SPECIAL POLICY: TEMPORARY REDUCTION OF POWER STRG.-COLD

TEMPORARY REDUCTION OF POWER STEERING ASSIST WHEN COLD (Revised to Update Page 5)

VEHICLES AFFECTED: 1982-84 'A', 'J' AND 'X' CARS AND 1985 'C' CARS WITH POWER STEERING; 1982-84 CHEVROLET CELEBRITY, CAVALIER AND CITATION, PONTIAC 6000, SUNBIRD AND PHOENIX, OLDSMOBILE CIERA, FIRENZA AND OMEGA, BUICK CENTURY, SKYHAWK AND SKYLARK, CADILLAC CIMARRON; 1985 OLDSMOBILE NINETY-EIGHT, BUICK ELECTRA AND CADILLAC DEVILLE WITH POWER STEERING

General Motors has determined that some 1982-84 'A, J, X' and 1985 'C' Cars 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 80,000 Kilometers whichever occurs first, from the date the vehicle was originally placed in service. Correction of this condition will consist of installation of a seal service kit.

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

SPECIAL POLICY ADJUSTMENT ANNOUNCEMENT

This special policy will be announced to owners by a general press release (a representative copy of the press release is included with this bulletin).

REIMBURSEMENT

Customer claims for reimbursement on previously paid repairs to correct a temporary reduction of power steering assist when cold condition, are to be submitted according to the instructions included with 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.

Quantity/ Part Number Description Vehicle ----------- ----------- --------- 26010340 Seal Service Kit .............. 1

A quantity of seal service kits will be preshipped along with a service procedure training video tape and all necessary special tools, on a no charge basis. Additional seal service kits, as required, are to be ordered. Special tools to be shipped each dealer are as follows:

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

SERVICE PROCEDURE

See instruction sheet attached to this bulletin for installation of Seal Service Kit.

In the unlikely event the seal service kit does not correct the condition, installation of a replacement gear assembly may be necessary. ZONE AUTHORIZATION WILL BE REQUIRED FOR INSTALLATION OF A REPLACEMENT GEAR ASSEMBLY. Order parts from the appropriate service parts catalog and follow service procedure in applicable service manual.

RETURN OF STEERING GEAR ASSEMBLIES

To assure proper payment for work performed when steering gear assemblies are replaced under this special policy program, the following MUST be suppli- ed with the returned assemblies:

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

- The dealer code of the dealer performing the service Steering gear assemblies returned for reasons other than this special policy need not include the above information.

WARRANTY CLAIM INFORMATION

A. SEAL SERVICE KIT INSTALLATION

When performing the installation as outlined in this bulletin, submit a warranty claim for credit as follows:

Labour Parts Failed Parts Operation Time Net Item Count Part Number Amount Number Description Allowance Amount- ----- ----------- ------ --------- ----------- --------- -------- 1 26010340 * * TXXXX * Install Seal Kit * $9.07***

* Refer to the chart 1 for Labour Operation and Time Allowance.

* * Enter the Dealer Net Price (in effect at the time of repair), Plus 30% for the Seal Service Kit Part No. 26010340.

*** the $9.07 identified in the "Net Item Amount" column represents the cost plus 30% of power steering fluid used in conjunction with these repairs.

Authorization IS NOT REQUIRED for claims meeting the criteria outlined in this bulletin.

B. REPLACEMENT GEAR INSTALLATION

In the unlikely event that the Seal Service Kit does not correct the condition, a replacement gear may need to be installed. Submit a warranty claim for credit as follows:

Labour Parts Failed Parts Operation Time Net Item Count Part Number Amount Number Description Allowance Amount ----- ----------- ------ --------- ----------- --------- --------- 1 **** ** TXXXX * Install * $9.07*** Replacement Gear

* Refer to the chart 2 for Labour Operation and Time Allowance.

* * Enter the Dealer Net Price (in effect at the time of repair), Plus 30% for the Replacement Steering Gear Assembly.

*** the $9.07 identified in the "Net Item Amount" column represents the cost plus 30% of power steering fluid used in conjunction with these repairs.

**** Enter the part number for the Replacement Steering Gear Assembly.

Authorization IS REQUIRED for all claim submissions which fall into the gear replacement category.

C. OWNER REIMBURSEMENT

Claims for customer reimbursement of previously paid repairs are to be submitted as a Net Item Dollar Amount on a warranty claim as follows:

Labour Net Item Operation Dollar Number Amount ---------- -------- T10221303 $xx.xx

Authorization IS REQUIRED on all claim submissions which fall into the Owner Reimbursement category. This labour operation is to be used for owner reimbursement only.

SAMPLE PRESS RELEASE

DETROIT -- General Motors is making available, a Special Policy of five years or 80,000 kilometers to cover a temporary reduction in power steering assist on some 4.7 million GM front-wheel drive cars produced between 1982 and 1985.

Some of the vehicles may experience reduced power steering assist upon first starting the car, primarily in cold weather. Once the system warms up - - usually in one or two minutes -- normal power steering assist is restored. The phenomenon does not occur while the vehicle is being driven after warmup.

GM dealers will repair free of charge power steering systems that exhibit the problem for five years or 80,000 kilometers, whichever occurs first. GM will reimburse owners who in the past paid to have the problem corrected, within the time and mileage limits of the Special Policy, provided they present proper receipts to their dealer.

Specific models included are as follows:

o 1982-84 Buick Skyhawk, Skylark and Century; Cadillac Cimarron; Chevrolet Cavalier, Citation and Celebrity; Oldsmobile Firenza, Omega and Cutlass Ciera; and Pontiac Sunbird, Phoenix and 6000 models.

o 1985 Buick Electra, Cadillac DeVille and Oldsmobile Ninety-Eight models.

INSTRUCTION SHEET

FOR EFFECTIVE REPAIR, USE ALL PARTS W 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:

o Reduced power steering assist when parking. o 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 nicks or loose drive pin. If a loose drive pin is found, replace the gear assembly.

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 370". 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 5. If pinion and valve assembly will not align properly in housing bore, replace rack and pinion assembly.

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 14.)

ADJUST

With rack centered in the housing, turn adjuster plug clockwise until it bottoms in the housing, then back off 500 to 700 (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 #9985010). 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.