Question1996 Jeep Cherokee Country, 4wd, 6 cyl, leaking PS fluid from the bottom of the stering gearbox (where the "pittman arm"? goes into the gearbox). What's involved in replacing the gearbox? Is there a manual or instruction document I can download from somewhere? What do we need to be watchful of when performing this repair? Thanks in advance...
AnswerClay,
Unfortunately, unless you luck out, most good service info is not free. That said, the best thing you can do is buy the factory manual for your Jeep. They're not perfect, but they're better than any others (Haynes, etc.). If you are interested, www.alldatadiy.com has a yearly subscription, per car, for $25.
As for the Steering Gear, it's relatively easy to change:
-Make sure the wheels are straight, and put a drain pan under the gearbox
-Disconnect both the pressure and the return line from the gear, and move (or bungee) them to the side
-Remove the steering column coupler shaft from the gearbox; you may need to pry open the coupler to get it to release
-Remove the Pitman Arm; this will take a Pitman Arm puller
-Remove the gear mounting bolts, while an assistant holds the gearbox, because it ain't light!
Reverse the steps to install the new gearbox. HOWEVER, if the only issue is a leaking Pitman Shaft seal, then you could just replace those seals (in-car), instead of replacing the gearbox:
-Remove the Pitman Arm with the puller
-Remove the single lip seal
-Using snap ring pliers, remove the retaining ring
-Remove both backup washers
-Start engine, and SLOWLY turn the wheel to the left -- the double-lip seal will be pushed out; turn engine off and remove it with a pocket screwdriver or pick tool
After coating the new seals with grease, reverse the steps.
Whatever you decide to do, good luck!
