Steering Gear Removal; End Plug O-Ring Seal Replacement - Jeep 1979 CJ-5 Technical & Service Manual

2L-20 POWER STEERING GEAR AND PUMP
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CAUTION: To avoid excessive fluid loss and possible
pump damage, do not hold the gear in the full left turn
position for more than one or two seconds at a time.
(6) Stop engine and remove seals and backup wash-
ers from pitman shaft.
(7) Inspect outer diameter of seals for damage. If
scored or cut, inspect housing bore for burrs and nicks.
Remove any burrs or nicks, before installing replace-
ment seals, using crocus cloth.
(8) Inspect pitman shaft surface for roughness, pit-
ting, scoring, rust, or nicks. Clean dirt, rust corrosion
from shaft seal surfaces using crocus cloth. Replace
shaft if pitted or severely corroded.
(9) Lubricate replacement seals and shaft surfaces
with power steering fluid.
(10) Apply single layer of thin tape to pitman shaft
splines to avoid cutting seals.
(11) Insert single lip seal in bore first; then insert
backup washer (fig. 2L-10).
HOUSING B A C K U P
S I N G L E LIP D O U B L E LIP
S E A L S E A L 6 0 1 8 8
Fig. 2L-10 Pitman Shaft Seals and Backup Washers
(12) Seat single lip seal and washer using Snap Ring
Tool J-21553. Install seal and washer only far enough to
provide clearance for remaining seal, backup washer,
retaining ring, and for clearance between seals. Do not
allow seal to bottom in housing bore.
CAUTION: To ensure proper seal action, be sure to
allow enough space for clearance between the two seals.
(13) Install double lip seal and backup washer in
housing bore using tool J-21553. Install seal only far
enough into bore to allow clearance for retaining ring.
(14) Install retaining ring using Snap Ring Tool J-
4245. Be sure ring is fully seated.
(15) Install pitman arm on shaft and install replace-
ment pitman arm nut and lockwasher. Tighten nut to
185 foot-pounds (251 N*m) torque. Stake nut in two
places to retain it.
(16) Lower vehicle.
(17) Fill power steering pump reservoir to correct
level with power steering fluid.
(18) Start and idle engine for at least three minutes.
Do not turn steering wheel during this time.
(19) Turn steering wheel left and right and check for
leaks. Add additional fluid as necessary.
End Plug O-Ring Sea! Replacement
CJ Models
(1) Raise vehicle.
(2) Rotate end plug retaining ring (fig. 2L-11) until
one end of ring is positioned over hole in side of housing.
(3) Remove retaining ring by inserting punch
through hole in housing and unseating ring.
(4) Remove end plug by turning steering wheel
slowly to left until rack piston forces end plug out of
housing.
(5) Turn steering wheel back to center position.
CAUTION: Do not turn the steering wheel any farther
than necessary or the ball bearings in the rack piston
may fall out of the rack piston bearing circuit and drop
into the piston chamber.
(6) Remove and discard end plug O-ring seal.
(7) Lubricate replacement seal with power steering
fluid and install seal on end plug.
(8) Install assembled end plug and seal in housing.
(9) Install retaining ring.
(10) Lower vehicle.
(11) Check and correct power steering fluid level as
necessary.
Cherokee-Wagoneer-Truck Models
On Cherokee, Wagoneer and Truck models, the posi-
tion of the steering gear prevents on-vehicle replace-
ment of the end plug O-ring seal (fig. 2L-11).
STEERING GEAR REMOVAL > - . ,
(1) Disconnect pressure and return hoses a t gear.
Keep hoses raised to avoid excessive fluid loss and cap
hoses to prevent dirt entry.
(2) On Cherokee, Wagoneer, and Truck models, re-
move clamp bolt and nut attaching flexible coupling to
steering gear stub shaft and disengage coupling from
stub shaft.