GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Steering 🢒 Power Steering System 🢒 Steering Gear Replacement

Tools Required

    • J 43628 Frame Alignment Fixture
    • J 44015 Steering Linkage Installer
    •  SA91100C Tie Rod Separator

Removal Procedure

    Object Number: 892945 Size: SH
  1. From inside the vehicle, remove the intermediate shaft to steering gear pinch bolt. Disconnect the shaft from the steering gear.

    2. Object Number: 892053 Size: SH
  2. On vehicles equipped with L81 engines, remove the rear exhaust manifold pipe heat shield.

    3. Object Number: 891629 Size: SH
  3. Remove the rear transaxle mount through bolt, and the transaxle mount-to-frame bolt.

    4. Object Number: 891755 Size: SH
  4. Place an approved drain container under the pressure and return hoses at the steering gear.
  5. Remove the power steering pump pressure and return hoses from the steering gear and allow the system to drain.

    6. Object Number: 894225 Size: SH
  6. Raise the vehicle on a hoist.
  7. Remove the front wheel and tire assemblies.
  8. Remove the right front lower splash shield.
  9. Disconnect the O2 sensor electrical connection.

    10. Object Number: 892079 Size: SH
  10. Remove the O2 sensor clamp to underbody attachment nut on a vehicle equipped with L61.

    11. Object Number: 892062 Size: SH
  11. Remove the O2 sensor from the exhaust manifold pipe on L81 engines.

    12. Object Number: 891772 Size: SH
  12. Remove the exhaust manifold pipe on L81 engines and on L61 engines with manual transmissions. (L81 shown)

    13. Object Number: 891633 Size: SH
  13. Remove the remaining rear transaxle mount-to-frame bolts.
  14. Remove the rear transaxle mount.

    15. Object Number: 854972 Size: SH
  15. Remove the tie rod end torque prevailing nuts and discard the nuts.
  16. Using the , separate the tie rod end from the steering knuckle.

    17. Object Number: 893335 Size: SH
  17. Remove the cradle to shifter link pivot pin clip on vehicles equipped with an L61 engine and manual transaxle.

    18. Object Number: 891603 Size: SH
  18. Remove the steering gear-to-frame assembly bolts.
  19. On vehicles equipped with an L61 engine and an automatic transaxle, remove the steering gear heat shield.

    20. Object Number: 891609 Size: SH
  20. Remove the stabilizer bar links from the strut assembly.

    21. Object Number: 891611 Size: SH
  21. Remove the front suspension support assemblies.

    22. Object Number: 891619 Size: SH
  22. Loosen the remaining frame-to-body attachment fasteners until there is enough clearance to remove the steering gear through the drivers side wheel opening.
  23. Remove the steering gear from vehicle.

Installation Procedure

    Object Number: 891923 Size: SH
  1. One at a time, remove the frame bolts and replace the cage nuts which are located in the body. Use new bolts. The torque retention of old nuts and bolts may not be sufficient.
  2. Install the steering gear into the vehicle through the left wheel opening.
  3. Using the powertrain support dolly and the J 43628 , raise the frame assembly to the vehicle and tighten the fasteners.

    4. Tighten
    Tighten the frame assembly-to-body bolts to 90 N·m (66 lb ft) +45-60 degrees.


    Object Number: 891619 Size: SH
  4. Install new cage nuts for suspension supports. The torque retention of old nuts may not be sufficient.

    5. Object Number: 891611 Size: SH
  5. Install the suspension supports using new bolts and tighten.

    6. Tighten
    Tighten the suspension support-to-body bolts to 90 N·m (66 lb ft) +45-60 degrees.


    Object Number: 893335 Size: SH
  6. On vehicles equipped with L61 and manual transaxle, install the cradle-to-shifter link pivot pin clip.

    7. Object Number: 891603 Size: SH

    Important: New bolts and nuts must be used as torque retention of old bolts and nuts may not be sufficient.

  7. Using NEW bolts and nuts, install the steering gear to frame.

    8. Tighten
    Tighten the steering gear-to-frame to 45 N·m (30 lb ft) + 90-105 degrees.

  8. On vehicles equipped with an L61 engine and an automatic transaxle, install the steering gear heat shield.

    9. Tighten
    Tighten the steering gear heat shield-to-frame to 4 N·m (35 lb in).

    Important: The tie rod ends must be thoroughly cleaned before installing and tightening.


    Object Number: 891579 Size: SH
  9. Install the tie rod end into the steering knuckle.
  10. Using the J 44015 , seat the tie rod end into the knuckle.

    11. Tighten
    Tighten the tie rod end linkage installer to 44 N·m (33 lb ft).

    Important: Use a new nut. The torque retention of the old nut may not be sufficient.

  11. Remove the linkage installer and install a NEW tie rod end nut.

    12. Tighten
    Tighten the tie rod end-to-steering knuckle nut to 60 N·m (44 lb ft).

  12. Inspect the boot for damage and replace if damaged.

    13. Object Number: 891609 Size: SH
  13. Install the stabilizer bar link-to-strut assembly.

    14. Tighten
    Tighten the stabilizer bar link-to-strut to 65 N·m (48 lb ft).

  14. Inspect the boot for damage and replace if damaged.
  15. Install the rear transaxle mount.

    16. Object Number: 891633 Size: SH
  16. Install the rear transaxle mount to frame bolts.

    17. Tighten
    Tighten the rear transaxle mount-to-frame bolts to 60 N·m (44 lb ft).


    Object Number: 891755 Size: SH
  17. Install the power steering high pressure and return lines.

    18. Tighten
    Tighten the power steering lines-to-steering gear to 27 N·m (20 lb ft).


    Object Number: 891772 Size: SH
  18. Install the exhaust manifold pipe on vehicles equipped with L81 engines, and L61 engines with manual transaxles.
  19. Tighten the exhaust manifold pipe to exhaust manifold nuts.

    20. Tighten
    Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (22 lb ft).

  20. Tighten the exhaust manifold pipe to exhaust pipe bolts.

    21. Tighten
    Tighten the exhaust manifold pipe-to-exhaust pipe to 20 N·m (15 lb ft).


    Object Number: 892079 Size: SH
  21. Install the O2 sensor clamp to the underbody attachment nut on vehicles equipped with L61.

    22. Tighten
    Tighten the O2 sensor clip-to-underbody attachment nut to 4 N·m (35 lb in).

  22. Connect the O2 sensor electrical connector.
  23. Install the wheel and tire assemblies onto the hub.
  24. Install the wheel bolts and tighten in a crisscross pattern.
    25. • Hand tighten all 5 wheel bolts.
    • Use a torque wrench to tighten the wheel bolts using a crisscross pattern.

    Tighten
    Tighten the wheel bolts -- initial torque to 63 N·m (46 lb ft).

    • Use a torque wrench to final tighten the wheel bolts using a crisscross pattern.

    Tighten
    Tighten the wheel bolts -- final torque to 125 N·m (92 lb ft).


    Object Number: 891629 Size: SH
  25. Lower vehicle.
  26. Install the remaining rear transaxle mount to frame bolt.

    27. Tighten
    Tighten the rear transaxle mount-to-frame bolts to 60 N·m (44 lb ft).

  27. Install the rear transaxle mount through bolt and heat shield, on vehicle with L61 and auto transaxle.

    28. Tighten
    Tighten the rear transaxle mount through bolts to 90 N·m (66 lb ft).


    Object Number: 892062 Size: SH
  28. Install the O2 sensor on exhaust manifold pipe on vehicles equipped with L81 engines.

    29. Tighten
    Tighten the O2 sensor on exhaust manifold pipe (L81) to 45 N·m (33 lb ft).


    Object Number: 892053 Size: SH
  29. Install the exhaust manifold pipe heat shield on vehicles equipped with L81 engines.

    30. Tighten
    Tighten the exhaust manifold pipe heat shield bolts to 8 N·m (71 lb in).


    Object Number: 892945 Size: SH

    Important: Use Loctite® Threadlocker, or equivalent on threads of pinch bolt.

  30. Install the intermediate shaft onto the steering gear and torque pinch bolt.

    31. Tighten
    Tighten the intermediate shaft pinch bolt to 30 N·m (22 lb ft).

  31. Bleed the power steering system. Refer to Power Steering System Bleeding .
  32. Set the toe. Refer to Front Toe Adjustment in Wheel Alignment.