Power Steering Gear Disassembly - Jeep 1979 CJ-5 Technical & Service Manual

21-22
POWER STEERING GEAR AND PUMP
(a) Apply Loctite or equivalent material to all
steering gear mounting bracket attaching bolts.
(b) Position upper and lower mounting brackets
on steering gear and install bracket attaching bolts.
Tighten bolts to 70 foot-pounds (95 N«m) torque.
(c) Apply Loctite or equivalent material to
steering gear mounting bracket-to-frame and cross-
member attaching bolts.
(d) Align and connect intermediate shaft cou-
pling to steering gear stub shaft.
(e) Position assembled steering gear and
mounting brackets on frame and crossmember and in-
stall attaching bolts. Tighten all attaching bolts to 55
foot-pounds (75 N*m) torque.
(f) Remove support stands and lower vehicle.
. (g) Install intermediate shaft coupling-to-steer-
ing gear stub shaft clamp bolt and nut. Tighten nut to 45
foot-pounds (61 N*m) torque.
(3) On all models, align and install pitman arm on
pitman shaft using reference marks made during
removal.
(4) Install replacement pitman shaft lockwasher
and nut. Tighten nut to 185 foot-pounds (251 N»m)
torque and stake nut in two places to retain it.
(5) Connect pressure and return hoses to steering
gear. Tighten hose fittings to 25 foot-pounds (34 N*m)
torque.
(6) Check and adjust fluid level as necessary. Refer
to Fluid Level and Initial Operation.
STEERING GEAR DISASSEMRLY
N O T E : In most cases, complete disassembly of the
power steering gear will not be necessary. Only those
subassemblies that have malfunctioned should be dis-
assembled. In addition, steering gear repair operations
must always be performed on a clean work bench.
Cleanliness is very important. The work bench, tools,
and steering gear component parts must be kept clean at
all times to avoid a problem recurring after assembly.
Thoroughly clean the gear exterior with solvent before
disassembly. Refer to Figure 2L-11 for parts nomencla-
ture and disassembly/assembly sequence during service
operations.
(1) Drain fluid from gear.
(2) Cap all openings in gear and clean gear exterior
thoroughly.
(3) Mount steering, gear in vise so pitman shaft
points downward. Clamp unmachined housing boss por-
tion of gear in vise only (fig. 2L-12).
(4) Rotate end plug retaining ring until one end of
ring is aligned with hole in side of housing. Unseat ring
using punch inserted through hole in housing and re-
move ring using screwdriver (fig. 2L-13).
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Fig. 2 U 2 l i n t i i i Slisrli| Gear li Vise
Fig. ZL-13 End Plug Retaining ling Removal
(5) Remove end plug. Install 12-point deep socket
and ratchet handle on stub shaft and slowly rotate shaft
counterclockwise until rack piston forces end plug out of
housing.
CAUTION: Do not rotate the stub shaft any farther
than necessary or the ball bearings will drop out of the
rack piston circuits. , This causes the rack piston and
pitman shaft sector teeth to disengage preventing re-
moval. If disengagement should occur, remove the side
cover and pitman shaft and reengage the teeth.