Jeep CJ/Scrambler 1971-1986 Repair Guide

Power Steering Gear

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7 and 8

1972-75 Models
  1. Disconnect the hoses at the gear and raise them above the pump to prevent fluid loss.
  2.  
  3. Remove the pinch bolt from the lower flange.
  4.  
  5. Remove the pitman arm nut and lockwasher, and remove the pitman arm with a puller.
  6.  
  7. Unbolt and remove the pump.
  8.  
  9. Installation is the reverse of removal. Torque the pitman arm nut to 160-210 ft. lbs. and the gear-to-frame bolts to 55 ft. lbs.
  10.  



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Fig. Fig. 1: Exploded view of the power steering gear



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Fig. Fig. 2: Marking the power steering gear housing to the location of the adjuster



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Fig. Fig. 3: Making the second mark on the housing



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Fig. Fig. 4: Measuring the worm shaft bearing preload on the power steering gear

1976-86 Models
  1. Disconnect the hoses at the gear and raise them above the pump to prevent fluid loss.
  2.  
  3. Remove the clamp bolt and nut attaching the intermediate shaft coupling to the steering gear stub shaft and disconnect the intermediate shaft.
  4.  
  5. Mark the pitman shaft and arm for alignment. Remove the pitman nut and lockwasher and remove the pitman arm with a puller.
  6.  
  7. Raise the left side of the vehicle slightly to relieve tension from the spring. Support with a jackstand under the frame.
  8.  
  9. Remove the three lower steering gear mounting bracket-to-frame bolts.
  10.  
  11. Remove the two steering gear-to-crossmember upper bolts. Remove the gear and brackets as an assembly.
  12.  
  13. Remove the brackets from the gear.
  14.  

Prior to installation, all bolts must be coated with Loctite® 271 or its equivalent.

  1. Position the mounting brackets on the gear and torque the bolts to 70 ft. lbs.
  2.  
  3. Align and connect the intermediate shaft coupling to the steering gear stub shaft.
  4.  
  5. Position the steering gear on the frame and crossmember. Install and tighten the bolts to 55 ft. lbs.
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the intermediate shaft coupling-to-steering gear stub shaft clamp bolt and nut. Tighten the nut to 45 ft. lbs.
  10.  
  11. Align and install the pitman arm, nut and lockwasher. Torque the nut to 185 ft. lbs. Stake the nut in two places.
  12.  
  13. Connect the hoses. Torque the hose connections to 25 ft. lbs.
  14.  

POWER STEERING GEAR ADJUSTMENTS



The gear must be adjusted off the vehicle. All adjustments must be made in the sequence described below. Worm bearing preload is always adjusted first!

Worm Bearing Preload Adjustment
  1. Mount the gear assembly in a vise.
  2.  
  3. Torque the adjuster plug to 20 ft. lbs.
  4.  
  5. Mark the gear housing in line with one of the adjuster plug holes.
  6.  
  7. Measure counterclockwise 3 / 16 - 1 / 4 in. (5-6mm) from the first mark on models through 1979; 1 / 2 in. (13mm) from the first mark on 1980-86 models and make another mark.
  8.  
  9. Turn the adjuster plug counterclockwise to align the hole with the second mark.
  10.  
  11. Hold the adjuster plug and torque the locknut to 85 ft. lbs. Do not allow the adjuster to turn.
  12.  
  13. Turn the stubshaft clockwise to its stop, then back 1 / 4 turn.
  14.  
  15. Using a torque wrench of no more than 50 inch lbs. capacity and a 12 point deep socket, check the rotating torque at the splined end of the stub shaft at or near a vertical position. Torque should be 4-10 inch lbs.
  16.  
  17. If the torque cannot be adjusted within these limits, the gear will have to be rebuilt.
  18.  

Pitman Shaft Overcenter Adjustment
  1. Loosen the adjuster screw locknut.
  2.  
  3. Turn the adjuster screw counterclockwise until the screw is fully extended. Turn the screw back in one full turn.
  4.  
  5. Count the number of turns to rotate the stubshaft from stop-to-stop.
  6.  
  7. Turn the shaft back 1 / 2 the number of turns. At this point the flat surface of the stubshaft should be upward and the master spline on the pitman shaft should be aligned with the adjuster screw.
  8.  
  9. Install a 50 inch lbs. torque wrench and deep 12 point socket on the splined end of the stub shaft. Place the torque wrench in a vertical position.
  10.  
  11. Rotate the torque wrench 45 degrees to each side and record the highest torque at or near center. Record this reading.
  12.  
  13. Adjust the torque by turning the adjuster screw clockwise. Adjustment is: the recorded reading plus 4-8 inch lbs. for new gears, but not exceeding 14. inch lbs. total; the previously recorded reading plus 4-5 inch lbs. for used gears, but not exceeding 14 inch lbs. combined total.
  14.  
  15. Tighten the adjuster screw locknut to 35 ft. lbs. while holding the adjuster screw.
  16.  
  17. Install the gear.
  18.  



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Fig. Fig. 5: Stubshaft (1) position with the gear centered. (2) is the gear housing



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Fig. Fig. 6: Pitman shaft master spline (3) position with the gear centered. (4) is the adjusting screw



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Fig. Fig. 7: Measuring the piitman shaft overcenter torque drag



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Fig. Fig. 8: You must hold the locknut while turning the adjusting screw, to prevent it from turning

 
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