Service Procedure
MANUAL STEERING GEAR ASSEMBLY REPLACEMENTREMOVAL
1. Disconnect negative battery cable.
CAUTION:
MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
2. Raise vehicle on hoist.
3. Remove front road wheels.
4. Loosen tie rod jam nuts.
5. Remove and discard tie rod end cotter pins.
6. Remove tie rod end to knuckle castle nuts.
7. Using SA91100C, remove tie rod ends from steering knuckles.
NOTICE:
Do not attempt to separate the joint using a wedge-type tool because the seal may be damaged.
8. Remove two push pins from left side splash shield.
9. Remove lower shield to cradle molded-in fasteners at cradle by gently prying at three fastener locations on left side splash shield.
10. Remove left side splash shield.
IMPORTANT:
Remove front section of shield first, then rear.
11. Pull-up intermediate shaft cover from steering gear and move up enough to access pinch bolt.
12. Remove pinch bolt and separate intermediate shaft from steering gear.
13. Remove steering gear to cradle bolt and nuts, and discard nuts.
14. Remove steering gear from vehicle through left wheel opening.
DISASSEMBLY
1. Unthread outer tie rods from inner tie rods and remove tie rods from steering gear assembly.
2. Remove inner tie rod - to - outer tie rod jam nuts from inner tie rods.
3. Remove boot clamps (tie rod end).
4. Remove boot clamps (steering gear housing end) with cutters and discard clamps.
5. Remove steering gear boots from steering gear,
6. Slide shock dampers off inner tie rods toward the steering gear.
NOTICE:
Steering gear rack must be held stationary during inner tie rod removal to prevent steering gear damage. Use a 23 mm (15/16 inch) wrench at the rack teeth to hold the rack during inner tie rod removal. Protect rack teeth with a shop cloth.
7. Remove inner tie rod assemblies from steering gear.
ASSEMBLY
NOTICE:
The manual steering gear service kit may contain an instruction sheet with service procedures for installing a "staked" type of inner tie rod. This instruction sheet does not apply to Saturn vehicles. Discard instruction sheet and use the following service procedures.
1. Remove old Loctite from threads of inner tie rods.
IMPORTANT:
Threads must be clean prior to Loctite 262 Threadlocker application. Make sure container of Loctite 262 Threadlocker (or equivalent) has not passed expiration date. Do not use too much Loctite 262 Threadlocker (or equivalent). Use only enough to evenly coat threads.
2. Apply Loctite 262 Threadlocker (or equivalent) to inner tie rod threads.
3. If shock dampers were removed, slide them onto new partial steering gear assembly.
NOTICE:
Steering gear must be held stationary during inner tie rod installation to prevent steering gear damage.
4. Install inner tie rod assemblies onto new steering gear assembly.
Torque: 95 Nm (70 ft-lbs)
5. Slide shock dampers up against inner tie rod assemblies.
6. Loosely install new boot clamps onto steering gear boots (steering gear housing end).
7. Apply grease in service kit prior to boot installation. This grease provides a water barrier and must be used to protect internal gear components from corrosion.
8. Install boots onto inner tie rod assemblies, then slide each boot along rod assembly until the large end of the boot is seated in the steering gear housing groove.
NOTICE:
The boot has a small pad near the clamp location on the housing end. The boot should be turned so that the pad is toward the front of the vehicle.
NOTICE:
The boot must not be twisted or puckered during installation.
9. Crimp clamps on housing end of boots using steering gear clamp installer SA9164C.
10. Install clamps on inner tie rod end of boots.
11. Thread inner tie rod-to-outer tie rod jam nuts onto inner tie rods approximately 15 full turns.
12. Thread outer tie rods onto inner tie rods approximately 15 fill turns.
INSTALLATION
1. Place steering gear in vehicle through left wheel opening.
2. Install steering gear-to-cradle bolts and new nuts.
Torque: 50 Nm (37 ft-lbs)
IMPORTANT:
Make sure that the steering gear is centered and steering wheel is in its normal level position.
3. Install intermediate shaft onto the steering gear and torque pinch bolt.
Torque: 47 -m (35 ft-lbs)
IMPORTANT:
Use Loctite 242 Threadlocker (or equivalent) on threads of pinch bolt.
4. Install intermediate shaft cover onto steering gear.
5. Install left side splash shield.
IMPORTANT:
If molded-in fasteners are damaged or broken, drill out with a 5/16 bit and replace with a push pin.
IMPORTANT:
Install rear section of shield first, then front.
6. Install tabs in body cut-out.
7. Align molded-in shield fasteners with holes in cradle. Push straight in to install.
8. Install push pins.
IMPORTANT:
Make sure splash shield flaps are tucked in at body locations.
IMPORTANT:
Tie rod end threads must be thoroughly cleaned and lubricated with oil before tightening nut. Lubricate only the thread part of the stud. Do not lubricate the smooth tapered portion of stud.
9. Install tie rod ends into steering knuckles. Torque castle nuts.
Torque: 45 Nm (33 ft-lbs)
IMPORTANT:
If it is necessary to rotate the castle nut after tightening to orient it to the hole in the stud, always tighten the nut to align it; never loosen it.
10. Install new cotter pins into castle nuts.
NOTICE:
Before installing wheels remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel lug nuts to loosen in service.
11. Position wheel onto hub.
12. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to make sure torque is correct.
Torque: 140 Nm (103 ft-lbs)
13. Lower vehicle from hoist.
14. Connect negative battery cable.
FRONT WHEEL TOE ADJUSTMENT
IMPORTANT:
Prior to setting front end toe:
a. Vehicle must be set-up to alignment equipment in accordance with the equipment manufacturer's instructions.
b. Vehicle must be at curb weight.
If vehicle fuel tank is not full, the chart may be used to determine amount of weight necessary to be added to the trunk of vehicle to simulate a full fuel tank.
c. Adjust tire pressure to correct specifications:
Front - 207 kPa (30 psi)
Rear - 179 kPa (26 psi)
NOTICE:
When performing the toe adjustment, the steering wheel must be locked in the straight ahead position.
1. Lock steering wheel in the straight ahead position.
2. Loosen left and right outer tie rod jam nuts.
NOTICE:
Make sure steering gear boots do not become twisted.
3. Turn inner tie rods (by flats) in direction of desired toe change.
4. After adjustment, tighten left and right outer tie rod jam nuts.
Torque: 100 Nm (74 ft-lbs)
5. Check toe angle settings as shown and adjust if necessary.
6. Affix the Campaign Completion Label to the radiator core support.