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Steering Gear: Reassembly

  1. Lubricate all parts with power steering fluid before reassembly. Install lower thrust bearing and washers on worm shaft. See Fig 1 .
    NOTE: If conical thrust washers are used, ensure tapered surfaces are parallel to each other and cupped sides face toward stub shaft.
    Fig 1: Exploded View Of Valve Body & Worm Shaft Assembly (Except 1999 Grand Cherokee)
    G90A15198Courtesy of CHRYSLER CORP.
  2. Place worm shaft in valve body. Install NEW "O" ring in valve body. Align notch in valve body with pin in worm shaft. Install valve body and worm assembly into housing. Installation is correct when fluid return port in housing is fully visible.
  3. Place seal protector over stub shaft. Using NEW "O" ring, install adjuster plug until it seats against valve body. Remove seal protector from housing.
  4. Loosely install adjuster plug lock nut. Insert rack piston (with arbor to retain recirculating balls) into housing. Align worm and rack piston. Turn stub shaft clockwise to engage worm. Maintain pressure on arbor until worm is fully engaged.
  5. Rotate stub shaft clockwise to align middle rack groove in rack piston with center of sector shaft roller bearing. Remove arbor. Install a NEW side cover seal or gasket.
  6. Thread side cover onto adjuster screw until bottomed. Back off 1/2 turn. Install sector shaft so center gear tooth meshes with center groove in rack piston. Install cover attaching bolts.
  7. Install adjuster lock nut halfway onto sector shaft. Install piston and plug into rack piston. Install housing end cover "O" ring, end plug and retainer ring. Adjust worm shaft thrust bearing preload and sector shaft over-center preload. See WORM SHAFT THRUST BEARING PRELOAD  and SECTOR SHAFT OVER-CENTER PRELOAD  under ADJUSTMENTS.


CAUTION: Pitman shaft will not clear the housing if shaft is not centered.
  1. Coat sector shaft oil seal and backup washers with special grease supplied with new seal. Install NEW oil seal in gear housing. Install plastic backup washer with inner lip facing towards oil seal. Install metal backup washer and retainer ring in gear housing. Apply special grease to dust seal and install dust seal. Lubricate NEW "O" ring, teflon rings and rack piston/valve assembly with power steering fluid. Install rack piston/valve assembly into gear housing.
  2. Install upper sector shaft bearing. Turn gear over and install lower sector shaft bearing. Ensure upper and lower sector shaft bearings are fully seated. Install NEW "O" ring on side cover. Install sector shaft into gear housing. Install side cover and tighten bolts to 46 ft. lbs. (62 N.m). Grease stub shaft seal with special grease. Install NEW "O" rings in stub shaft housing. Install stub shaft housing on steering gear. Tighten housing bolts to 46 ft. lbs (62 N.m)
  3. Perform over-center rotation torque adjustment. See Figure . See SECTOR SHAFT OVER-CENTER PRELOAD  in ADJUSTMENTS.
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