LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saturn >> 2007 >> Relay 3.9 1 >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

  1. Position the power steering gear to the vehicle through the left side wheel opening.
    2. Fig 1: View Power Steering Gear Mounting Nuts And Bolts
    GM1801645Courtesy of GENERAL MOTORS CORP.
    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 .
  2. Install the power steering gear mounting nuts (1) and bolts (2).

    Tighten:  Tighten the power steering gear nuts (1) and bolts (2) to 60 N.m (44 lb ft) plus 60 degrees.

    3. Fig 2: Power Steering Gear Inlet Pipe/Hose And Power Steering Cooler Pipe/Hose
    GM1801586Courtesy of GENERAL MOTORS CORP.
  3. Using NEW O-ring seals, connect the power steering gear inlet pipe/hose and power steering cooler pipe/hose to the power steering gear.

    Tighten: 

    • Tighten the power steering gear inlet pipe/hose fitting to 27 N.m (20 lb ft).
    • Tighten the power steering cooler pipe/hose fitting to 27 N.m (20 lb ft).

    4. Fig 3: Power Steering Gear Heat Shield Bolts And Shield
    GM1831765Courtesy of GENERAL MOTORS CORP.
  4. Position the steering gear heat shield and install the 2 bolts.

    Tighten:  Tighten the steering gear heat shield bolts to 14 N.m (124 lb in).

  5. Using the jack stand, raise the rear of the cradle support.
  6. Install the 2 rear cradle support bolts.

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

  7. Remove the jack stand.
    8. Fig 4: View Of Intermediate Shaft Pinch Bolt
    GM1831763Courtesy of GENERAL MOTORS CORP.
  8. Position the intermediate shaft to the steering gear and install the pinch bolt.

    Tighten:  Tighten the bolts to 48 N.m (35 lb ft).

  9. Position the outer tie rod ends into the steering knuckles.
    10. Fig 5: View Of Outer Tie Rod Castle Nut
    GM1801218Courtesy of GENERAL MOTORS CORP.
    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.
    IMPORTANT: Ensure that 2.5-4.5 tie rod end threads are visible beyond the tie rod nut nylon.
  10. Install the outer tie rod end castle nuts.

    Tighten:  Tighten the outer tie rod end castle nuts to 30 N.m (22 lb ft) + 120 degrees (2 flats).

  11. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement (with Rear IRS) or Stabilizer Shaft Replacement (with Rear Twist Axle) .
  12. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  13. Lower the vehicle.
  14. Fill and bleed the air from the system. Refer to Power Steering System Bleeding .
  15. Inspect and adjust front toe as necessary. Refer to Front Toe Adjustment .
scientia non olet · About LEMON Manuals