GM Metro/Sprint 1985-1993 Repair Guide

Manual Rack and Pinion

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REMOVAL & INSTALLATION



See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Steering shaft universal joints



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Fig. Fig. 2: Manual rack and pinion mounting

  1. Slide the driver's seat back as far as possible.
  2.  
  3. Pull off the front part of the floor mat on the driver's side and remove the steering shaft joint cover.
  4.  
  5. Loosen the steering shaft upper joint bolt, but do not remove.
  6.  
  7. Remove the steering shaft lower joint bolt and disconnect the lower joint from the pinion.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Remove the tie rod ends from the steering knuckles. Mark the left and right tie rods accordingly.
  12.  
  13. From under the dash, remove the steering joint cover.
  14.  
  15. Remove the lower steering shaft-to-steering gear clinch bolt and separate the steering shaft from the steering gear.
  16.  
  17. Remove the steering gear mounting bolts, the brackets and the steering gear case from the vehicle.
  18.  

To install:
  1. Install the steering gear, brackets and mounting bolts. Tighten bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Connect the steering shaft to the steering gear. Install the lower steering shaft-to-steering gear clinch bolt and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the steering joint cover.
  6.  
  7. Install the tie rod ends to the steering knuckles. Tighten tie rod end-to-steering knuckle nut to 32 ft. lbs. (43 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the lower joint to the pinion. Install the steering shaft lower joint bolt and tighten to 18 ft. lbs. (25 Nm).
  12.  
  13. Tighten the steering shaft upper joint bolt to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the steering shaft joint cover.
  16.  
  17. Check and adjust the front wheel alignment.
  18.  

OVERHAUL



See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Manual rack and pinion - exploded view

Disassembly
  1. Remove the rack from the vehicle.
  2.  
  3. Matchmark the tie rod end threads for installation reference and remove the tie rod ends.
  4.  
  5. Remove the boots from the tie rods by removing the retaining wires and clips.
  6.  
  7. Remove the tie rods from the rack. Unstake the lock washers by bending flat. Unscrew and remove the tie rods.
  8.  
  9. Remove the rack damper screw cap, damper screw, plunger spring and plunger from the gear housing.
  10.  
  11. Remove the upper case packing and then remove pinion bearing plug using tool J39534 or equivalent.
  12.  
  13. Remove the pinion from the housing by tapping on the housing with a plastic hammer.
  14.  
  15. Remove the rack from the housing through the pinion end.
  16.  
  17. Remove the pinion bearing from the gear housing using tool J34839, or equivalent.
  18.  
  19. Remove the rack bushing snapring.
  20.  
  21. Remove the rack bushing using tools J34869 and J239075, or equivalent.
  22.  

Cleaning and Inspection
  1. Clean dirt and grease from all steering gear parts using an appropriate solvent.
  2.  
  3. Inspect steering rack boots for wear, deterioration or tears. Replace if even the smallest sign of wear is evident.
  4.  
  5. Inspect tie rod end ball stud dust seal for deterioration, wear or tears. Replace if even the smallest sign of wear is evident. Coat the inside of the seal with grease prior to installation.
  6.  
  7. Inspect rack plunger and spring for wear or damage. Replace as necessary.
  8.  
  9. Inspect pinion, pinion gasket and pinion oil seal for wear or damage. Replace any part found to be defective.
  10.  
  11. Inspect pinion needle bearing for wear and rotational smoothness. Replace if defective.
  12.  
  13. Inspect steering rack bushing for damage or wear. Replace if defective.
  14.  
  15. Check steering rack run-out using V-blocks and a dial indicator. Run-out should not exceed 0.016 in. (40 mm).
  16.  

Assembly
  1. Coat entire surface of rack bushing with a thin layer of manual steering gear lubricant and install bushing into housing using tool J34868 and J7079-2, or equivalent. Install the snapring.
  2.  

The inside of the bushing has a fragile, special coating. Be sure to use the correct tool when installing the bushing, using care not to damage the special coating.

  1. Apply manual steering gear lubricant to pinion bearing rollers. Install bearing to housing using tool J34840, or equivalent and a hammer. Following installation, check roller for proper operation.
  2.  
  3. Apply manual steering gear lubricant to steering rack toothed surface. Install rack into housing from the pinion end.
  4.  
  5. Apply manual steering gear lubricant to pinion gears, needle bearings and gear case oil seal lip. Install pinion bearing plug using Loctite® 414 on the bearing plug threads. Tighten plug to 70 ft. lbs. (95 Nm). Install upper case packing.
  6.  
  7. Apply manual steering gear lubricant to sliding surface of rack plunger. Install plunger, spring and damper screw. Tighten screw until it is snug.
  8.  
  9. Measure rotation resistance using a torque wrench and tool J34871. If observed torque is greater than specification, back off the rack damper screw (up to 1 / 4 turn) until specified torque is 10.6 inch lbs. (1.2 Nm).
  10.  
  11. If observed pinion rotational torque is less than specification, tighten the plunger damper screw until specification is reached.
  12.  
  13. Install rack damper screw cap as deeply as possible.
  14.  
  15. Install the tie rods to the rack, positioning lock washers in between. Align flats on washers with flats on rack. Tighten tie rod to 63 ft. lbs. (85 Nm) and stake lockwasher over each tie rod ball nut.
  16.  
  17. Apply manual steering gear lubricant to inside portion of the outer end of each steering gear boot. Position boots on grooves of the steering gear housing and secure with new wires. Secure the outer end of each boot with clamp. Make sure boots are free from twists and properly fastened.
  18.  
  19. Install tie rod end and locknut. Align locknuts with marks make on tie rod threads during removal. Tighten locknuts to 32 ft. lbs. (43 Nm).
  20.  
  21. Install manual steering gear assembly to vehicle.
  22.  

 
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