LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 238 (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 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft.

    Tighten:  Tighten the nut to 30 N.m (22 lb ft).

    Fig 1: Identifying Hexagon Lock Nut
    GM416153Courtesy 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).
    Fig 2: View Of Stub Shaft Bearing Annulus Assembly
    GM416154Courtesy of GENERAL MOTORS CORP.
  4. Install J 29810  onto the valve stub shaft.
    Fig 3: Identifying J 29810
    GM470309Courtesy 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)
      Fig 4: Removing/Installing Adjuster Plug Lock Nut & Adjuster Plug
      GM470307Courtesy 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.
    Fig 5: Identifying Adjuster Plug Degree Of Rotation
    GM416159Courtesy 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:  Tighten the nut to 68 N.m (50 lb ft).

    Fig 6: Removing/Installing Adjuster Plug Lock Nut & Adjuster Plug
    GM470307Courtesy of GENERAL MOTORS CORP.
  14. Install the steering gear into the vehicle, refer to Power Steering Gear Replacement (Automatic Transmission)  or Power Steering Gear Replacement (Manual Transmission) .
    IMPORTANT: 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 .
scientia non olet · About LEMON Manuals