GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Steering Column Housing Steering Shaft and Ignition Switch Housing Jacket Bushing

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DISASSEMBLY



See Figures 1, 2 and 3

  1. Disconnect the negative battery cable and disable the SIR system, if equipped.
  2.  
  3. Remove the pad and horn lead, retainer and nut and remove the steering wheel from the column, using a suitable puller.
  4.  
  5. Remove the tilt lever, if so equipped.
  6.  
  7. Remove the 2 lower column cover retaining screws.
  8.  
  9. Remove the 3 bottom retaining screws from lower column cover.
  10.  
  11. Disconnect the park lock cable from the ignition switch and lock cylinder assembly by depressing the locking tab with a small screwdriver.
  12.  
  13. Disconnect the wire harness at the bulkhead.
  14.  
  15. Remove the steering column from the vehicle as outlined in this section.
  16.  
  17. Remove the steering column jacket bushing from from the lower end of the jacket assembly.
  18.  
  19. Separate the rose bud fastener (integral to wire harness) from the jacket assembly.
  20.  
  21. Remove the turn signal switch retaining screws.
  22.  
  23. Depress the locking tab and remove the 2 wire harness connector from the switch.
  24.  
  25. Depress the locking tab and remove the cruise connector from the wire harness, if so equipped.
  26.  
  27. Depress the locking tab and remove the harness connector from the wipe/wash switch.
  28.  
  29. Depress the locking tabs and remove the 2 wire harness connectors from the ignition switch.
  30.  
  31. Remove the ignition switch screws and remove the ignition switch from the housing.
  32.  

The turn signal switch must be removed before compressing the cam plate and shaft spring to prevent damage to the switch.

  1. Compress the cam plate and shaft spring with tools J 23653-91 and J 23653-C or equivalent, and remove the retaining ring, orientation cam plate, cancelling cam assembly, upper steering shaft spring and thrust washer.
  2.  
  3. Place the lock cylinder in the RUN position.
  4.  
  5. Remove the steering shaft assembly from the lower end of the jacket assembly.
  6.  
  7. Remove the shear bolts, shear bolt washers and ignition switch housing as follows:
    1. Drill of the head of the shear bolts with a 1 / 4 in. (6mm) drill bit.
    2.  
    3. Separate the washers and switch housing from the column housing.
    4.  
    5. Remove the threaded ends of the shear bolts from the ignition switch housing with pliers.
    6.  
    7. Clean all metal shavings from the housing.
    8.  

  8.  
  9. Remove the 4 hex head screws from the housing.
  10.  
  11. Separate the column housing from the jacket assembly.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Ignition switch connectors



Click image to see an enlarged view

Fig. Fig. 2: Park/lock cable removal and installation



Click image to see an enlarged view

Fig. Fig. 3: Shear bolt removal using a proper sized drill bit

To install:

Firmly seat all the fasteners in the following steps before tightening them to the specified torque.

  1. Install the column housing to the jacket assembly and torque to 47 inch lbs. (5.3 Nm).
  2.  
  3. Install the ignition switch housing to the column housing with shear bolt washers and shear bolts. Tighten the shear bolts until the bolt head separates from the body, approximately 8 ft. lbs. (11 Nm).
  4.  
  5. Place the lock cylinder in the RUN position.
  6.  
  7. Install the steering shaft assembly into the lower end of the jacket assembly until bottomed.
  8.  
  9. Place the lock cylinder in the OFF position and remove the key.
  10.  
  11. Rotate the steering shaft until the lock bolt engages and locks the steering shaft into position.
  12.  
  13. Install the thrust washer and upper steering shaft spring on the steering shaft.
  14.  
  15. Fasten the cancelling cam and orientation cam plate.
  16.  
  17. Install the retaining ring into the groove on the shaft.
  18.  
  19. Place the jacket bushing over the lower end of the steering shaft, into the lower end of the jacket assembly and snap into position.
  20.  
  21. Attach the 2 wire harness connectors to the ignition switch.
  22.  
  23. Fasten the wiper/wash switch retaining screws and tighten to 49 inch lbs. (5.5 Nm).
  24.  
  25. Install the turn signal switch retaining screws and tighten to 49 inch lbs. (5.5 Nm).
  26.  
  27. Install the steering column in the vehicle as outlined later in this section.
  28.  
  29. Connect the wire harness at the bulkhead.
  30.  
  31. Connect the park lock cable to the ignition switch and lock cylinder assembly.
  32.  
  33. Install the rose bud fastener (integral to wiring harness) to the jacket assembly.
  34.  
  35. Tighten the upper and lower cover screws to 49 inch lbs. (5.5 Nm) and the steering wheel retaining nut to 30 ft. lbs. (41 Nm).
  36.  

 
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