GM Cavalier/Sunfire 1995-2000 Repair Guide

Power Rack and Pinion Steering Gear

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Remove the lower pinch bolt from the flange inter-shaft assembly



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Fig. Fig. 2: The power steering-to-rack and pinion hose connections



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Fig. Fig. 3: Rack and pinion assembly mounting

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left side sound insulator under the driver's side of the instrument panel.
  4.  
  5. Remove the upper pinch bolt on the intermediate-shaft assembly.
  6.  
  7. Remove the line retainer, if applicable.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the left front tire and wheel assembly.
  12.  
  13. Disconnect the tie rod ends from the steering knuckles using an appropriate tie rod removal tool.
  14.  
  15. Remove the left and right mounting bolts.
  16.  
  17. Disconnect the gear inlet and outlet hose assemblies from the rack and pinion.
  18.  
  19. Remove the lower pinch bolt from the flange inter-shaft assembly.
  20.  
  21. Remove the inter-shaft assembly.
  22.  
  23. Loosen the subframe bolts to gain additional clearance for removal.
  24.  
  25. Remove the rack and pinion through the left wheel opening.
  26.  

To install:
  1. Install the rack and pinion through the left wheel opening.
  2.  
  3. Install the subframe bolts as follows:
    1. Tighten the left rear outboard 1st to 96 ft. lbs. (130 Nm).
    2.  
    3. Tighten the right rear outboard 2nd to 96 ft. lbs. (130 Nm).
    4.  
    5. Tighten the front upper bolts to 96 ft. lbs. (130 Nm).
    6.  
    7. Tighten the rear inboard bolts last to 96 ft. lbs. (130 Nm).
    8.  

  4.  
  5. Install the lower pinch bolt (flange to inter-shaft bolt) and tighten to 30 ft. lbs. (41 Nm).
  6.  
  7. Connect the gear inlet and outlet pipes to the rack and pinion and tighten to 20 ft. lbs. (27 Nm).
  8.  
  9. Hand start bolts and nuts. Tighten left side bolt to 89 ft. lbs. (120 Nm) and then tighten right side to 89 ft. lbs. (120 Nm).
  10.  
  11. Connect the tie rod ends to the steering knuckles and tighten to 44 ft. lbs. (60 Nm) and install new cotter pins.
  12.  
  13. Install left tire and wheel assembly.
  14.  
  15. Install line retainer, if applicable.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the upper pinch bolt and tighten to 30 ft. lbs. (41 Nm).
  20.  
  21. Install the left side sound insulator.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill with fluid and bleed air from system.
  26.  
  27. Check toe setting and adjust as required.
  28.  
  29. Road test vehicle and verify no leaks.
  30.  

 
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