Steering Gear Removal and Replace

Removal:

1. With wheels in the straight ahead position, lift front tires approximately 2 inches off ground allowing front suspension to be fully extended. Jack on the rear engine to body mount.

NOTICE: Care should be taken not to jack vehicle on exhaust system or in such a manner as to damage the underbody.

2. Open hood of vehicle, put fender covers on both front fenders and front drivers seat to prevent any damage from occurring.

FIGURE 1:

3. From inside vehicle remove the
(2) pinch bolts from the flexible coupling using a 13 mm socket. Gently separate ears of both flanges with a screw driver to allow coupling to slide up lower steering shaft (see Figure 1).

4. Using a #3 philips screw driver, remove the two bolts holding the air cleaner. Disconnect vacuum hose from connector on intake manifold and move air cleaner assembly to front left of engine compartment. Disconnect map sensor vacuum line and move out of the way.
5. Remove windshield washer solvent reservoir from bracket on fenderwell and position on cowling so as not to block access to rack and pinion gear.

6. Remove both pressure and return lines from gear using a 18 mm flare nut crowfoot wrench and 24" extension bar. Position lines to prevent fluid leakage and interference with gear removal.

7. Install shipping plugs into both pressure and return ports.

FIGURE 2:

8. Using a screw driver, pry off lock, plate using center hole from inner tie rod bolts. Dispose of lock plate - DO NOT REUSE (see Figure 2) .

9. Remove inner tie rod bolts and bolt support plate and push tie rods down out of the way. Be sure not to lose center housing flat washers that are between inner tie rod and rack and pinion boot. Use 15 mm 6-point socket (see Figure 2).
10. Using a 13 mm deep well socket, remove jam nut from lower stud on right side (passenger side). Remove fuel line retainer from stud, move retainer so it will not interfere with removal of locknut and flat washer from stud. Remove hex head bolt from top of mounting bracket.

NOTICE: Care should be taken to avoid shearing bolt head because of excessive thread locker.

11. Using a 13 mm deep well socket remove lock-nut and washer from lower stud and hex head bolt from mounting bracket.

IMPORTANT: If studs were removed during removal of mounting brackets, reinstall studs into cowl using thread Locking kit number 1052624 or equivalent must be used and studs retightened to specification.

12. Move gear forward away from firewall.

13. Remove mounting bracket and dash seal from gear.

14. Remove mounting bracket and split gromment from right side of gear.

15. With stub shaft of gear tilted toward firewall, move gear assembly to right side under brake booster/master cylinder assembly and around fuel lines and throttle cable. Slide cylinder end of gear into right wheel well access hole. (Tilt valve end of gear upward moving toward the left side of engine compartment between throttle and transmission kickdown cables, removing gear assembly from engine compartment.) Be sure not to kink throttle or kickdown cables.

Installation:

1. Slide rack and pinion gear between throttle and transmission cables moving cylinder end of gear into wheel well opening. Tilt stub shaft of gear toward firewall and move toward left side under brake booster/master cylinder assembly and speedometer cable. Align gear with studs and firewall opening.

2. Align notch on housing and dash seal. Install dash seal on gear.

3. Install left hand mounting bracket with notch facing down on gear. Align gear on stud and opening in firewall.

4. Place washer and lock nut on lower stud, install upper bolt, and lightly tighten lock nut and bolt to draw gear up to firewall.

5. Position and install gromment and mounting bracket with notch facing down on the right side.

6. Place washer and lock nut on lower stud, install upper bolt, and lightly tighten bolt and jam nut.

7. Torque lower lock nut and upper bolt on left side to 22 N-m 16 ft. lb.

8. Torque lower lock nut and upper bolt on right side to 22 N-m 16 ft. lb.

9. Install fuel line retainer and jam nut on right lower stud and tighten.

10. Install inner tie rod bolts thru bolt support plate and inner tie rods. Be sure center housing flat washers are between inner tie rods and boot seal before installing bolts into gear.

NOTICE: It may be necessary to wiggle tie rod assembly/wheel to get bolt properly started in gear.

11. Torque inner tie rod bolts to 90 N-m 67 ft. lb.

FIGURE 2:

12. Install new lock plate with fingers facing outward and notches on plate correctly positioned over inner tie rod bolts. Note: Seat lock plate on bolt head using a 13/16" or 7/8" socket (see Figure 2).
13. Reconnect map sensor vacuum line.

14. Install air cleaner assembly and attach vacuum line to connector on intake manifold. Tighten two philips head bolts.
15. Using standard pliers remove shipping plugs from ports, in gear. Install lower line in gear first and torque to 22 N-m 16 ft. lb.; then install upper line and torque to 22 N-m 16 ft. lb.

16. Install windshield washer solvent reservoir on fender well bracket.

17. Slide flexible coupling down lower steering shaft. Install onto stub shaft of gear and install both upper and lower pinch bolts.

18. Torque lower pinch bolt on gear first to 22 N-m 16 ft. lb.; then torque pinch bolt on steering shaft to 22 N-m 16 ft. lb.

19. Check power steering fluid reservoir and fill with power steering fluid, if required, to COLD mark on cap stick.

NOTICE: When adding power steering fluid or making a complete fluid change, always use GM part number 1050017 (or equivalent meeting GM Spec. No. 9985010) power steering fluid.

20. Start up vehicle, check fluid level again, add fluid if necessary. Check system for any leaks. Bleed system by turning the wheels from side to side without hitting or holding gear against the stops. Return wheels to center position; continue to run engine until system has stabilized. Stop engine; lower vehicle. Check fluid level and add power steering fluid, if required, to bring level up to HOT mark on cap stick.

Tools Required:

15 mm 6-Point Socket - inner tie rods 18 mm Flare Nut Crowfoot - cylinder line nuts 13 mm Deep Well Socket - stud lock nuts bolts 13 mm Standard Socket - flexible coupling pinch bolts Torque Wrench 7/16" or 13/16" Socket - to seat lock plate 24" Extension Bar #3 Philips Screw Driver Assorted Regular Flat Bladed Screw Drivers

Sockets, flare nut crowfoot, and 24" extension bar can be 3/8" drive.