GM Malibu/Cutlass 1997-2000

Power Rack and Pinion Steering Gear

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REMOVAL & INSTALLATION





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



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Fig. View of the power steering-to-rack and pinion hose connections



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Fig. Exploded view of the tack and pinion assembly mounting

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left side sound insulator from under the driver's side of the instrument panel.
  4.  
  5. Remove the upper pinch bolt from 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 puller.
  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. Step 1: Tighten the left rear outboard bolts to 96 ft. lbs. (130 Nm).
    2.  
    3. Step 2: Tighten the right rear outboard bolts to 96 ft. lbs. (130 Nm).
    4.  
    5. Step 3: Tighten the front upper bolts to 96 ft. lbs. (130 Nm).
    6.  
    7. Step 4: Tighten the rear inboard bolts 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 the bolts and nuts. Tighten the left side bolt to 89 ft. lbs. (120 Nm), then tighten the right side bolt to 89 ft. lbs. (120 Nm).
  10.  
  11. Connect the tie rod ends to the steering knuckles, tighten the nut to 44 ft. lbs. (60 Nm) and install new cotter pins. If necessary, you can tighten the nut further to align the cotter pin holes for installation. Never loosen the nut to install the cotter pin.
  12.  
  13. Install left tire and wheel assembly.
  14.  
  15. Install the 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 the power steering system with fluid and bleed the air from system, as outlined later in this section.
  26.  
  27. Have the toe setting checked and adjusted, as required.
  28.  
  29. Road test the vehicle and verify that there are no leaks.
  30.  

 
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