Replacing the gearbox (also known as the steering gear or steering box) on a Jeep Cherokee XJ can be a complex task that requires attention to detail and a solid understanding of vehicle mechanics. click here for more details on the download manual…..
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Below is a step-by-step guide detailing every component and step necessary for a successful gearbox replacement.
### Tools and Equipment Needed:
1. **Basic Hand Tools:**
– Socket set (including deep sockets)
– Wrenches (both standard and metric)
– Screwdrivers (flathead and Phillips)
– Torque wrench
– Pliers
– Hammer
– Pry bar
2. **Specialized Tools:**
– Steering wheel puller (optional but helpful)
– Pitman arm puller
– Ball joint separator (if needed)
– Gearbox alignment tool (if available)
3. **Replacement Parts:**
– New steering gearbox
– New pitman arm (recommended)
– New power steering fluid
– New steering gear mounting bolts (if necessary)
4. **Safety Equipment:**
– Jack and jack stands
– Wheel chocks
– Gloves and safety glasses
### Step-by-Step Guide:
#### 1. Preparation:
– **Safety First:** Park the Jeep on a flat, stable surface and engage the parking brake. Place wheel chocks behind the rear wheels.
– **Disconnect Battery:** Disconnect the negative terminal of the battery to prevent any electrical issues.
#### 2. Raise the Vehicle:
– **Jack Up the Front:** Use a jack to lift the front of the Jeep and secure it on jack stands for safety.
#### 3. Remove the Front Wheels (Optional):
– **Wheels Removal:** This step can be optional, but removing the front wheels provides better access. Use a lug wrench to remove the lug nuts and take off the wheels.
#### 4. Disconnect Steering Components:
– **Remove the Pitman Arm:**
– Use a pitman arm puller to separate the pitman arm from the steering gearbox. If you are not replacing the arm, take care to avoid damaging it.
– **Disconnect the Steering Shaft:**
– Locate the steering shaft that connects the steering wheel to the gearbox. There may be a pinch bolt or set screw that needs to be removed. If applicable, use a steering wheel puller to help remove the shaft.
– **Remove Power Steering Lines:**
– Locate the high-pressure and low-pressure power steering lines connected to the gearbox. Use a wrench to loosen and remove these lines. Be prepared for some fluid spillage; have a catch pan ready.
#### 5. Remove the Gearbox:
– **Unbolt the Gearbox:**
– Locate the mounting bolts securing the gearbox to the frame. Typically, there are four bolts. Use a socket and ratchet to remove these bolts.
– **Remove the Gearbox:**
– Gently maneuver the gearbox out of its mounting position. It may require some twisting and tilting to get it out.
#### 6. Install the New Gearbox:
– **Position the New Gearbox:**
– Place the new steering gearbox into position. Make sure that it is oriented correctly, matching the position of the old unit.
– **Bolt the Gearbox in Place:**
– Reinstall the mounting bolts and tighten them to the manufacturer’s specifications using a torque wrench.
#### 7. Reconnect Steering Components:
– **Reconnect Power Steering Lines:**
– Reattach the high-pressure and low-pressure lines to the new gearbox. Ensure they are tight to prevent leaks.
– **Reconnect the Steering Shaft:**
– Slide the steering shaft back onto the gearbox and secure it with the pinch bolt or set screw.
– **Reinstall the Pitman Arm:**
– If you removed the pitman arm, reinstall it onto the gearbox. Ensure it is properly seated
and secured.
#### 8. Reinstall Front Wheels (if removed):
– **Put Wheels Back On:** Place the front wheels back onto the hubs and hand-tighten the lug nuts.
#### 9. Lower the Vehicle:
– **Remove Jack Stands:** Carefully lower the vehicle back to the ground using the jack.
#### 10. Refill Power Steering Fluid:
– **Add Fluid:** Check the power steering fluid reservoir and fill it with the appropriate fluid as recommended in your owner’s manual.
#### 11. Reconnect the Battery:
– **Reconnect Terminal:** Reconnect the negative terminal of the battery.
#### 12. Test the System:
– **Start the Engine:** Start the Jeep and let it idle. Turn the steering wheel from lock to lock to circulate the new fluid and remove any air from the system.
– **Check for Leaks:** Inspect the gearbox and the power steering lines for any leaks. If everything looks good, take the Jeep for a short test drive to ensure proper function.
### Conclusion:
Replacing the gearbox on a Jeep Cherokee XJ requires careful attention to detail and a systematic approach. Following the steps outlined above will help ensure a successful replacement. Always consult the vehicle’s service manual for specific torque specifications and additional details relevant to your particular model year. If you’re not comfortable with any part of this process, consider seeking professional assistance to ensure safety and proper installation.
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