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Home >> Saturn >> 2005 >> Relay AWD >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Exploded View Of Power Steering Gear
    GM294314Courtesy of GENERAL MOTORS CORP.
  1. Install the power steering gear through the vehicle left side wheel opening to the frame.
  2. Install the power steering gear bolts.
    3. IMPORTANT: This is a prevailing torque type fastener. This fastener may be reused ONLY if:
    • The fastener and its counterpart are clean and free from rust
    • The fastener develops 2 N.m (18 lb in) of torque/drag against its counterpart prior to the fastener seating.

    If the fastener does not meet these criteria, REPLACE the fastener.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the power steering gear nuts.

    Tighten:  Tighten the power steering gear nuts to 60 N.m (44 lb ft) plus 60 degrees.

  4. Install the power steering gear heat shield. Refer to Power Steering Gear Heat Shield Replacement .
    5. Fig 2: View Of Power Steering Lines And Power Steering Gear
    GM417973Courtesy of GENERAL MOTORS CORP.
  5. Connect the power steering gear pressure hose to the power steering gear.

    Tighten:  Tighten the fitting to 27 N.m (20 lb ft).

    6. Fig 3: View Of Power Steering Gear Cooler Pipe
    GM417967Courtesy of GENERAL MOTORS CORP.
  6. Connect the power steering gear cooler pipe to the power steering gear.

    Tighten:  Tighten the fitting to 27 N.m (20 lb ft).

  7. Install the power steering gear cooler pipe retaining clip.
  8. Use the utility stand in order to raise the frame and the powertrain.
  9. Install the frame rear bolts.

    Tighten:  Tighten the bolts to 165 N.m (122 lb ft).

  10. Remove the utility stand from the frame.
  11. Install the steering intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  12. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement  in Power Steering System.
  13. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement (FWD) or Stabilizer Shaft Replacement (AWD) in Front Suspension.
  14. Lower the vehicle.
  15. Fill the power steering system. Refer to Checking and Adding Power Steering Fluid .
  16. Bleed the air from the system. Refer to Bleeding the Power Steering System .
  17. Inspect the system for leaks. Refer to Power Steering Fluid Leaks .
  18. Inspect and adjust the toe as necessary. Refer to Front Toe Adjustment in Wheel Alignment.
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