Cavalier, Sunfire 2001-2005

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Inlet and outlet hose assemblies from the rack and pinion
     
    Tie rod ends from the steering knuckles
     
    Intermediate shaft
     
    Brake pipes from the retainers on the front suspension support
     
    Crossmember bolts, loosen them to gain additional clearance
     
    Rack and pinion mounting bolts
     
    Rack and pinion
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the rack and pinion steering gear mounting

  1. Install the rack and pinion and hand tighten the bolts.
  2.  
  3. Install the crossmember bolts in the following order:
    1. Step 1: Left rear outboard to 71 ft. lbs. (110 Nm).
    2.  
    3. Step 2: Right rear outboard 2nd to 71 ft. lbs. (110 Nm).
    4.  
    5. Step 3: Front upper bolts to 71 ft. lbs. (110 Nm).
    6.  
    7. Step 4: Rear inboard bolts to 71 ft. lbs. (110 Nm).
    8.  
    9. Tighten the rack and pinion gear-to-crossmember bolts to 89 ft. lbs. (120 Nm).
    10.  

  4.  
  5. Install or connect the following:

    Intermediate shaft. Torque the pinch bolt to 30 ft. lbs. (41 Nm).
     
    Brake pipes to the retainers on the front suspension crossmember
     
    Tie rod ends. Torque the nuts to 44 ft. lbs. (60 Nm), use new cotter pins.
     
    Inlet and outlet hoses to the rack and pinion. Torque the fittings to 20 ft. lbs. (27 Nm).
     
    Wheels
     
    Negative battery cable
     

  6.  
  7. Refill and bleed the power steering system.
  8.  
  9. Check and/or adjust the toe setting.
  10.  
  11. Road test vehicle and verify no leaks.
  12.  

 
label.common.footer.alt.autozoneLogo