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HOMESERVICE MANUALSCHEVROLET1992CAVALIER RS, 2D CONVERTIBLE, 3.1 T, STANDARDREPAIR AND DIAGNOSISSTEERINGPOWER STEERINGSTEERING SYSTEM - POWEROVERHAULRACK ASSEMBLYREASSEMBLY
1992 Chevrolet Cavalier RS, 2D Convertible, 3.1 T, Standard

Rack Assembly: Reassembly

1992 Chevrolet Cavalier RS, 2D Convertible, 3.1 T, StandardSECTION Reassembly
  1. Coat all seals with power steering fluid. Install upper pinion bushing into housing. Seat pinion shaft seal into housing using Pinion Seal Installer (J-29822). Press pinion bearing assembly into housing. Install retaining ring in groove in housing. Ensure retaining ring is installed in proper position.
  2. Install piston rod seal and "O" ring on piston rod guide. Install piston rod seal and "O" ring on rack piston. Install seal back-up washer, piston rod guide assembly and rack piston on rod and rack assembly. Install rack piston-to-rack nut on rack assembly and tighten to specification. See TORQUE SPECIFICATIONS  table at end of article.
  3. Slide piston rod assembly into housing. Apply 3 drops of Loctite 242 in equally spaced locations around threaded portion of housing. Install cylinder tube assembly to rack housing. Tighten to specification. Ensure fittings on cylinder tube are aligned with reference marks made during disassembly.
  4. Install insert and guide assembly to rod and rack assembly in housing. Center rack guide assembly in housing window opening. Install pinion and valve assembly into housing using Pinion and Valve Assembly Ring Protector (J-33057).
  5. When pinion and valve assembly are fully seated in housing, notch in pinion shaft and mark on housing will be aligned. insert and guide assembly will be centered in housing window.
    CAUTION: Pinion teeth will be damaged if input shaft is not held when tightening lock nut.
  6. While holding pinion shaft, tighten pinion shaft lock nut to specification. Install dust cover on housing. Install pinion shaft annulus bearing assembly onto pinion shaft, and slide into housing.
  7. Install Seal Protector (J-29810) on pinion shaft. Install pinion shaft seals over seal protector and into housing. Install retaining ring in groove in housing. Coat rack guide, "O" ring, spring and adjusting plug with lithium-based grease. Install assembly in housing.
  8. With rack centered in window in housing, turn adjusting plug clockwise until it bottoms in housing, then back off plug 35-45 degrees (50-70 degrees on Beretta and Corsica). Check rack bearing preload. If preload is not 8-16 INCH lbs. (.9-1.8 N.m), adjust preload. See RACK BEARING PRELOAD  under ADJUSTMENTS. Install adjusting plug lock nut, and tighten to specification while holding adjusting plug stationary.
  9. Slide boot retaining bushing from rack and pinion boot. Install new boot clamp on rack and pinion boot. Insert boot retaining bushing in boot. Coat inner lip of bushing with grease to ease installation. Slide boot assembly onto housing.
  10. Ensure center housing cover washers are installed on rack and pinion boot. To ease assembly, install inner tie rod retaining bolt through center housing cover washers, and insert and guide. Lightly thread bolts into rod and rack assembly to keep components in proper alignment.
  11. Slide on rack and pinion boot and boot retaining bushing until seated in bushing groove in housing. Position boot clamps on boot, positioning boot clamp bridge over split in boot retaining bushing. Crimp boot clamps.
  12. With new "O" rings on cylinder line fittings, install lines on steering gear. Install fittings at valve. Tighten fittings to specification.
  13. Install inner tie rod retaining bolts through bolt support plate, inner tie rod assemblies, center housing cover washers, insert and guide assembly, and into threaded holes in rod and rack assembly. Tighten inner tie rod retaining bolts to specification. Install new lock plate over inner tie rod bolts.
Fig 1: Exploded View Of Power Rack & Pinion Steering Gear
G28481Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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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.