SPECIAL POLICY: TEMPORARY REDUCTION OF POWER STRG.-COLD

MODELS AFFECTED: 1985-88 SKYHAWK WITH POWER STEERING AND ALUMINUM VALVE HOUSING STEERING GEARS 1985 AND 1987-88 SKYLARK WITH ALUMINUM VALVE HOUSING STEERING GEARS 1985 REGAL SOMERSET 1986 SOMERSET 1985-88 CENTURY WITH ALUMINUM VALVE HOUSING STEERING GEARS 1986-88 LESABRE, ELECTRA/PARK AVENUE AND RIVIERA WITH ALUMINUM VALVE HOUSING STEERING GEARS

This bulletin is being issued to supplement bulletin 85-POL-2 dated January, 1988, and updated by bulletin supplements A, B, C, and D.

Some 1985-88 Skyhawk, 1985 and 1987-88 Skylark, 1985 Regal Somerset, 1986 Somerset, 1985-88 Century and 1986-88 LeSabre, Electra/Park Avenue and Riviera model vehicles equipped with power steering may exhibit a temporary reduction of power steering assist when the vehicle is started cold. After a short period of engine operation, full assist is restored.

SPECIAL POLICY ADJUSTMENT

This special policy covers the condition described above for a period of five (5) years or 50,000 miles, whichever occurs first, from the date the vehicle was originally placed in service. Correction will consist of installation of a seal service kit.

This "Special Policy Adjustment Bulletin" should be filed in the three ring binder previously furnished to dealers by General Motors.

SPECIAL POLICY ADJUSTMENT ANNOUNCEMENT

This special policy will be announced to owners by a general press release.

VEHICLES INVOLVED

All 1985-87 Skyhawks With Power Steering All 1985 and 1987 Skylarks All 1985 Regal Somersets All 1986 Somersets All 1985-87 Centurys All 1986-87 LeSabre, Electra/Park Avenues and Rivieras All 1988 Skyhawks, Skylarks, Centurys, LeSabres, Electra/Park Avenues and Rivieras within the following serial numbers:

SERIES PLANT FROM THROUGH AND INCLUDING ------ ----- ---- --------------------- Skyhawk Leeds JK400001 JK420909 Skylark Lansing JM000001 JMO28119 Century Tarrytown JT400001 JT428989 Oklahoma City J6400001 J6426495 LeSabre Buick City JH400001 JH469801 With F41 JH507159 Less F41 Electra/ Wentzville J1600001 J1669604 Park Avenue Riviera Hamtramck JU400001 JU405112 Less FE3 JU405229 With FE3

REIMBURSEMENT

Customer requests for reimbursement for prior repairs to correct a condition of temporary reduction of power steering assist when cold, are to be submitted according to the instructions included in this bulletin. Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expenses, a description of the repair, the date of the repair, and the person or entity performing the repair.

PARTS INFORMATION

Parts are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered on a "C.I.O." order with NO special instruction code, but on an advise code (2).

PART NUMBER DESCRIPTION QUANTITY/VEHICLE ----------- ----------- ----------------- 26010340 Seal Service Kit 1

SERVICE PROCEDURE

See instruction sheets attached to this bulletin for installation of Seal Service Kit. Special tools required for this repair (previously furnished to dealers are as follows:

- J 37090 Pinion and Valve Ring Protector - J 29822 Pinion Seal Installer - J 29810 Stub Shaft Seal Protector

In the unlikely event the Seal Service Kit does not correct the condition, installation of a short gear assembly may be necessary. PRIOR AUTHORIZATION IS REQUIRED FOR INSTALLATION OF A SHORT GEAR ASSEMBLY. Contact your Zone/Branch for prior authorization. Order parts from appropriate service parts catalog and follow service procedure in applicable service manual.

RETURN OF STEERING GEAR ASSEMBLIES

To assure proper payment for work performed for short gear installation under this special policy program, the following MUST be supplied with the returned assemblies:

- A copy of the repair order including the VIN and the labor operation performed.

- The dealer code of the dealer performing the service.

Refer to General Motors Parts Information Bulletin IB No. 88-48 for further shipping instructions.

WARRANTY CLAIM INFORMATION

When performing the repairs outlined in the Service Procedure of this bulletin, submit a warranty claim for credit, as follows:

FAILED OTHER SUBLET LABOR OP TROUBLE REPAIR PART PARTS LABOR HOURS DLR*** NUMBER CODE MODEL PERFORMED NUMBER ALLOW HOURS ****** MTL TWG ------ ---- ----- --------- ------ ----- ----- ------ -------- T1464 95 85-88 Install 26010340 * # 1.0 $5.15 Skyhawk Seal Serv. Kit

T1463 95 85 Skylark " " * # 1.0 "

T1470 95 85 Regal " * # 1.0 " Somerset 86 Somerset 87-88 Skylarks

T1465 95 85-88 Cent " * # 1.0 "

T1468 95 86-88 LeSab * # 1.0 " Electra & Pk Ave " T1469 95 86-88 Riv. " * # 1.0

T1478 ****95 85-88 Install ** * ## -- " Skyhawk Replacement Short Gear

T1477 ****95 85 Skylark " ** * ## -- "

T1484 ****95 85 Regal " ** * ## -- " Somerset 86 Somerset 86-87 Skylark

T1479 ****95 85-88 Century " ** * ## -- "

T1482 ****95 86-88 LeSab " ** * ## -- " Electra/Pk Ave

T1483 ****95 86-88 Riv " ** * ## -- "

T1471 ****95 All Reimbursement for See Instructions Previous repair For Reimbursement

* List current dealer price of part, plus 30%

** Use part number of appropriate Rack and Pinion (short gear).

*** Allowance for power steering fluid used in conjunction with these operations.

**** These "T" operations are only to be used in the unlikely event that the Seal Service Kit does not correct the condition. PRIOR AUTHORIZATION FROM YOUR ZONE/BRANCH WILL BE REQUIRED.

***** The 1.0 hours in the "Other Hours" column for labor operations T1463, T1464, T1465, T1468, T1469, and T1470 represent time required for seal kit installation.

# Use applicable warranty labor time guide for steering gear assembly R and R (Operation Number E9720).

## Use applicable warranty labor time guide for short gear replacement (Operation Number E9730).

REQUEST FOR REIMBURSEMENT INSTRUCTIONS

1. Customer presents dealer with original paid receipts covering repairs to correct a temporary reduction of power steering assist when cold condition.

2. Dealer Completes a Repair Order (R.O.) showing:

- Repair order date. - Vehicle Identification Number. - Current mileage. - Owner's address. - Attaches original owner's or dealer's paid invoices/receipts covering repair within the Special Policy 5 year/ 50,000 mile guidelines. - Use Labor Operation Number T1471 and Failure Code 95. - Enters total amount of reimbursement based on 100% of OWNER'S EXPENSE related to covered steering repair.

3. Owner signs the repair order as acknowledgement of requested reimbursement amount.

4. Owner is given a copy of repair order.

5. Dealer assigns a Warranty Management System (WMS) authorization code to the claim and enters it on the WMS Authorization Log.

6. The dealer submits a claim to Buick for processing.

7. Dealer issues the owner a reimbursement check for the approved amount. The check number must be entered on the repair order and a copy of the check must be attached to original paid invoices/receipts.

8. All supporting documentation must be available for review by Buick personnel as needed.

NOTICE: Refer to Buick Service Policies and Procedures Manual, Section 1.6.1 l for specific procedures for Customer Reimbursement verification.

In the event the Dealer Service Manager and the owner cannot reach agreement on amount eligible for reimbursement after review of invoices/receipts, the Zone/Branch should be contacted for detemination of covered expenses. In such cases, an explanation should be included on the R.O.

INSTRUCTION SHEET

FOR EFFECTIVE REPAIR, USE ALL PARTS IN KIT REGARDLESS OF ORIGINAL CONDITION.

SERVICE PROCEDURE FOR INSTALLING "SPECIAL" VALVE BODY RINGS ON RACK AND PINION ASSEMBLIES WITH HARD STEERING ON INITIAL START-UP

READ INSTRUCTIONS COMPLETELY AND CAREFULLY BEFORE PROCEEDING.

Some complaints about the power steering system on initial start up may be reported as:

Reduced power steering assist when parking. Increased steering effort.

For further information, refer to the "Steering Diagnosis" section in vehicle service manual.

Tools Required:

J 37090 Pinion and Valve Ring Protector J 29822 Pinion Seal Installer J 29810 Stub Shaft Seal Protector

A. Remove rack and pinion assembly from car.

B. Valve removal:

1. Remove adjuster plug lock nut from adjuster plug.

2. Remove adjuster plug from housing.

3. Remove adjuster spring, rack bearing and O-ring if required.

4. Drain power steering fluid from gear. (Rotate stub shaft allowing rack to travel corner to corner for removal.)

5. Remove retaining ring from housing.

6. Remove dust cover from housing.

7. While holding the stub shaft, remove lock nut from pinion.

Important

If stub shaft is not held, damage to the pinion teeth will occur.

8. With gear centered, mark location of stub shaft flat or notch on housing and measure distance "A" indicated in Figure 3 for your specific vehicle; this will aid in proper reassembly.

Important

DO NOT hammer or pound on pinion and valve assembly, this could cause damage or loosen the drive pin.

9. Use an arbor press to press on threaded end of pinion until it is possible to remove the pinion and valve assembly from housing. Just before removal of pinion and valve assembly from housing, mark second location of stub shaft flat or notch on housing. The second mark is used to position flat or notch prior to reassembly.

10. Remove stub shaft dust seal, stub shaft seal, stub shaft bearing annulus assembly, pinion and valve assembly, with spool shaft retaining ring, and valve body rings attached.

11. Remove valve body rings from pinion and valve assembly.

Important

Use care when removing rings from valve assembly to prevent damage to valve assembly.

12. Thoroughly clean valve assembly ring grooves.

Inspect

Inspect pinion and valve assembly for broken drive pin. If broken drive pin is found, replace the gear assembly.

Important

Use the same Housing and Valve Assembly regardless of depth of grooves in housing bore.

C. Install new split rings onto the valve assembly as follows:

Important

Valve assemblies and housings are NOT interchangeable. The same valve assembly MUST be reinstalled or rack and pinion assembly must be replaced.

Important

Apply a liberal quantity of grease supplied in kit, in each ring groove and to new valve body rings when installed to hold rings in position. (See Figure 7.)

1. Install new valve body rings to pinion and valve assembly. (Care must be taken not to cut rings at installation.)

2. Place pinion and valve assembly into clear pinion and valve assembly ring protector J 37090. (Be sure to use only the clear protector.) Allow to set for approximately three minutes while continuing installation preparation. This allows the valve rings to be properly sized.

3. Position valve assembly in protector so that valve body is flush with bottom of clear protector. (See Figure 8.)

Inspect

Inspect valve body rings for cuts, nicks or other damage, proper seating of rings in grooves and engagement of split tabs.

4. Rack must be centered in housing. (See Figure 3 on page 2.)

5. Wipe housing bore clean of any foreign material.

Important

Apply a liberal quantity of grease to the valve housing bore. Be sure to fill grooves with grease. This will ease reassembly of valve into housing.

Inspect

Inspect stub shaft bearing annulus for flatness and damage. Clean before reassembly.

6. Align stub shaft flat or notch with second mark on housing made during disassembly. (See step 9 on page 2.) Install pinion and valve assembly with spool shaft retaining ring, and valve body rings included, into housing using J 37090 to prevent damage to valve rings during assembly.

Important

Set pinion and valve assembly onto housing using J 37090. Use J 29822 pinion seal installer to push assembly into housing bore. DO NOT hammer or use excessive force. If pinion and valve assembly does not fully seat in housing, check to be sure valve body rings are not binding in housing bore. Check rings for cuts or damage. Repeat installation steps 1 through

Inspect

When pinion and valve assembly is fully seated, flat or notch in stub shaft and first mark on housing must line up while the rack is centered in the housing. Refer to measurement "A" to verify proper rack position. (See Figure 3.)

7. While holding the stub shaft, thread lock nut onto pinion and torque to 35 N-m (26 Lbs. Ft.).

Important

If the stub is not held, damage to the pinion teeth will occur.

8. Install dust cover to housing.

9. Install stub shaft bearing annulus onto stub shaft.

10. Place seal protector J 29810 onto stub shaft.

11. Install stub shaft seal and stub shaft dust seal over protector and into housing. (Apply a small quantity of grease between seals and on top of dust seal.)

12. Install retaining ring into groove in housing.

13. Coat rack bearing, adjuster spring and adjuster plug with lithium base grease and install in housing. (See Figure 13.)

Adjust

With rack centered in the housing, turn adjuster plug clockwise until it bottoms in the housing, then back off 50 DEG to 70 DEG (approx. one flat). Check torque on pinion. Maximum pinion preload torque is 1.8 N-m (16 Lbs. In.).

14. Install adjuster plug lock nut to adjuster plug. Tighten firmly against housing while holding adjuster plug stationary.

15. Install rack and pinion assembly into car. (Use appropriate service manual.)

Important

Flush power steering system (hoses, reservoir and cooler lines) with power steering fluid - GM Part #1050017 (or equivalent meeting GM Specification #985010). Disconnect return line at pump reservoir. (Refer to bleeding procedure in vehicle service manual.) Be sure pump reservoir fluid level is maintained during the flush procedure.

16. Reconnect return line at pump reservoir.

17. Fill with power steering fluid.

18. Bleed air from system.

Inspect

Inspect for leaks.

19. Check toe angle and reset if necessary.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.