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

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

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

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

—

Power Steering Gear

Gear to Frame Bolts

—

Power Steering Gear

Pitman Shaft Nut

251

185

—

Power Steering Gear

Pressure Line

—

Power Steering Gear

Return Line

—

SPECIAL TOOLS

POWER STEERING GEAR

Remover, Pitman Arm C-4150A

19 - 16

GEAR

GEAR (Continued)

Content .. 472 473 474 475 ..