Jeep Wrangler TJ. Manual — part 474
GEAR
TABLE OF CONTENTS
page
page
GEAR
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GEAR
DESCRIPTION
CAUTION: MOPAR
T
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.
The power steering system has a hydraulic pump.
The pump is a constant flow rate and displacement
vane-type pump. The pump reservoir on the 4.0L
engine is mounted to the pump body (Fig. 1)& (Fig.
2). The 2.4L engine has a remote pump reservoir
mounted to the fan shroud (Fig. 3).
The steering gear used is a straight ratio recircu-
lating ball type gear. A tilt and non-tilt column pro-
vide steering input.
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 upper end. When
the worm shaft is turned the rack piston moves. The
rack piston teeth mesh with the pitman shaft. Turn-
ing the worm shaft turns the pitman shaft, which
turns the steering linkage.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
DIAGNOSIS AND TESTING - POWER STEERING
GEAR LEAKAGE AREAS
NOTE: Do not service the Steering Gear, if the gear
is leaking it must be replaced with a new gear
assembly.
(1) Possible power steering gear leakage areas.
(Fig. 4).
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.
Fig. 1 POWER STEERING GEAR & PUMP - 4.0L
1 - POWER STEERING GEAR
2 - PRESSURE HOSE
3 - POWER STEERING RESERVOIR
4 - POWER STEERING PUMP
5 - RETURN HOSE
TJ
GEAR
19 - 13
(1) Place the front wheels in the straight ahead
position with the steering wheel centered and locked.
(2) Siphon out as much power steering fluid as
possible.
(3) Remove the bumper shield.
(4) Remove power steering hoses/tubes from steer-
ing gear.
(5) Remove the column coupler shaft from the
gear.
(6) Remove pitman arm from gear. (Refer to 19 -
STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(7) Remove the steering gear retaining bolts and
remove the gear (Fig. 5).
INSTALLATION
(1) Install steering gear on the frame rail and
tighten bolts to 95 N·m (70 ft. lbs.)
(2) Align and install the pitman arm and tighten
nut to 251 N·m (185 ft. lbs.).
(3) Align the column coupler shaft to steering gear.
Install a new coupler pinch bolt and tighten to 49
N·m (36 ft. lbs.).
Fig. 2 RHD POWER STEERING HOSES
1 - PRESSURE HOSE
2 - RETURN HOSE
3 - MOUNTING BRACKETS
4 - STEERING GEAR
Fig. 3 POWER STEERING GEAR & PUMP - 2.4L
1 - REMOTE RESERVOIR
2 - POWER STEERING PUMP
3 - PUMP MOUNT BRACKET
4 - MOUNTING BOLTS (3)
5 - PRESSURE SWITCH LOCATION
6 - PRESSURE OUTLET HOSE (GEAR TO PUMP)
7 - RETURN HOSE (RESERVOIR TO PUMP)
8 - CLAMPS
9 - STEERING GEAR
10 - INLET HOSE (RESERVOIR TO GEAR)
Fig. 4 STEERING GEAR
1 - VALVE HOUSING O-RING
2 - ADJUSTER NUT
3 - POWER STEERING LINE FITTINGS
4 - INPUT SHAFT HOUSING GASKET
5 - INPUT SHAFT SEAL
6 - PITMAN SHAFT SEAL HOUSING / COVER O-RING
Fig. 5 STEERING GEAR REMOVAL/INSTALL
1 - STEERING GEAR
2 - FRAME MOUNT
19 - 14
GEAR
TJ
GEAR (Continued)
(4) Install power steering hoses/tubes to steering
gear and tighten to 28 N·m (21 ft. lbs.).
(5) Install the bumper shield.
(6) Fill power steering system to proper level,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
ADJUSTMENTS
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
NOTE: Off center torque (180 to 360 degrees from
gear center) = 0.4 to 0.8 Nm (3.5 in-lb to 7.0 in-lb)
This torque is set in the assembly plant and can’t
be adjusted in the field
OVER-CENTER ROTATING TORQUE
(1) Mount the gear carefully into a vise.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Rotate the input shaft with a crows foot socket
from stop to stop and count the number of turns.
(3) Starting at either stop, turn the input shaft
back 1/2 the total number of turns. This is the center
of the gear travel.
(4) Loosen the adjuster plug locknut.
(5) Place the torque wrench in the vertical position
on the input shaft. Rotate the wrench 50 degrees
each side of the center and record the highest rota-
tional torque in this range (Fig. 6). This is the Over-
Center Rotating Torque.
NOTE: The input shaft must rotate smoothly with-
out sticking or binding.
(6) The Over-Center Rotating Torque should be
0.53-0.93 N·m (4.5 - 8 in. lbs.) higher in addition to
the off center torque from above (Fig. 6). than the
Preload Rotating Torque.
(7) If an adjustment to the Over-Center Rotating
Torque is necessary, first loosen the adjuster lock
nut. Then turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE)
increases
torque,
(CLOCKWISE) reduces torque (Fig. 7).
(8) Remeasure Over-Center Rotating Torque. If
necessary turn the adjuster screw and repeat mea-
surement until correct Over-Center Rotating Torque
is reached (Fig. 7).
NOTE: To increase the Over-Center Rotating Torque
turn the screw COUNTERCLOCKWISE.
(9) Prevent the adjuster screw from turning while
tightening adjuster lock nut (Fig. 7). Tighten the
adjuster lock nut to 65 N·m (48 ft. lbs.).
Fig. 6 OVER-CENTER TORQUE
1 - CROWSFOOT WRENCH
2 - INCH POUND TORQUE WRENCH
3 - STEERING GEAR
Fig. 7 OVER-CENTER ADJUSTMENT
1 - RATCHET WITH ADAPTER
2 - WRENCH
3 - CROWSFOOT WRENCH
4 - INCH POUND TORQUE WRENCH
5 - STEERING GEAR
6 - ALLEN HEAD SOCKET
TJ
GEAR
19 - 15
GEAR (Continued)
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Steering Gear
Type
Recirculating Ball
Steering Gear
Gear Ratio
15:24
Worm Shaft Bearing
Preload
0.53–.93 N·m (3.5–8 in.
lbs.)
Pitman Shaft Over-
Center Drag
New Gear (under 400
miles)
.133 N·m (1.17 in. lbs.) +
Worm Shaft Preload
Pitman Shaft Over-
Center Drag
Used Gear (over 400
miles)
.133 N·m (1.17 in. lbs.) +
Worm Shaft Preload
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Power Steering Gear
Adjustment Screw Locknut
65
48
—
Power Steering Gear
Gear to Frame Bolts
95
70
—
Power Steering Gear
Pitman Shaft Nut
251
185
—
Power Steering Gear
Pressure Line
28
21
—
Power Steering Gear
Return Line
28
21
—
SPECIAL TOOLS
POWER STEERING GEAR
Remover, Pitman Arm C-4150A
19 - 16
GEAR
TJ
GEAR (Continued)
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