fig. 23 Installing Balls in Rack Piston CAUTION: The rack piston balls must be installed alternately into the rack piston and ball guide. This maintains worm shaft preload. There are 12 black balls and 12 silver (Chrome) balls. The black balls are smaller than the silver balls. Fig. 21 Rack Piston Teflon Ring and O-Ring
    • GUIDE BALLS PETROLEUM JELLY PUNCH STUB SHAFT LOCK NUT19 - 18 STEERING XJDISASSEMBLY AND ASSEMBLY (Continued) (4) Lubricate and install rack piston balls through ADJUSTMENTSreturn guide hole while turning worm shaft COUN-TERCLOCKWISE (Fig. 23). STEERING GEAR (5) Install remaining balls in guide using grease tohold the balls in place (Fig. 24). 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. WORM THRUST BEARING PRELOAD (1) Remove adjuster plug locknut (Fig. 25). (2) Rotate the stub shaft back and forth to drain the remaining fluid. Fig. 24 Balls in the Return Guide (6) Install the guide onto rack piston and installclamp and clamp bolts. Tighten bolts to 58 N·m (43ft. lbs.). (7) Insert Arbor C-4175 into bore of rack pistonand hold tool tightly against worm shaft. (8) Turn the worm shaft COUNTERCLOCKWISEwhile pushing on the arbor. This will force the rackpiston onto the arbor and hold the rack piston ballsin place. (9) Install the races and thrust bearing on theworm shaft and install shaft in the housing (Fig. 22). (10) Install the stub shaft with spool valve, thrustsupport assembly and adjuster nut in the housing. (11) Install the rack piston and arbor tool into the Fig. 25 Loosening the Adjuster Plughousing. (12) Hold arbor tightly against worm shaft and (3) Turn the adjuster in with Spanner Wrenchturn stub shaft CLOCKWISE until rack piston is C-4381. Tighten the plug and thrust bearing in theseated on worm shaft. housing until firmly bottomed in housing. (13) Install pitman shaft and side cover in the (4) Place an index mark on the housing even withhousing. one of the holes in adjuster plug (Fig. 26). (14) Install rack piston plug and tighten to 150 (5) Measure back (counterclockwise) 13 mm (0.50N·m (111 ft. lbs.). in) and mark housing (Fig. 27). (15) Install housing end plug. (6) Rotate adjustment cap back (counterclockwise) (16) Adjust worm shaft thrust bearing preload and with spanner wrench until hole is aligned with theover-center rotating torque. second mark (Fig. 28). (7) Install and tighten locknut to 108 N·m (80 ft. lbs.). Be sure adjustment cap does not turn while tightening the locknut.
    • ENCE MARK REFER- INDEX MASTER SPLINE SECOND MARK FIRST MARK ADJUSTMENTWRENCH SPANNER SCREWXJ STEERING 19 - 19ADJUSTMENTS (Continued) Fig. 26 Alignment Marking On Housing Fig. 28 Aligning To The Second Mark Fig. 27 Second Marking On HousingOVER-CENTER ROTATION TORQUE (1) Rotate the stub shaft back and forth to drain Fig. 29 Steering Gear Centeredthe remaining fluid. (5) Place the torque wrench in the vertical position (2) Rotate the stub shaft from stop to stop and on the stub shaft. Rotate the wrench 45 degrees eachcount the number of turns. side of the center and record the highest rotational (3) Starting at either stop turn the stub shaft back torque on center (Fig. 30).1/2 the total number of turns. This is the center ofthe gear travel (Fig. 29). NOTE: The stub shaft must rotate smoothly without (4) Turn the pitman shaft adjuster screw back not sticking or binding.(COUNTERCLOCKWISE) until fully extended, thenturn back in (CLOCKWISE) one full turn.
    • CENTER19 - 20 STEERING XJADJUSTMENTS (Continued) TORQUE CHART DESCRIPTION TORQUE Power Steering Gear Adjustment Cap Locknut . . . . 108 N·m (80 ft. lbs.) Adjustment Screw Locknut . . . 49 N·m (36 ft. lbs.) Gear to Frame Bolts . . . . . . . . 95 N·m (70 ft. lbs.) Pitman Shaft Nut . . . . . . . . 251 N·m (185 ft. lbs.) Rack Piston Plug . . . . . . . . . . 102 N·m (75 ft. lbs.) Side Cover Bolts . . . . . . . . . . . 60 N·m (44 ft. lbs.) Pressure Line . . . . . . . . . . . . . 28 N·m (21 ft. lbs.) Return Line . . . . . . . . . . . . . . . 28 N·m (21 ft. lbs.) Return Guide Clamp Bolt . . . . 58 N·m (43 ft. lbs.) SPECIAL TOOLS POWER STEERING GEAR Fig. 30 Checking Over-Center Rotation Torque (6) The recorded bearing preload should be 0.7-1.7N·m (6-15 in. lbs.). If the torque is outside this range,the gear should be readjusted. (7) If an adjustment is necessary, turn the pitmanshaft adjuster screw to obtain the correct preload 0.7-1.7 N·m (6-15 in. lbs.). Remover/Installer, Steering Plug C-4381NOTE: To increase the preload turn the screwCLOCKWISE. (8) Prevent the adjuster screw from turning whiletightening adjuster lock nut. Tighten the adjusterlock nut to 49 N·m (36 ft. lbs.).SPECIFICATIONSPOWER STEERING GEAR Remover, Pitman Arm C-4150ASteering Gear Type . . . . . . . . . . . . . . . . . . . . . Recirculating BallGear Ratio RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1 LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1Worm Shaft Bearing Preload . . . . . . . . . . 0.45–1.13 N·m (4–10 in. lbs.)Pitman Shaft Overcenter Drag New Gear (under 400 miles) . . . . . 0.45–0.90 N·m (4–8 in. lbs.) + Worm Shaft Preload Remover/Installer Steering Rack Piston C-4175 Used Gear (over 400 miles) . . . . . . . . 0.5–0.6 N·m (4–5 in. lbs.) + Worm Shaft Preload
    • STEERING WHEEL PULLERXJ STEERING 19 - 21 STEERING COLUMN INDEX page pageGENERAL INFORMATION SPECIFICATIONS STEERING COLUMN . . . . . . . . . . . . . . . . . . . . 21 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 23REMOVAL AND INSTALLATION STEERING COLUMN . . . . . . . . . . . . . . . . . . . . 21GENERAL INFORMATIONSTEERING COLUMN The standard non-tilt and tilt steering column hasbeen designed to be serviced as an assembly. The keycylinder, switches, clock spring, trim shrouds andsteering wheel are serviced separately. The column is mounted to the column supportbracket studs and secured by four nuts. The columnis connected to the steering gear by a one piece col-lapsible shaft with a coupler at each end. The cou-plers secure the shaft to the steering column andsteering gear.REMOVAL AND INSTALLATION Fig. 1 Steering WheelSTEERING COLUMN (6) Remove knee blocker cover and knee blocker,WARNING: BEFORE SERVICING THE STEERING Refer to Group 8E Instrument Panel Systems.COLUMN THE AIRBAG SYSTEM MUST BE DIS- (7) Remove screws from the lower column shroudARMED. REFER TO GROUP 8M RESTRAINT SYS- (Fig. 3) and remove lower shroud.TEMS FOR SERVICE PROCEDURES. FAILURE TO (8) Remove the steering coupler bolt and columnDO SO MAY RESULT IN ACCIDENTAL DEPLOY- mounting nuts (Fig. 4) then lower column.MENT OF THE AIRBAG AND POSSIBLE PERSONAL (9) Remove upper column shroud (Fig. 3).INJURY. (10) Disconnect and remove the wiring harness from the column (Fig. 5).REMOVAL NOTE: If vehicle is equipped with automatic trans- (1) Position front wheels straight ahead. mission, remove shifter interlock cable. Refer to (2) Remove negative ground cable from the bat- Group 21 Transmission and Transfer Case for pro-tery. cedure. (3) Remove the airbag, refer to Group 8MRestraint Systems for service procedures. (11) Remove column. (4) Remove the steering wheel with an appropriate (12) Remove switches and clock spring, refer topuller (Fig. 1). Group 8 Electrical for service procedures. (13) Remove nut and bolt from the upper columnCAUTION: Ensure the puller bolts are fully engaged mounting bracket on non-tilt column. Remove theinto the steering wheel before attempting to remove bracket from the column.the wheel. Failure to do so may damage the steer-ing wheel. INSTALLATION (1) Install upper column mounting bracket on non- (5) Turn ignition cylinder to the on position and tilt column. Install the mounting bolt and tighten theremove cylinder by pressing release through lower nut to 17 N·m (150 in. lbs.).shroud access hole (Fig. 2).
    • UPPER SHROUD LOWER SHROUD STEERING COLUMN MOUNTING NUTS LOWER SHROUD COUPLER BOLT RELEASE HOLE ACCESS COLUMN NESS HAR- STEERING COLUMN INTERLOCK CABLE19 - 22 STEERING XJREMOVAL AND INSTALLATION (Continued) Fig. 2 Key Cylinder Release Access Hole Fig. 5 Steering Column Harness (2) Install switches and clock spring, refer to Group 8 Electrical for service procedures. (3) Align and install column into the steering cou- pler. (4) Install column harness and connect harness to switches. NOTE: If vehicle is equipped with automatic trans- mission install shifter interlock cable. Refer to Group 21 Transmission and Transfer Case for pro- cedure. (5) Install upper column shrouds. (6) Install column onto the mounting studs. (7) Install mounting nuts and tighten to 23 N·m (17 ft. lbs.). Fig. 3 Column Shrouds (8) Install steering column coupler bolt and tighten to 49 N·m (36 ft. lbs.). (9) Install lower column shroud and install mount- ing screws. (10) Install ignition cylinder. (11) Install knee blocker and knee blocker cover, Refer to Group 8E Instrument Panel Systems. (12) Install steering wheel and tighten nut to 54 N·m (40 ft. lbs.). (13) Install airbag, refer to Group 8M Restraint Systems for service procedures. (14) Install negative battery terminal. Fig. 4 Tilt Steering Column Mounting
    • XJ STEERING 19 - 23SPECIFICATIONSTORQUE CHARTDESCRIPTION TORQUETilt Steering Column Steering Wheel Nut . . . . . . . . . 54 N·m (40 ft. lbs.) Mounting Nuts . . . . . . . . . . . . 23 N·m (17 ft. lbs.) Coupler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)Non-Tilt Steering Column Steering Wheel Nut . . . . . . . . . 54 N·m (40 ft. lbs.) Mounting Nuts . . . . . . . . . . . . 23 N·m (17 ft. lbs.) Coupler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.) Upper Bracket Nut . . . . . . . . 17 N·m (150 in. lbs.)
    • DRAG LINK PITMANARM STEERING DAMPENER TIE ROD ADJUSTMENT SLEEVE FWD19 - 24 STEERING XJ STEERING LINKAGE INDEX page pageGENERAL INFORMATION STEERING DAMPER . . . . . . . . . . . . . . . . . . . . 26 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 24 TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25SERVICE PROCEDURES SPECIFICATIONS STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 24 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 26REMOVAL AND INSTALLATION SPECIAL TOOLS DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 27 PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 26GENERAL INFORMATION SERVICE PROCEDURESSTEERING LINKAGE STEERING LINKAGE The steering linkage consist of a pitman arm, draglink, tie rod, tie rod ends and a steering damper (Fig. NOTE: If any steering components are replaced or1) and (Fig. 2). The service procedures and torque serviced an alignment must be performed, tospecifications are the same for LHD and RHD vehi- ensure the vehicle meets all alignment specifica-cles. tions.CAUTION: Components attached with a nut and The tie rod end and ball stud seals should becotter pin must be torqued to specification. Then if inspected during all oil changes. If a seal is damaged,the slot in the nut does not line up with the cotter it should be replaced. Before installing a new seal,pin hole, tighten nut until it is aligned. Never loosen inspect ball stud at the throat opening. Check forthe nut to align the cotter pin hole. lubricant loss, contamination, ball stud wear or cor- rosion. If these conditions exist, replace the tie rod. A replacement seal can be installed if lubricant is in Fig. 1 Steering Linkage—LHD
    • CLAMP STEERING MENTNERC-3894–A TIE-ROD END ADJUST- TIE ROD MENT ADJUST- SLEEVEDAMP- LINK PULLER SLEEVE TOOL DRAG SEAL DRAGCLAMPS LINK FWD PITMAN ARM TIE ROD CLAMPXJ STEERING 19 - 25SERVICE PROCEDURES (Continued) Fig. 2 Steering Linkage—RHDgood condition. Otherwise, a complete replacement (2) Loosen the ball studs with a puller tool toball stud end should be installed. remove the tie rod. (3) Loosen clamp bolts and unthread the tie rod end from the tube.REMOVAL AND INSTALLATION INSTALLATIONTIE ROD (1) Thread the tie rod end into the tube and posi- tion the clamp to it’s original position (Fig. 4).CAUTION: Use a Puller tool C-3894-A for tie rod Tighten the clamp bolts to 27 N·m (20 ft. lbs.).removal. Failure to use this tool could damage theball stud and seal (Fig. 3). Fig. 4 Tie Rod/Drag Link Clamps Fig. 3 Ball Stud Puller (2) Install the tie rod on the drag link and steering knuckle. Install the retaining nuts.REMOVAL (3) Tighten the ball stud nut on the steering (1) Remove the cotter pins and nuts at the tie rod knuckle to 47 N·m (35 ft. lbs.). Tighten the ball studball studs and drag link. nut to drag link to 88 N·m (65 ft. lbs.). Install new cotter pins.
    • WRENCH ARM PITMAN SPECIAL C-4150-A TOOL19 - 26 STEERING XJREMOVAL AND INSTALLATION (Continued)PITMAN ARM INSTALLATION (1) Install the drag link onto steering knuckle andREMOVAL pitman arm. (1) Remove the cotter pin and nut from the drag (2) Install nut at steering knuckle and tighten tolink at the pitman arm. 47 N·m (35 ft. lbs.). Install new cotter pins. (2) Remove the drag link ball stud from the pit- (3) Install nut at pitman arm and tighten to 75man arm with a puller. N·m (55 ft. lbs.). Install new cotter pins. (3) Remove the nut and washer from the steering (4) Install tie rod onto drag link and install nut.gear shaft. Mark the pitman shaft and pitman arm Tighten nut to 75 N·m (55 ft. lbs.) and install newfor installation reference. Remove the pitman arm cotter pins.from steering gear with Puller C-4150-A (Fig. 5). (5) Install steering damper onto drag link and install nut. Tighten nut to 75 N·m (55 ft. lbs.) and install a new cotter pin. STEERING DAMPER REMOVAL (1) Remove the steering damper retaining bolt from the axle bracket. (2) Remove the cotter pin and nut from the ball stud at the drag link. (3) Remove the steering damper ball stud from the drag link with Puller C-3894-A. INSTALLATION (1) Install steering damper onto the axle bracket and drag link. (2) Install steering damper bolt in axle bracket and tighten nut to 75 N·m (55 ft. lbs.). (3) Install ball stud nut at the drag link and tighten nut to 75 N·m (55 ft. lbs.). Install a new cot- ter pin. Fig. 5 Pitman Arm Puller SPECIFICATIONSINSTALLATION (1) Align and install the pitman arm on steering TORQUE CHARTgear shaft. (2) Install the washer and nut on the shaft and DESCRIPTION TORQUEtighten nut to 251 N·m (185 ft. lbs.). Pitman Arm (3) Install drag link ball stud to pitman arm Shaft . . . . . . . . . . . . . . . . . . 251 N·m (185 ft. lbs.)install nut and tighten to 74 N·m (55 ft. lbs.). Install Drag Linka new cotter pin. Ball Studs . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.) Clamp . . . . . . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)DRAG LINK Tie Rod Ends Ball Studs . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)REMOVAL Clamp . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft. lbs.) (1) Remove cotter pins and nuts from drag link Tie Rod (2) Remove the steering damper ball stud from the Ball Stud . . . . . . . . . . . . . . . . . 88 N·m (65 ft. lbs.)drag link. Steering Damper (3) Remove tie rod from drag link Frame . . . . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.) (4) Remove drag link from the steering knuckle Drag Link . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)and pitman arm.
    • XJ STEERING 19 - 27SPECIAL TOOLSSTEERING LINKAGE Puller C-3894–A Remover Pitman C-4150A