Theres a precedure for adjusting the box. Let me find it in the FSM.
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
WORM THRUST BEARING PRELOAD
NOTE: Off center torque (180 to 360 degrees from
gear center) = 0.4 to 0.8 Nm (3.5 in-lb to 7.0 in-lb)
This torque is set in the assembly plant and canít
be adjusted in the field
OVER-CENTER ROTATING TORQUE
(1) Mount the gear carefully into a vise.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Rotate the input shaft with a crows foot socket
from stop to stop and count the number of turns.
(3) Starting at either stop, turn the input shaft
back 1/2 the total number of turns. This is the center
of the gear travel.
(4) Loosen the adjuster plug locknut.
(5) Place the torque wrench in the vertical position
on the input shaft. Rotate the wrench 50 degrees
each side of the center and record the highest rotational
torque in this range (Fig. 6). This is the Over-
Center Rotating Torque.
NOTE: The input shaft must rotate smoothly without
sticking or binding.
(6) The Over-Center Rotating Torque should be
0.53-0.93 N∑m (4.5 - 8 in. lbs.) higher in addition to
the off center torque from above (Fig. 6). than the
Preload Rotating Torque.
(7) If an adjustment to the Over-Center Rotating
Torque is necessary, first loosen the adjuster lock
nut. Then turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) increases torque,
(CLOCKWISE) reduces torque (Fig. 7).
(8) Remeasure Over-Center Rotating Torque. If
necessary turn the adjuster screw and repeat measurement
until correct Over-Center Rotating Torque
is reached (Fig. 7).
NOTE: To increase the Over-Center Rotating Torque
turn the screw COUNTERCLOCKWISE.
(9) Prevent the adjuster screw from turning while
tightening adjuster lock nut (Fig. 7). Tighten the
adjuster lock nut to 65 N∑m (48 ft. lbs.).
2004 Black Rubicon w/ 5 spd
RE 3.5 SuperFlex & Front Trackbar / JKS 1.25" BL & MML / 35x12.5 MTRs on 15x8 AR-23s / Currie Anti-Rock / Jeeperman Bumpers / Rokmen Sliders / York OBA / Harbor Freight 8k Winch