Jeep Wrangler/YJ 1987-1995 Repair Guide

Manual Steering Gear

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REMOVAL & INSTALLATION



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Steering gear mounting

  1. Remove the intermediate shaft-to-wormshaft coupling clamp bolt and disconnect the intermediate shaft.
  2.  
  3. Raise and support the front end on jackstands.
  4.  
  5. Disconnect the center link from the Pitman arm.
  6.  
  7. Remove the front stabilizer bar.
  8.  
  9. Remove the Pitman arm nut and washer.
  10.  
  11. Matchmark the Pitman arm and shaft, then remove the Pitman arm with a puller, such as J-6632-01 or equivalent.
  12.  
  13. Remove the mounting bolts and the gear.
  14.  

To install:
  1. Position the gear on the frame and install the mounting bolts. Torque the gear-to-frame bolts to 65-78 ft. lbs. (88-108 Nm).
  2.  
  3. Install the Pitman arm. Torque the Pitman arm nut to 185 ft. lbs. (251 Nm) and stake it in two places.
  4.  
  5. Install the front stabilizer bar. Torque the stabilizer bar-to-frame bolts to 55 ft. lbs. (75 Nm). Torque the stabilizer bar-to-link bolts to 27 ft. lbs. (37 Nm).
  6.  
  7. Connect the center link to the Pitman arm. Torque the center link-to-Pitman arm nut to 55 ft. lbs. (75 Nm).
  8.  
  9. Install the intermediate shaft-to-wormshaft coupling clamp bolt. Torque the bolt to 33 ft. lbs. (45 Nm).
  10.  

ADJUSTMENT



See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Cross-sectional view of a common manual steering gear


WARNING
Adjustments must be made in the order given. Failure to following sequence could result in damage to the gear.

Worm Bearing Preload
  1. Check that the steering gear mounting bolts are properly torqued.
  2.  
  3. If necessary, remove the front stabilizer bar.
  4.  
  5. Matchmark and remove the Pitman arm.
  6.  
  7. Remove the horn button and cover. Attach an inch-pound torque wrench and socket to steering wheel nut, then turn the shaft to the extreme right or left, gently, until you hit the stop. Rotate it back from the stop 1 / 2 turn.
  8.  
  9. Turn the torque wrench through a 90º arc and check the torque reading. Torque should be 5-8 inch lbs. If not, proceed with Steps 4 and 5.
  10.  
  11. Loosen the adjuster locknut. Tighten the worm bearing adjuster until the torque wrench shows 5-8 inch lbs. within 1 / 2 turn of either extreme.
  12.  
  13. Tighten the adjuster locknut to 50 ft. lbs. (68 Nm) and recheck the torque reading on the shaft.
  14.  

Pitman Shaft Overcenter
  1. With the Pitman shaft removed, rotate the wormshaft from stop-to-stop and count the number of turns.
  2.  
  3. Rotate the wormshaft back from the stop, 1 / 2 the total number of turns.
  4.  
  5. Install an inch-pound torque wrench and socket on the steering wheel nut. Check the rotating torque as the shaft passes over the center point of travel. Overcenter torque should be equal to the worm bearing preload plus 4-10 inch lbs. (0.5-1.0 Nm), but not more than 18 inch lbs. (2 Nm). If not, proceed with steps 4-6.
  6.  
  7. Loosen the adjuster locknut.
  8.  
  9. Rotate the shaft over center and tighten the adjuster as necessary.
  10.  
  11. Hold the adjuster screw and tighten the locknut to 25 ft. lbs. (34 Nm). Do not allow the adjuster to turn, or the adjustment will have to be made over again!
  12.  
  13. Install the Pitman arm, torque it to 185 ft. lbs. (251 Nm) and stake it in two places.
  14.  

 
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