GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Rack and Pinion Unit

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable and disable the SIR system, if equipped.
  2.  
  3. From the driver's side, remove the sound insulator.
  4.  
  5. From under the instrument panel, pull the seal assembly down from the steering column and remove the upper pinch bolt from the flexible coupling.
  6.  
  7. Remove the air cleaner and the windshield washer fluid reservoir, if necessary for easier access.
  8.  
  9. On power steering models: disconnect the pressure line from the steering gear and remove the screw securing the pressure line bracket to the cowl. Move the pressure line aside.
  10.  
  11. Raise and support the car on jackstands.
  12.  
  13. Remove both front wheel and tire assemblies.
  14.  
  15. Disconnect both tie rods from the struts.
  16.  
  17. Carefully lower the car.
  18.  
  19. Remove the right side rack mounting clamp.
  20.  
  21. Remove the left side rack mounting clamp.
  22.  
  23. Move the gear forward slightly. On power steering models, disconnect the fluid return pipe from the gear.
  24.  
  25. Remove the lower pinch bolt from the flexible coupling and separate the rack from the coupling.
  26.  
  27. Remove the dash seal from the rack assembly.
  28.  
  29. Raise and support the car on jackstands.
  30.  
  31. On some models it may be necessary to remove the splash shield from the inner, left fender.
  32.  
  33. Turn the left knuckle and hub assembly to the full left turn position and remove the rack and pinion assembly through the access hole on the left fender.
  34.  

To install:


Click image to see an enlarged view

Fig. Fig. 1: Manual rack and pinion assembly



Click image to see an enlarged view

Fig. Fig. 2: Power rack and pinion assembly

  1. Installation is the reverse of removal while noting the following points:
    1. If the mounting studs backed out during removal, it will be necessary to re-position them prior to rack installation. Double-nut the stud so that it can be torqued to 15 ft. lbs. (20 Nm).
    2.  
    3. It will be helpful to have an assistant inside the car to guide the flexible coupling onto the stub shaft and onto the steering column.
    4.  
    5. Observe the following torques:

      Coupling-to-stub shaft: 1982-86 vehicles: 37 ft. lbs. (50 Nm), 1987-94 vehicles: 29-30 ft. lbs. (39-41 Nm)
       
      Coupling-to-column: 30 ft. lbs. (41 Nm)
       
      Mounting clamps: 1982-86 vehicles: 28 ft. lb. (38 Nm), 1987-94 vehicles: 22 ft. lbs. (30 Nm)
       
      Tie rod nuts: 35-37 ft. lbs. (47-50 Nm)
       

    6.  

  2.  

 
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