Power Steering Gear: Section 6C

SECTION 6C
POWER STEERING GEAR

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Dust Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
General Specifications . . . . . . . . . . . . . . . . . . . . . 6C-1 Straight-Ahead Check . . . . . . . . . . . . . . . . . . . . . 6C-14
Fastener Tightening Specifications . . . . . . . . . . . 6C-2 Intermediate Shaft and Dash Seal . . . . . . . . . . 6C-15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Hydraulic Cylinder Lines . . . . . . . . . . . . . . . . . . . 6C-19
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-21
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-3 Rack and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-21
Power Rack and Pinion Steering Gear . . . . . . . 6C-3 Stub Shaft Seals and Upper and
Power Rack and Pinion Steering Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 6C-26
Gear Bench Testing . . . . . . . . . . . . . . . . . . . . . . 6C-5 Rack Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-30
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . 6C-6 Rack Bearing Preload Adjustment . . . . . . . . . . 6C-32
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-6 Valve and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . 6C-32
Rack and Pinion Assembly . . . . . . . . . . . . . . . . . 6C-6 General Description and System
Outer Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-36
Inner Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 Power Rack and Pinion . . . . . . . . . . . . . . . . . . . 6C-36
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description
Capacity 1.0 Liter (1.06 qt)
Lubricant Power Steering Fluid DEXRONr-III
DAEWOO J-100 BL2 / BL3

6C -- 2 POWER STEERING GEAR
FASTENER TIGHTENING SPECIFICATIONS
Application NSm Lb-Ft Lb-In

Adjuster Plug 5 - 44
Adjuster Plug Locknut 70 52 -
Dash Seal Retaining Ring Nuts 9 - 80
Hydraulic Cylinder Line Fittings - Cylinder End 27 20 -
Hydraulic Cylinder Line Fittings - Valve End 18 13 -
Inner Tie Rods 100 74 -
Lower Intermediate Shaft Pinch Bolt 25 18 -
Outer Tie Rod Adjusting Nut 22 16 -
Outer Tie Rod Nut 60 44 -
Pinion Locknut 30 22 -
Pinion Preload 1 - 9
Steering Gear Inlet and Outlet Pipe Fittings 27 20 -
Steering Gear Mounting Bracket Nut and Bolts 57 42 -
Upper Intermediate Shaft Pinch Bolt 25 18 -
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J-42459
KM-507-B
Rack Guide Spring Cap
Ball Joint Remover
Wrench
A106C034 C105C001
KM-J-22610
Installer
A104A008

POWER STEERING GEAR 6C - 3
DIAGNOSIS
POWER RACK AND PINION STEERING GEAR
Hissing Noise
Checks Action
Check the intermediate shaft joints for looseness. Tighten the intermediate shaft joints.
Check the power steering hose for contact with other Be sure the power steering hose is correctly fitted into
components. the hose clips.
Rattling Noise in Steering Gear

Checks Action
Check the power steering hose for contact with the Be sure the power steering hose is correctly fitted into
body. the hose clips.
Check the steering gear for insufficient lubrication. Lubricate the steering gear.
Check the steering gear mounting for improper Tighten the steering gear mounting bracket nuts.
installation.
Check the outer tie rods for improper installation. Tighten the outer tie rod joints. Replace the outer tie
rods.
Poor Return of Steering Wheel to Center

Checks Action
Check the steering wheel for contact with the turn Adjust the turn signal housing.
signal housing.
Check the intermediate shaft joints for binding or Replace the intermediate shaft.
looseness.
Check the power steering pump flow control valve for Replace the power steering pump.
sticking and improper alignment.
Check the wheel alignment. Align the wheels.
Check the wheel bearings for wear or damage. Replace the wheel bearings.
Check the intermediate shaft joints for improper Adjust the intermediate shaft between the steering
installation. gear and the steering column. Replace the
intermediate shaft.
Check the outer tie rods and the ball joints for binding Tighten the tie rods and the ball joints. Replace the tie
or looseness. rods and the ball joints.
Check the steering gear adjustments. Perform a straight-ahead check.
Check the steering column shaft seal for rubbing on Replace the dash seal.
the shaft.
Check the steering shaft bearings for binding. Replace the stub shaft bearings.
Momentary Increase in Effort When Turning the Wheel Quickly

Checks Action
Check the power steering pump for internal leaks. Replace the power steering pump.
Check the hoses for damage or restricted flow. Replace the power steering hoses and/or pipes.
Check the power steering fluid level. Fill the power steering fluid reservoir.
sticking and improper operation.

Steering Surges or Jerks When Turning with Engine Running

Checks Action
Check the power steering pump for insufficient Replace the power steering pump.
pressure.
sticking and improper operation.
Check the power steering pump serpentine belt for Tighten the power steering serpentine belt.
slippage.
Check for air contamination in the power steering Bleed the power steering system.
system.
Steering Vibrates During Low Speed or Static Steering

Checks Action
system.
Check the power steering pump serpentine belt for Tighten the power steering serpentine belt.
looseness.
Excessive Wheel Kickback or Loose Steering

Checks Action
system.
Check the wheel bearings for wear or damage. Replace the wheel bearings.
Check the steering gear mounting for improper Tighten the steering gear mounting bracket nuts.
installation.
installation. gear and the steering column. Replace the
intermediate shaft.
Check the outer tie rods and ball joints for looseness. Tighten the tie rods and the ball joints. Replace the tie
rods and the ball joints.
Hard Steering or Lack of Assist (Especially During Parking)

Checks Action
installation. gear and the steering column. Replace the coupling
flange.
sticking and improper installation.
Check the power steering pump for insufficient Replace the power steering pump.
pressure.
Check the power steering pump for internal leaks. Replace the power steering pump.
Check for a loose or a worn intermediate shaft. Tighten the intermediate shaft. Replace the
intermediate shaft as needed.
Check the power steering pump serpentine belt Tighten the power steering serpentine belt.
tension.

POWER RACK AND PINION 7. Check the power steering fluid level. Refer to Section
6A, Power Steering System.
STEERING GEAR BENCH TESTING
8. Start the engine and turn the rack and pinion stub
Removal, Setup, and Testing Procedure shaft a full turn in each direction. Hold the shaft
Important: Pressure checks or pressure and flow against each stop for 5 seconds.
checks may also be conducted using this setup. 9. Inspect for possible leak points. Refer to Section 6A,
Power Steering System.
1. Disconnect and remove the power steering gear.
Refer to “Rack and Pinion Assembly” in this section. Installation Procedure
2. Place the power steering gear on a bench next to the 1. Stop the engine.
vehicle. 2. Disconnect the power steering pipes from the power
3. Disconnect the pressure line at the point where the steering gear.
hose connects to the pipe. Extend this line in order to 3. Remove the extensions and reconnect the pressure
reach the power steering gear on the bench. and return lines.
4. Disconnect the return line from the the power steering 4. Install and connect the power steering gear. Refer to
fluid reservoir. Extend this line in order to reach the “Rack and Pinion Assembly” in this section.
power steering gear on the bench. 5. Start the engine and allow if to idle for 10 seconds.
5. Connect the power steering pipes to the power 6. Check the power steering fluid level. Refer to Section
steering gear. 6A, Power Steering System.
6. Start the engine and allow it to idle for 10 seconds.

MAINTENANCE AND
REPAIR
ON-VEHICLE SERVICE
RACK AND PINION ASSEMBLY
(Left-Hand Drive Shown, Right-Hand Drive
Similar)
Tools Required
KM-507-B Ball Joint Remover
Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
B105A010 3. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
4. Disconnect the outer tie rods. Refer to “Outer Tie
Rod” in this section.
5. Disconnect the power steering gear fluid outlet pipe.
Place a drain pan under the steering gear to catch the
power steering fluid.
6. Disconnect the power steering gear fluid inlet pipe.
B105A011

7. Position the steering gear straight ahead by turning
the steering wheel until the steering wheel spokes
are vertical and pointed to the left.
8. Scribe a mark on the stub shaft housing that lines up
with a mark on the intermediate shaft lower cou-
pling.
B105C024
9. Loosen the intermediate shaft pinch bolt.
B105C003
10. Remove the crossmember assembly. Refer to Sec-

tion 2C, Front Suspension.
11. Remove the lower bolt and the upper nut from the
left-side mounting bracket.
12. Remove the upper bolt from the right-side mounting
bracket.
13. For right-hand drive vehicles, remove the lower bolt
and the upper nut from the right-side mounting
bracket. Remove the upper bolt from the left-side
mounting bracket.
14. Remove the rack and pinion assembly from below.
B105C006

Installation Procedure
1. Install the rack and pinion assembly from below. The
steering gear must be in a straight-ahead position,
and the steering wheel spokes must be vertical and
pointing to the left. Align the marks on the shafts to
ensure proper positioning.
B105C024
2. Install the lower bolt and the upper nut onto the left-
side mounting bracket. Install the upper bolt onto the
right-side mounting bracket.
3. For right-hand drive vehicles, install the lower bolt
and the upper nut onto the right-side mounting brack-
et. Install the upper bolt onto the left-side mounting
bracket.
Tighten
Tighten the steering gear mounting bracket bolts and
the nut to 57 NSm (42 lb-ft).
4. Install the crossmember assembly. Refer to Section
2C, Front Suspension.
B105C006
5. Tighten the lower intermediate shaft pinch bolt.

Tighten
Tighten the lower intermediate shaft pinch bolt to
25 NSm (18 lb-ft).
B105C003

6. Connect the power steering gear fluid inlet pipe.
Tighten
Tighten the steering gear inlet pipe fitting to 27 NSm
(20 lb-ft).
B105A011
7. Connect the power steering gear fluid outlet pipe.

Tighten
Tighten the steering gear outlet pipe fitting to 27 NSm
(20 lb-ft).
8. Connect the outer tie rods. Refer to “Outer Tie Rod”
in this section.
9. Install the wheels. Refer to Section 2E, Tires and
Wheels.
10. Lower the vehicle.
11. Do a straight-ahead check. Refer to “Straight-Ahead
Check” in this section.
Notice: When adding fluid or making a complete fluid
change, always use power steering fluid DEXRONr-III
or equivalent. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
B105A010 12. Refill the power steering system and check for
leaks. If leaks are found, correct the cause of the
leak and bleed the system. Refer to Section 6A,
Power Steering System.
13. Connect the negative battery cable.

OUTER TIE ROD

Tools Required
KM-507-B Ball Joint Remover
Removal Procedure
1. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
2. Mark the threads on the inner tie rod to aid in reposi-
tioning the adjusting nut.
3. Remove the outer tie rod nut and disconnect the
outer tie rod from the steering knuckle using the ball
joint remover KM-507-B.
B105C005
4. Loosen the outer tie rod adjusting nut and remove the
outer tie rod by twisting it off the inner tie rod.
B105C001
1. Reposition the adjusting nut to the marks on the inner
tie rod.
B105C002

2. Install the outer tie rod by twisting it onto the inner tie
rod.
B105C004
3. Connect the outer tie rod to the steering knuckle.

4. Perform a front toe adjustment. Refer to Section 2B,
Wheel Alignment.
5. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 22 NSm
(16 lb-ft).
B105C008
6. Install the outer tie rod nut.

Tighten
Tighten the outer tie rod nut to 60 NSm (44 lb-ft).
7. Install the wheel. Refer to Section 2E, Tires and
Wheels.
B105C009

INNER TIE ROD

Removal Procedure
Wheels.
3. Remove the outer tie rod. Refer to “Outer Tie Rod” in
this section.
4. Remove the dust boot. Refer to “Dust Boot” in this
section.
5. Push back the plastic retainer that protects the con-
nection between the inner tie rod and the power
steering gear rack.
B105C013
6. Remove the inner tie rod.
B105C014
Important: The right and the left inner tie rods are un-
equal in length. Be sure to install the correct inner tie rod
on the proper side of the power steering gear.
1. Install the inner tie rod.
Tighten
Tighten the inner tie rods to 100 NSm (74 lb-ft).
B105C014

2. Push the plastic retainer over the tie rod.
3. Install the dust boot. Refer to “Dust Boot” in this
section.
4. Install the outer tie rod. Refer to “Outer Tie Rod” in
this section.
Wheels.
B105C013
DUST BOOT
Tools Required
KM-J-22610 Installer
Removal Procedure
1. Raise and suitably support the vehicle
Wheels.
3. Remove the outer tie rod. Refer to “Outer Tie Rod” in
this section.
4. Remove the dust boot retaining clamps.
B105C016
5. Remove the dust boot.
B105C018

1. Install the dust boot.
B105C018
2. Install the tie rod end dust boot retaining clamp.

Install the cylinder end dust boot retaining clamp with
the installer KM-J-22610.
3. Install the outer tie rod. Refer to “Outer Tie Rod” in
this section.
Wheels.
B105C019
STRAIGHT-AHEAD CHECK
After all the necessary operations on the steering gear
are completed (removing and installing, disassembling
and assembling), check the exact straight-ahead posi-
tion of the steering in each case.
With the vehicle on the floor, place the steering wheel in
the straight-ahead position. Mark the centerline of both
tires on the floor. Turn the steering wheel all the way to
the right and mark the new centerline of both tires on the
floor.
B105C060

Straight-Ahead Check Table

Step Action Value(s) Yes No
Place the steering wheel in the straight-ahead
1 position. - -
Is the wheel in the correct position? Go to Step 2
Is the lower intermediate shaft pinch bolt lying
2
parallel to the steering gear? - Go to Step 3 Go to Step 4
Is the steering wheel off-center by more than
3
5 degrees? - Go to Step 5 Go to Step 6
The pinion is displaced on the rack. Correct the
4 steering pinion position. - -
Is the repair complete? Go to Step 2
Remove steering wheel and center it on the spindle
5 splines. - -
Turn the steering wheel all the way to the right.
Measure the inner and the outer angles of the tire Inner angle:
6 centerline compared to the straight-ahead 36_
centerline. Outer angle:
Are the angles within specifications? 31.5_ System OK Go to Step 7
The rack assembly was not assembled correctly.
7 Repair it as needed. - -
INTERMEDIATE SHAFT AND DASH

SEAL
(Left-Hand Drive Shown, Right-Hand Drive
Similar)
Removal Procedure
1. Turn the steering wheel until it is horizontal, with the
spokes pointing down. This is the straight-ahead
position. Make a mark on the stub shaft housing that
lines up with a mark on the intermediate shaft lower
universal joint. This mark will be used for proper align-
ment during installation.
B105C024

2. Remove the lower pinch bolt from the universal joint
on the intermediate shaft.
B105C003
3. Turn the steering wheel to the straight-ahead posi-

tion. Remove the upper pinch bolt from the universal
joint on the intermediate shaft.
B105C028
4. Remove the nuts from the dash seal retaining ring

and remove the dash seal retaining ring.
B105C020

5. Remove the coupling from the power steering gear
and pull the intermediate shaft out of the engine
compartment.
B105C029
1. Install the intermediate shaft into the vehicle.
B105C029
2. Install the dash seal retaining ring with the nuts.

Tighten
Tighten the dash seal retaining ring nuts to 9 NSm
(80 lb-in).
B105C020

Important: When attaching the upper universal joint,
the steering wheel must be placed in the straight-ahead
position with the spokes pointing down.
3. Attach the upper universal joint of the intermediate
shaft onto the steering column.
4. Install the pinch bolt into the upper universal joint on
the intermediate shaft and tighten the bolt.
Tighten
Tighten the upper intermediate shaft pinch bolt to
25 NSm (18 lb-ft).
B105C028
Important: When attaching the lower universal joint, the

marks on the intermediate shaft and on the stub shaft
should line up.
5. Attach the lower universal joint of the intermediate
shaft onto the steering gear stub shaft.
B105C024
Important: When installing the lower intermediate shaft

pinch bolt, make sure the bolt goes through the univer-
sal joint on the side of the stub shaft with the notch. If
you have trouble seating the universal joint completely
down onto the stub shaft, rotate the steering wheel
slightly while pushing down on the universal joint.
6. Install the bolt into the lower universal joint on the
intermediate shaft and tighten the bolt.
Tighten
Tighten the lower intermediate shaft pinch bolt to
25 NSm (18 lb-ft).
B105C003

HYDRAULIC CYLINDER LINES

Removal Procedure
1. Siphon the power steering fluid from the fluid reser-
voir.
3. Disconnect the power steering gear hydraulic cylinder
pipes from the power steering gear at the valve end.
Replace the O-ring seals as needed.
B105A006
4. Disconnect the power steering gear hydraulic cylinder

pipes from the power steering gear at the cylinder
end.
5. Unclip the steering gear hydraulic cylinder pipes from
the power steering fluid reservoir return line and
remove them from the vehicle.
B105A005
1. Lubricate any new O-ring seals with power steering
fluid.
2. Place the O-ring seals into the housing and install the
steering gear hydraulic cylinder pipes.
3. Connect the power steering gear hydraulic cylinder
pipes to the power steering gear at the valve end.
Tighten
Tighten the hydraulic cylinder line fittings at the valve
end to 18 NSm (13 lb-ft).
B105A006

4. Connect the power steering gear hydraulic cylinder
pipes to the power steering gear at the cylinder end
and clip them to the power steering fluid reservoir
return line.
Tighten
Tighten the hydraulic cylinder line fittings at the
cylinder end to 27 NSm (20 lb-ft).
Notice: When adding fluid or making a complete
change, always use DEXRONr-III power steering fluid.
Failure to use the proper fluid will cause hose and seal
damage and fluid leaks.
6. Fill the fluid reservoir with power steering fluid.
7. Inspect for leaks. If there are leaks, correct the cause
of the leaks and bleed the system. Refer to “Bleeding
B105A005
the Power Steering System” in this section.

UNIT REPAIR
RACK AND PINION
Tools Required
KM-J-22610 Installer
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the valve and pinion assembly from the rack
and pinion steering assembly. Refer to “Valve and
Pinion” in this section.
3. Remove the rack bearing assembly from the rack and
pinion steering assembly. Refer to “Rack Bearing” in
this section.
B105C050
4. Mark the threads on the inner tie rod to aid in reposi-
tioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie rod
nut and the adjusting nut.
6. Remove the dust boot retaining clamps.
B105C011

7. Remove the dust boot.
B105C021
8. Push back the plastic retainer that protects the con-

nection between the inner tie rod and the power
steering gear rack.
B105C012
9. Counterhold the pinion-side inner tie rod and remove

the cylinder-side inner tie rod.
B105C023

10. Place a rag over the rack, counterhold the rack
assembly on the teeth with a wrench, and remove
the pinion-side inner tie rod.
B105C057
Important: The retaining ring can be released by insert-

ing a small screwdriver through the hole in the side of
the housing.
11. Remove the bulkhead inner cylinder retaining ring,
the bulkhead inner cylinder, and the rack.
B105C025
Assembly Procedure
Notice: Coat all the seals with power steering fluid to
ensure proper sealing.
1. Install the rack, the bulkhead inner cylinder, and the
bulkhead inner cylinder retaining ring.
B105C025

Notice: To prevent the inner tie rods from loosening,
use Loctiter 242 (or equivalent) on both inner tie rod
connections to secure them to the rack shaft.
Important: The right and the left inner tie rods are un-
equal in length. Be sure to install the correct inner tie rod
on the proper side of the power steering gear.
2. Firmly seat the inner tie rods against the rack and
tighten both ends simultaneously.
Tighten
Tighten the inner tie rods to 100 NSm (74 lb-ft).
B105C023
3. Push the plastic retainer back onto the connection

between the inner tie rod and the power steering gear
rack.
B105C012
4. Install the dust boot.
B105C021

5. Install the cylinder end dust boot retaining clamps
with the installer KM-J-22610.
B105C026
6. Install the tie rod end boot retaining clamps.
B105C027

7. Reposition the adjusting nut to the marks on the
inner tie rod and install the outer tie rod by twisting
it onto the inner tie rod.
8. Perform a front toe adjustment. Refer to Section 2B,
Wheel Alignment.
9. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 22 NSm
(16 lb-ft).
10. Install the rack bearing assembly into the rack and
pinion steering assembly. Refer to “Rack Bearing” in
this section.
11. Install the valve and pinion assembly into the rack
and pinion steering assembly. Refer to “Valve and
Pinion” in this section.
B105C010 12. Install the rack and pinion steering assembly into the
vehicle. Refer to “Rack and Pinion Assembly” in this
section.
STUB SHAFT SEALS AND UPPER

AND LOWER BEARING
this section.
2. Remove the dust cover from the lower end of the
housing.
B105C054

Notice: If the stub shaft is not held, damage to the
pinion teeth will occur.
3. While holding the stub shaft with a wrench, remove
the locknut from the pinion.
B105C055
4. With the gear centered, mark the location of the stub

shaft notch on the housing to aid in properly installing
the valve and pinion assembly.
B105C031
5. Remove the stub shaft retaining ring and, using an

arbor press, press on the threaded end of the pinion
until it is possible to remove the pinion and valve
assembly from the housing.
B105C030

6. Remove the stub shaft dust seal, the stub shaft
bearing annulus assembly, and the valve assembly
from the housing. Discard the stub shaft dust seal.
B105C032
7. Remove the lower valve assembly bearing and the

bushing.
B105C034
8. Remove the lower bearing assembly retaining ring

and press the lower bearing assembly from the lower
end of the housing.
B105C033

Assembly Procedure
Notice: Coat all the seals with power steering fluid to
ensure proper sealing and prevent vehicle damage.
1. Install the lower bearing assembly and the lower
bearing assembly retaining ring into the lower end of
the housing.
B105C033
2. Install the lower valve assembly bearing and the

bushing.
B105C034
3. Center the rack in the housing.

4. Install the the valve assembly, the stub shaft bearing
annulus assembly, and a new stub shaft dust seal into
the housing.
B105C032

Important: When the valve and pinion assembly is fully
seated in the housing, be sure that the notch in the stub
shaft and the mark on the housing line up.
5. While holding the stub shaft, install the locknut onto
the pinion shaft.
Tighten
Tighten the pinion locknut to 30 NSm (22 lb-ft).
B105C058
6. Replace the dust cover onto the housing.

7. Install the rack and pinion steering assembly. Refer to
“Rack and Pinion Assembly” in this section.
B105C054
RACK BEARING
Tools Required
J-42459 Rack Guide Spring Cap Wrench
this section.
2. Remove the adjuster plug locknut from the adjuster
plug, and remove the adjuster plug from the housing
with the rack guide spring cap wrench J-42459, or
with a 19 mm allen wrench.
C105C035

3. Remove the adjuster spring and the rack bearing.
B105C053
Assembly Procedure
1. Coat the rack bearing, the adjuster spring, and the
adjuster plug with lithium-based grease and install
them into the housing.
B105C035
2. With the rack centered, turn the adjuster plug clock-

wise until a torque of 5 NSm (44 lb-in) is obtained,
then back it off by 30 to 40 degrees. Check the pinion
torque. Maximum pinion preloaded torque is 1 NSm
(9 lb-in).
3. Thread the locknut on the adjuster plug and tighten it
while holding the adjuster plug stationary with the
rack guide spring cap wrench J-42459 or with a
19 mm allen wrench.
Tighten
Tighten the adjuster plug locknut to 70 NSm (52 lb-ft).
4. Install the rack and pinion assembly. Refer to “Rack
and Pinion Assembly” in this section.
C105C035

RACK BEARING PRELOAD

ADJUSTMENT
Adjustment Procedure
2.Center the steering wheel.
3. Remove the power steering gear. Refer to “Rack and
Pinion Assembly” in this section.
4. Loosen the locknut and turn the adjuster plug clock-
wise until a torque of 5 NSm (44 lb-in) is obtained,
then loosen it by 30 to 40 degrees.
5. Tighten the locknut on the adjuster plug while holding
the adjuster plug stationary.
6. Install the power steering gear. Refer to “Rack and
Pinion Assembly” in this section.
7. Be sure to check the returnability of the steering
B105C015 wheel to center position after adjustment.
Tighten
Tighten the adjuster plug locknut to 70 NSm (52 lb-ft).
VALVE AND PINION

this section.
2. Remove the dust cover from the lower end of the
housing.
B105C054

3. While holding the stub shaft, remove the locknut from
the pinion.
B105C055
4. With the gear centered, mark the location of the stub

shaft notch on the housing to aid in properly installing
the pinion and valve assembly.
B105C031
5. Remove the upper housing retaining ring and, using

an arbor press, press on the threaded end of the
pinion until it is possible to remove the valve and
pinion assembly from the housing.
B105C030

6. Remove the stub shaft dust seal, the stub shaft
bearing annulus assembly and the valve and pinion
assembly from the housing.
B105C032
7. Inspect the valve body rings for wear or damage.

Replace the valve body rings as needed. Coat the
rings with power steering fluid before installation.
8. Remove the lower pinion valve seal and bushing.
Discard the seal.
B105C034
Assembly Procedure
Notice: Coat all of the seals and bushings with power
steering fluid to ensure proper sealing and prevent ve-
hicle damage.
1. Install the bushing and a new lower pinion valve seal.
B105C034

Important: When the valve and pinion assembly is fully
seated in the housing, be sure the notch in the stub shaft
and the mark on the housing line up. If this is not done,
the vehicle will not pass the straight-ahead check and
will have poor steering performance.
2. Install the valve and pinion assembly, the stub shaft
bearing annulus assembly, and the stub shaft dust
seal.
B105C032

3. While holding the stub shaft, tighten the locknut onto
the pinion shaft.
Tighten
Tighten the pinion locknut to 30 NSm (22 lb-ft).
B105C058
4. Replace the dust cover onto the housing.

5. Install the rack and pinion steering assembly. Refer to
“Rack and Pinion Assembly” in this section.
6. Perform the straight-ahead check. Refer to “Straight-
Ahead Check” in this section.
B105C054

GENERAL DESCRIPTION transmitted through the tie rods to the steering knuckles,
which turn the wheels.
AND SYSTEM OPERATION If power rack and pinion steering is not available,
manual rack and pinion control is used; however, with
POWER RACK AND PINION this system more steering effort is required. The move-
ment of the steering wheel is transferred to the pinion.
The power rack and pinion steering system has a rotary The rotary movement of the pinion is then transferred
control valve that directs hydraulic fluid coming from the through the pinion threads, which mesh with teeth on
hydraulic pump to one side or the other side of the rack the rack, thereby causing the rack to move in a linear
piston. The integral rack piston is attached to the rack. direction.
The rack piston converts hydraulic pressure to a linear A vane-type hydraulic pump provides hydraulic pressure
force that moves the rack left or right. That force is then for both steering systems.

Power Steering Gear: Section 6C

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Power Steering Gear: Section 6C

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SECTION 6C

POWER STEERING GEAR

DAEWOO J-100 BL2 / BL3

FASTENER TIGHTENING SPECIFICATIONS

Application NSm Lb-Ft Lb-In

DAEWOO J-100 BL2 / BL3

Rattling Noise in Steering Gear

Poor Return of Steering Wheel to Center

Momentary Increase in Effort When Turning the Wheel Quickly

DAEWOO J-100 BL2 / BL3

Steering Surges or Jerks When Turning with Engine Running

Steering Vibrates During Low Speed or Static Steering

Excessive Wheel Kickback or Loose Steering

Hard Steering or Lack of Assist (Especially During Parking)

DAEWOO J-100 BL2 / BL3

DAEWOO J-100 BL2 / BL3

6. Disconnect the power steering gear fluid inlet pipe.

DAEWOO J-100 BL2 / BL3

9. Loosen the intermediate shaft pinch bolt.

10. Remove the crossmember assembly. Refer to Sec-

DAEWOO J-100 BL2 / BL3

5. Tighten the lower intermediate shaft pinch bolt.

DAEWOO J-100 BL2 / BL3

7. Connect the power steering gear fluid outlet pipe.

DAEWOO J-100 BL2 / BL3

OUTER TIE ROD

DAEWOO J-100 BL2 / BL3

3. Connect the outer tie rod to the steering knuckle.

6. Install the outer tie rod nut.

DAEWOO J-100 BL2 / BL3

INNER TIE ROD

6. Remove the inner tie rod.

DAEWOO J-100 BL2 / BL3

5. Remove the dust boot.

DAEWOO J-100 BL2 / BL3

2. Install the tie rod end dust boot retaining clamp.

DAEWOO J-100 BL2 / BL3

Straight-Ahead Check Table

INTERMEDIATE SHAFT AND DASH

DAEWOO J-100 BL2 / BL3

3. Turn the steering wheel to the straight-ahead posi-

4. Remove the nuts from the dash seal retaining ring

DAEWOO J-100 BL2 / BL3

2. Install the dash seal retaining ring with the nuts.

DAEWOO J-100 BL2 / BL3

Important: When attaching the lower universal joint, the

Important: When installing the lower intermediate shaft

DAEWOO J-100 BL2 / BL3

HYDRAULIC CYLINDER LINES

4. Disconnect the power steering gear hydraulic cylinder

DAEWOO J-100 BL2 / BL3

DAEWOO J-100 BL2 / BL3

6. Remove the dust boot retaining clamps.

DAEWOO J-100 BL2 / BL3

8. Push back the plastic retainer that protects the con-

9. Counterhold the pinion-side inner tie rod and remove

DAEWOO J-100 BL2 / BL3

Important: The retaining ring can be released by insert-