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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 151 (Power Steering System) >> Repair Instructions >> Steering Gear Stub Shaft Seals and Bearing Replacement - Off Vehicle >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE .
  1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft. Tighten the nut to 30 N.m (22 lb ft).
    2. Fig 1: Identifying Hex Lock Nut & Dust Cap
    G00374430Courtesy of GENERAL MOTORS CORP.
  2. Install the dust cover (2) to the rack and pinion gear assembly.
  3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2).
    4. Fig 2: Identifying Stub Shaft Bearing Annulus Assembly
    G00374431Courtesy of GENERAL MOTORS CORP.
  4. Install J 29810 onto the valve stub shaft.
    5. Fig 3: Identifying Seal Protector
    G00374432Courtesy of GENERAL MOTORS CORP.
  5. Lubricate the stub shaft seal (3) with grease.
  6. Install the stub shaft seal (3) into the rack and pinion gear assembly.
  7. Install the retaining ring (2) into the groove in the rack and pinion gear assembly.
  8. Install the spool shaft boot (1) onto the rack and pinion gear assembly.
  9. Lubricate the following items with lithium base grease:
    1. The rack bearing (2)
    2. The adjuster spring (3)
    3. The adjuster plug (4)
    10. Fig 4: Identifying Steering Gear Adjuster Plug
    G00374433Courtesy of GENERAL MOTORS CORP.
  10. Install the following items into the gear assembly:
    1. The rack bearing (2)
    2. The adjuster spring (3)
    3. The adjuster plug (4)
  11. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster plug (1) back 50 degrees to 70 degrees.
    12. Fig 5: Identifying Adjuster Plug Torque Angle
    G00374434Courtesy of GENERAL MOTORS CORP.
  12. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 N.m (16 lb in).
  13. Install the adjuster plug lock nut (5) to the adjuster plug (4). Finger tighten the adjuster plug lock nut (5) while holding the adjuster plug (4) stationary. Tighten the nut to 68 N.m (50 lb ft).
    14. Fig 6: Exploded View Of Rack & Pinion Gear Assembly
    G00374435Courtesy of GENERAL MOTORS CORP.
  14. Install the steering gear into the vehicle, refer to Power Steering Gear Replacement (Manual Transmission)  or Power Steering Gear Replacement (Automatic Transmission)  .
    NOTE: Flush and bleed power the steering system (hoses, reservoir and cooler lines) with power steering fluid GM P/N 1050017 (Canadian P/N 992646) (or equivalent meeting GM Specification number 9985010).
  15. Refer to Bleeding the Power Steering System .
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