SPECIAL POLICY: TEMPORARY REDUCTION/POWER STRG.-COLD

Model and Year: 1985-88 CELEBRITY, CAVALIER 1987-88 CORSICA, BERETTA 1985 CITATION

TO: ALL CHEVROLET DEALERS

This bulletin is being issued to supplement bulletin #84-272-3B dated January 1988. The vehicles listed below are equipped with power steering and 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 ANNOUNCEMENT

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

VEHICLES INVOLVED

Involved are all 1985-87 Chevrolet Celebrity & Cavalier,1985 Citation,1987 Corsica & Beretta, and also 1988 models within the following VIN breakpoints:

YEAR MODEL PLANT FROM THROUGH ---- ----- ----- ---- ------- 1988 "A" FRAMINGHAM JG100001 JG108701

" STE. THERESE J2100001 J2135649

" RAMOS ARIZPE JS100001 JS514610

"A" OKLAHOMA CITY J6100001 J6181328

"L" LINDEN JE100001 JE509735

"L" WILMINGTON JY100001 JY525519

"J" LORDSTOWN J7100001 J7158411

"J" JANESVILLE JJ100001 JJ184475

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 regardless of ownership. 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.

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 in this bulletin using the attached "Request For Reimbursement" form. Additional copies of the form are to be reproduced by Dealer. Owners must submit original repair invoices along with proof of payment (Charge card receipt, copy of cancelled check, or receipt marked "PAID" if paid with cash). The customer repair invoice should provide the description of the repair made and person or facility performing the repair. These documents are to be retained by the Dealer with the Dealer repair order and supporting warranty records.

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 Area Manager - Service for prior authorization. Order parts from appropriate service parts catalog and follow service procedure in applicable service manual.

CLAIM INFORMATION

Submit a Warranty Claim with the information indicated below:

* *** Failed Parts Labor LAB OTH NET Repair Performed PC Part No. Allow FC OP HRS HRS AMT ---------------- -- -------- ----- -- -- --- --- --- Install Seal Kit 1 26010340 ** 00 T1463 # 1.0 $5.15 1985 Citation

Install Sea Kit 1 26010340 ** 00 T1464 # 1.0 $5.15 1985-88 Cavalier

Install Seal Kit 1 26010340 ** 00 T1465 # 1.0 $5.15 1985-88 Celebrity

Install Seal Kit 1 26010340 ** 00 T1466 # 1.0 $5.15 1987-88 Corsica

Install Seal Kit 1 26010340 ** 00 T1467 # 1.0 $5.15 1987-88 Beretta

Use Install Short Gear 1 Applicable ** 00 T1477 ## --- $5.15 1985 Citation GMSPO P/N ****

Use Install Short Gear 1 Applicable ** 00 T1478 ## --- $5.15 1985-88 Cavalier GMSPO P/N ****

Use Install Short Gear 1 Applicable ** 00 T1479 ## --- $5.15 1985-88 Celebrity GMSPO P/N ****

Use Install Short Gear 1 Applicable ** 00 T1480 ## --- $5.15 1987-88 Corsica GMSPO P/N ****

Use Install Short Gear 1 Applicable ** 00 T1481 ## I --- $5.15 1987-88 Beretta GMSPO P/N ****

* The 1.0 Hrs. in the "Other Hours" column for labor operations T1463, T1464, T1465, T1466 and T1467 represents the time required for seal kit installation.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

*** The $ 5.15 identified in the "Net Amount" column represents the cost plus 30% for power steering fluid used in conjunction with these labor operations.

**** T1477, T1478, T1479, T1480 and T1481 are only to be used in the unlikely event that the Seal Service Kit does not correct the condition. AREA MANAGER-SERVICE AUTHORIZATION ("C") WILL BE REQUIRED.

# Use applicable warranty labor time guide for power steering gear assembly R and R (operation number E9720).

## Use applicable warranty labor time guide for power steering short gear assembly installation (operation number E9730).

Refer to the Chevrolet Claims Processing Manual for details on Claim Submission.

RETURN OF STEERING GEAR ASSEMBLIES

To assure proper payment for work performed for short gear installation under this special policv 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.

INSTRUCTIONS (See Figure 14 & 15) ------------ 1 R.O. # & DATE The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice. 2 REOUEST DATE (MONTH, DAY) Date owner or dealer requested reimbursement.

3 VEHICLE IDENTIFICATION NUMBER VIN involved.

4 MILEAGE Enter mileage at time of transaction. (If not available, enter "O".)

5 CC/FC Code is preprinted on form.

6 LABOR OPERATION Labor Operation is preprinted on form.

7 & 8 SUBLET DMN & Enter total amount of reimbursement. (Do not LINE TOTAL enter parts or labor hours on claim.)

9 AUTH CODE If the amount of reimbursement approved is $500 or less, no authorization is needed. If the total act amount exceeds $500, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.

10 REQUESTED Dealer Service Manager enter amounts determined REIMBURSEMENT from owner supplied invoices or paid receipts, which are covered.

11 APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin. If the total amount exceeds $500, contact Chevrolet Branch Customer Assistance Representative for instructions.

12 740 STAMP See Item #11 to determine need for authorization.

13 DEALER REFERENCE INFORMATION A Enter Document Number and Line Number on which claim was submitted.

B Enter Claim Memo Number and Date when claim is credited.

C Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14 OWNER Must include telephone number. INFORMATION

15 DEALER Includes Dealer Code, Dealer Name, Service Manager's INFORMATION signature and social security number. To be completed by Service Manager.

16 EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the file.

17 The dealer is then to issue the owner a check for the reimbumement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.

INSTRUCTION SHEET

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

SERVICE PROCEDURE FOR INSTALLING "SPECIAL" VALVE BODY RINGS ON RACK ND 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 0-ring if required. 4. Drain power steering fluid from gear. (Rotate stub shaft allowing rack to travel comer to comer 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 w ill 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 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 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 #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.