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Home >> Chevrolet >> 2004 >> Optra Base, Standard >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Steering Gear Replacement >> Removal Procedure
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Removal Procedure

    Fig 1: View Of Power Steering Gear And Pipes
    GM1290083Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable.
    2. CAUTION: Refer to Vehicle Lifting Caution in Cautions and Notices.
  2. Raise and suitably support the vehicle.
  3. Remove the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  4. Disconnect the power steering gear fluid outlet pipe. Place a drain pan under the steering gear to catch the power steering fluid.
  5. Disconnect the power steering gear fluid inlet pipe.
    6. Fig 2: Identifying Alignment Mark Location
    GM1290982Courtesy of GENERAL MOTORS CORP.
    NOTE: Use only the spark plug boot special removal tool to remove the spark plug boots. Prying or using regular pliers could damage the boots.
  6. Position the steering gear straight ahead by turning the steering wheel until the steering wheel spokes are vertical and pointed to the left.
  7. Scribe a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower coupling.
    8. Fig 3: View Of Intermediate Shaft Lower Pinch Bolt
    GM1290983Courtesy of GENERAL MOTORS CORP.
  8. Remove the intermediate shaft pinch bolt.
    9. Fig 4: View Of Outer Tie Rod, Nut And KM-507-C
    GM1290984Courtesy of GENERAL MOTORS CORP.
  9. Remove the outer tie rod nuts and disconnect the tie rod ends from the strut assembly using KM-507-C  . See Special Tools .
  10. Remove the crossmember assembly. Refer to Front Suspension Crossmember Replacement in Front Suspension.
  11. Remove the transaxle center bracket, if equipped with automatic transaxle. Refer to Transmission Mount Bracket Replacement in Automatic Transmission - ZF 4HP 16.
  12. Remove the bolts securing the transaxle center bracket to the transaxle and the engine, if equipped with a manual transaxle. Move the transaxle center bracket out of the way.
    13. Fig 5: View Of Steering Gear Mounting Bracket And Bolts
    GM1290986Courtesy of GENERAL MOTORS CORP.
  13. Remove the nuts and bolts from the steering gear mounting bracket.
    14. Fig 6: View Of Return Pipe Clip And Bolt
    GM1290084Courtesy of GENERAL MOTORS CORP.
  14. Remove the return line from the clip on the crossmember.
  15. Disconnect the rack and pinion assembly from the crossmember assembly.
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