Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1990STEP VAN 6.2 J, AUTOMATIC, 3L80-HD/M40REPAIR AND DIAGNOSIS (SINGLE PAGE)STEERINGPOWER STEERINGSTEERING GEAR - POWEROVERHAULSTEERING GEARREASSEMBLY
1990 Chevrolet Step Van 6.2 J, Automatic, 3L80-HD/M40
Steering Gear: Reassembly
1990 Chevrolet Step Van 6.2 J, Automatic, 3L80-HD/M40SECTION Reassembly
- Lubricate all parts with power steering fluid before reassembly. Install lower thrust bearing and races on worm shaft. See Figure
.NOTE: If conical thrust races are used, ensure tapered surfaces are parallel to each other and that cupped sides face toward stub shaft.
- Place worm shaft in valve body. Install "O" ring in valve body. Align notch in valve body with pin in worm shaft. Install valve body and worm assembly into housing. Installation is correct when fluid return port in housing is fully visible.
- Place seal protector over stub shaft. Using new "O" ring, install adjuster plug until it seats against valve body.
- Remove seal protector from housing. Loosely install adjuster plug lock nut. Insert rack piston (with arbor to retain recirculating balls) into housing. Align worm and rack piston. Turn stub shaft clockwise to engage worm. Maintain pressure on arbor until worm is fully engaged.
- Rotate stub shaft clockwise to align middle rack groove in rack piston with center of pitman shaft roller bearing. Remove arbor. Install a new pitman shaft cover seal.
- Thread pitman shaft cover onto adjuster screw until bottoms. Back off 1/2 turn. Install pitman shaft so that center gear tooth meshes with center groove in rack piston. Install cover attaching bolts.
- Install adjuster lock nut halfway onto pitman shaft. Install piston and plug in rack piston. Install housing end plug "O" ring, end plug and retainer ring. Adjust worm bearing preload and over-center preload. Refer to the appropriate ADJUSTMENT procedure in this article.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.