Jeep Wrangler/YJ 1987-1995 Repair Guide

Power Steering Gear

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REMOVAL & INSTALLATION



1987-91 Vehicles

See Figure 1, 2, 3, 4, 5, 6 and 7



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Fig. Fig. 1: Steering gear mounting

  1. Place the wheels in a straight-ahead position.
  2.  
  3. Place a drain pan under the steering gear.
  4.  
  5. Disconnect the hoses at the gear. Secure the hose ends in an upward position, higher than the gear. Cap the open ends.
  6.  
  7. Disconnect the intermediate shaft from the steering gear shaft.
  8.  
  9. Raise and support the front end on jackstands.
  10.  
  11. Matchmark the Pitman arm and shaft.
  12.  
  13. Disconnect the center link from the Pitman arm.
  14.  
  15. Remove the stabilizer bar.
  16.  
  17. Remove the Pitman arm nut and washer. Using a puller, remove the Pitman arm.
  18.  
  19. Remove the mounting bolts and remove the gear.
  20.  

To install:
  1. Position the gear and install the mounting bolts. Torque the steering gear-to-frame bolts to 65-78 ft. lbs. (88-108 Nm).
  2.  
  3. Install the Pitman arm, nut, and washer. Torque the Pitman arm nut to 185 ft. lbs. (251 Nm).
  4.  
  5. Install the stabilizer bar. Torque the stabilizer bar-to-frame bolts to 30 ft. lbs. (41 Nm); the stabilizer bar-to-link nuts to 45 ft. lbs. (61 Nm).
  6.  
  7. Connect the center link to the Pitman arm. Torque the center link-to-Pitman arm nuts to 35 ft. lbs. (47 Nm).
  8.  
  9. Connect the intermediate shaft to the steering gear shaft. Torque the intermediate shaft pinch bolt to 33 ft. lbs. (45 Nm)
  10.  
  11. Connect the hoses at the gear.
  12.  

1992-95 Vehicles

  1. Place the wheels in the straight-ahead position.
  2.  
  3. Disconnect and cap the power steering lines from the steering gear.
  4.  
  5. Remove the column coupler shaft from the gear.
  6.  
  7. Matchmark the Pitman arm to the gear and remove the Pitman arm.
  8.  
  9. Remove the steering gear retaining bolts and remove the gear.
  10.  

To install:
  1. Align the column coupler shaft to the steering gear.
  2.  
  3. Position the steering gear and bracket on the frame rail and install the bolts. Torque the bolts to 78 ft. lbs. (105 Nm).
  4.  
  5. Align and install the Pitman arm.
  6.  
  7. Connect the power steering lines.
  8.  
  9. Fill the power steering reservoir to the proper level with fluid and bleed the system.
  10.  

ADJUSTMENT



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


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Fig. Fig. 2: Loosen the adjuster locknut on the gear by driving it counterclockwise



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Fig. Fig. 3: Matchmark the housing to the adjuster plug hole



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Fig. Fig. 4: Measure back (counterclockwise) and scribe a second mark



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Fig. Fig. 4: Use a spanner wrench to align the adjuster plug with the second mark

  1. Mount the gear assembly in a vise.
  2.  
  3. Torque the adjuster plug to 20 ft. lbs. (27 Nm).
  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) 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. (115 Nm). Do not allow the adjuster to turn.
  12.  
  13. Rotate the stub shaft clockwise to its stop, then back 1 / 4 turn.
  14.  
  15. Using a torque wrench of no more than 50 inch lbs. (6 Nm) 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. (0.5-1.0 Nm).
  16.  
  17. If the torque cannot be adjusted within these limits, the gear will have to be rebuilt.
  18.  

Pitman Shaft Overcenter

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Fig. Fig. 6: Centered steering gear



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Fig. Fig. 7: Check the overcenter rotational torque with an inch lbs. wrench

  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 stub shaft from stop-to-stop.
  6.  
  7. Rotate the shaft back 1 / 2 the number of turns. At this point the flat surface of the stub shaft 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. (6 Nm) 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:
    1. Adjustment for 1987-91 vehicles is: the recorded reading plus 4-8 inch lbs. (0.5-0.9 Nm) for new gears or the previously recorded reading plus 4-5 inch lbs. (0.5-0.6 Nm) for used gears. BUT, on both either new or used gears, DO NOT exceed 18 inch lbs. (2 Nm) for a combined total adjustment.
    2.  
    3. Adjustment for 1992-95 vehicles is the recorded reading plus 6-10 inch lbs. (0.7-1.0 Nm).
    4.  

  14.  
  15. Tighten the adjuster screw locknut to 20 ft. lbs. (27 Nm) while holding the adjuster screw for 1987-92 vehicles. Tighten the jam nut to 36 ft. lbs. (49 Nm) for 1993-95 vehicles.
  16.  
  17. Install the gear.
  18.  

 
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