SPECIAL POLICY: TEMPORARY REDUCTION/POWER STRG.-COLD

MODELS AFFECTED 1985-1988 6000, Sunbird, Grand Am and 1987-88 Bonneville With Power Steering

TO: ALL PONTIAC DEALERS

This bulletin is being issued to supplement bulletin 84-SM-35, 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.

VEHICLES INVOLVED

Involved are all 1985-87 6000, Sunbird, Grand Am, and Bonneville models and 1988 models within the following VIN breakpoints: Up To Year Model Plant Beginning And Including ---- ----- ----- --------- ------------- 1988 6000 LE Oshawa #1 SOP J9236368

6000 SE Oshawa #1 SOP J9238041 6000 SE Tarrytown SOP JT218901 6000 Tarrytown SOP JT223649 6000 STE Oklahoma City SOP J6200116 Grand Am Lansing SOP JC700906 Sunbird Lordstown SOP J7540419

Bonneville Willow Run SOP JW247515

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 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 previously furnished to dealers by General Motors.

SPECIAL POLICY ADJUSTMENT ANNOUNCEMENT

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

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 from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2). Description Part Number Quantity/Vehicle

Seal Service Kit 26010340 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 replacement gear assembly may be necessary. PRIOR AUTHORIZATION FROM YOUR ZONE OFFICE 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 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 No. IB No. 88-48 for further shipping instructions. Steering gear assemblies returned for reasons other than this special policy need not include the above information.

REIMBURSEMENT

Customer claims for reimbursement on previously paid repairs to correct a temporary reduction of power steering under cold conditions are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation listed under the Claim section of this bulletin. Reimbursement amounts of $150.00 or less can be processed by the dealer. If the amount exceeds $150.00 an Owner Reimbursement Form 7201-039 (Rev. 6/88) must be forwarded to and processed by the Zone Office.

All expenses concerninq previous repairs must be listed on a separate claim and entered in the net items column of the warranty claim.

CLAIM INFORMATION

Dealers will be credited via Warranty Document or Teminal Transmission, whichever is their normal method of submission for payment. Claims should contain all information as required, and should list the appropriate labor operation as outlined below.

Failure Labor Labor ** Mtl.Amt. Description Code Operation Hours Net Items ------------ ---- --------- ----- ---------- Install Seal Service Kit:

1985-86 6000 42 T 1283 2.8 $ 5.15

1987 6000 42 T 1283 3.6 5.15

1988 6000 Exc-AWD 42 T 1283 3.1 5.15

1988 6000 AWD 42 T 1283 2.7 5.15

1985-86 Sunbird 42 T 1283 3.3 5.15

1987 Sunbird 42 T 1283 3.5 5.15

1988 Sunbird 42 T 1283 3.0 5.15

1985-87 Grand Am (Man) 42 T 1283 3.6 5.15

1985-87 Grand Am (Auto) 42 T 1283 4.1 5.15

1988 Grand Am 42 T 1283 3.6 5.15

1987 Bonneville 42 T 1283 3.0 5.15

1988 Bonneville 42 T 1283 2.8 5.15

Add Times: .2 - Locking Wheel Cover .1 - Locking Wheel Nuts

Failure Labor Labor ** Mtl. Amt. Description Code Operation Hours Net Items ------------ ---- --------- ----- ----------- Install Replacement Gear:

1985-86 6000 42 *** T 1293 1.8 $ 5.15

1987 6000 42 *** T 1293 2.6 5.15

1988 6000 Exc-AWD 42 *** T 1293 2.1 5.15

1988 6000 AWD 42 *** T 1293 1.7 5.15

1985-86 Sunbird 42 *** T 1293 2.3 5.15

1987 Sunbird 42 *** T 1293 2.5 5.15

1988 Sunbird 42 *** T 1293 2.0 5.15

1985-87 Grand Am (Man) 42 *** T 1293 2.6 5.15

1985-87 Grand Am (Auto) 42 *** T 1293 3.1 5.15

1988 Grand Am 42 *** T 1293 2.6 5.15

1987 Bonneville 42 *** T 1293 2.0 5.15

1988 Bonneville 42 *** T 1293 1.8 5.15

Add Times: .2 - Locking Wheel Cover .1 - Locking Wheel Nuts

Owner Reimbursement For Previous Repairs: 95 T 1303 xxxx *

* Put expense in net items column, of the warranty claim.

** The $ 5.15 identified in the "Net Amount" column represents the cost plus 30% of 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 OFFICE WILL BE REQUIRED.

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 0-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 wben 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 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 osition. See Fi ure 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 J29810 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 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.