Pontiac 26044821 Gear Kit,Steering (Partial)(Remanufacture)

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Begin by prying back the plastic cover over the intermediate shaft to expose the U-joint which can be replaced. After that, loosen the locking bolt and nut that hold the joint to the steering shaft. Afterward, jack up the front of the car and support it on jackstands, and take off both front wheels. If it is a power steering unit, disconnect the tie rods from the steering knuckles; if not, disconnect only the pressure pipe and return hose from rack and pinion housing. Insert a screwdriver into a rubber boot covering a U-joint so as to hold it aside. Take out of position nuts from mounting studs of rack and pinion after removing intermediate shaft bolt secure it on a pinion shaft. Remove cross-bracket's upper mounting nuts and U-brackets at once then get rid of both cross-bracket and U-brackets from mounting studs by pulling them off with your hands one by one. You should also carefully remove rack and pinion along with tie rods from left side of car without causing damage to emergency brake cable, fuel inlet line or mounting stud threads. Remove rear support brackets from mounting studs. Among other repair options are buying a new rack and pinion assembly or having it rebuilt in shop or finding one in junkyard or rebuilding by yourself if you want. Put right rear support bracket over mounting studs first then push rack and pinion into its cavity locate it over top side slightly towards rear of emergency brake cable as shown in following image 3-63. Afterwards install left rear support bracket on its mounting studs then align pinion shaft with intermediate shaft U-joint. Put pinion into this U-joint, loosely install bolt there afterwards install lower mounting nuts loosing U-brackets together with cross-bracket followed by upper mounting nuts respectively finally tighten all these fasteners evenly to specified torque values as indicated below: Tighten (first) all four mountings (nuts) evenly and recheck torque in a cross-diagonal sequence, retighten if necessary. Check that the O-ring is in place on the pressure pipe for power steering units, install it to the adapter and connect return hose to its fitting; for non-power steering systems, slide pressure pipe into the socket on the column adapter. Moreover, torque U-joint bolt then remove screwdriver from intermediate shaft so that rubber boot again covers U-joint and fix tie rods into steering knuckles. Finally, place a wheel/tire assembly on each side lower vehicle down onto ground until tires begin contacting fl exible ramps lower vehicle onto ground by turning handle counterclockwise raise lift arms enough install wheels so they are nearly touching of surface release jack's hydraulic pressure . If required, bleed power steering system and perform an alignment if outer tie rods were taken off.

First, remove the outer tie rods from the inner tie rods to remove the rack and pinion assembly from the car. Then, take out the rubber boot seals and slide off the shock dampener ring from the inner tie rod housing. Grasp wrench on rack while turning tie rod pivot housing counterclockwise towards separating inner tie rod assembly from rack. Remove adjuster plug locknut and turn adjuster plug counterclockwise to separate it from housing. Remove rack bearing spring and rack bearing. Pierce pinion seal and pry it out. Use internal snap-ring pliers to remove pinion retaining ring. Support pinion shaft in vise then tap on housing until pinion shaft separates from housing. Look at visually if damaged replace pinion roller bearing. Remove rack bushing retaining ring and use a puller to remove the bushing of the rack. Disengage rubber grommets from housing; wash all metal parts in solvent and inspect for wear or damage; if needed, replace pinion seal; reassemble by installing rubber grommets onto housing and pressing bushing into housing; install rack bushing retaining ring; press new roller bearing into housing; apply grease to teeth of rack, slide into housing; position the rack so that it is inserted into its bore for the pinion shaft, then install its retaining ring into place filled with grease in cavity of shaft hole; finally put new pinion seal in place then install spring &rack bearing . Install adjuster plug then adjust torque of pinion.Install adjuster plug locknut and torque to specs.Install inner tie rod onto rack then torque tie rod pivot housing.Stake both sides of pivoting cam over inner tube .Finally, reinstall rubber boot seals including outer tie rods before installing back again within vehicle a complete set of rake.

Power steering Rack And Pinion are very similar to installing and removing manual Rack And Pinion plus disconnecting and reconnecting the hydraulic lines. Both hoses and Rack And Pinion outlets shall be fitted with caps to avoid the possibility of material leaking into the system. Non-accessible or technically very difficult are preload settings, some of which can only be done if the Rack And Pinion is out of the car and done usually during its rebuild. When these two adjustments are correctly set, they are no longer re-adjusted to deal with wear; any problem with the Rack And Pinion has got to be dealt with by rebuilding.

Power steering Rack And Pinion are very similar to installing and removing manual Rack And Pinion plus disconnecting and reconnecting the hydraulic lines. Both hoses and Rack And Pinion outlets shall be fitted with caps to avoid the possibility of material leaking into the system. Non-accessible or technically very difficult are preload settings, some of which can only be done if the Rack And Pinion is out of the car and done usually during its rebuild. When these two adjustments are correctly set, they are no longer re-adjusted to deal with wear; any problem with the Rack And Pinion has got to be dealt with by rebuilding.

If one is to take off and reinstall rack and pinion assembly in a car, the process of removing the assembly and separating outer tie rods from inner tie rods would be first. After that, remove rubber boot seals and its shock dampener ring slides off from the inside tie rod housing. For you to disengage the inner tie rod assembly with a rack, wrench grip the rack and rotate the pivot housing of the tie rod counter clockwise. Next, screw off adjuster plug lock nut and separate adjuster plug by turning it anti- clockwise until it pulls out of its housing. Remove the rack bearing spring as well as rack bearing before taking away retaining ring on pinion shaft then dust cover at bottom of pinion housing. A ratchet wrench will be used to secure upper end of pinion shaft while lock nut is removed from lower end of shaft. Press threaded end of pinion shaft flush with ball bearing assembly using arbor press. Take out stub shaft dust seal, stub shaft seal plus needle bearing assembly. Align ends of rack equally from housing, mark position where pinion should leave housing and drive out pinion's shaft through press fit method using punch or drift tool positioned against outer edge surface only at location closest towards transmission case instead upwards towards oil pan on your transmission box side; however never on top part adjacent involving other gear teeth or outside wall between gears themselves themselves since this could damage those areas due rubbing against metal where contact might occur when shifting gears causing premature failure within gear engagement mechanisms like synchromesh sleeves. Remove retaining rings together valve body rings main driving force behind removal such items would usually have been use brass hammer hit out house till comes thereupon anything else pops up into place- now we can enjoy seeing what happens afterwards! Take bulkhead retaining ring off inner & outer bulkheads relating stuffs finally do same thing piston ring is taken down from above; which means either side left behind on its way down while still holding onto that part; otherwise both area need be replaced too. With appropriate device, knock out internal seal that surrounds whole rod housing so as access inside it without damaging the rest around or outside of such walls themselves within one movement. Carefully check all their conditions wear-off and damage ensuring any spoilt ones are taken off with new ones. Put together components ensuring right sealing, positioning according specified turning forces then apply fluid by means transmitted power steering system where necessity arises. Eventually, replace rack pinion assembly back into car.

Remove the battery ground cable and the coupling shield if applicable. Take off the nuts, lockwashers, and bolts at the steering shaft to coupling flange. Remove the Pitman arm lock nut and washer, marking the position of the Pitman arm in relation to the shaft before using a suitable puller to take it off. Unscrew the Rack And Pinion from the frame and take it out of the vehicle. When installing, position the Rack And Pinion so that the coupling mounts properly to the flanged end of the steering shaft, secure it to the frame, fit the washers and bolts, and then torque-tighten. Secure the steering coupling to the flanged end of the column with the lockwashers and nuts, ensuring the nuts are torque-tightened. Finally, install the Pitman arm and reconnect the battery ground cable along with the coupling shield if applicable.

Begin by prying back the plastic cover over the intermediate shaft to expose the U-joint which can be replaced. After that, loosen the locking bolt and nut that hold the joint to the steering shaft. Afterward, jack up the front of the car and support it on jackstands, and take off both front wheels. If it is a power steering unit, disconnect the tie rods from the steering knuckles; if not, disconnect only the pressure pipe and return hose from rack and pinion housing. Insert a screwdriver into a rubber boot covering a U-joint so as to hold it aside. Take out of position nuts from mounting studs of rack and pinion after removing intermediate shaft bolt secure it on a pinion shaft. Remove cross-bracket's upper mounting nuts and U-brackets at once then get rid of both cross-bracket and U-brackets from mounting studs by pulling them off with your hands one by one. You should also carefully remove rack and pinion along with tie rods from left side of car without causing damage to emergency brake cable, fuel inlet line or mounting stud threads. Remove rear support brackets from mounting studs. Among other repair options are buying a new rack and pinion assembly or having it rebuilt in shop or finding one in junkyard or rebuilding by yourself if you want. Put right rear support bracket over mounting studs first then push rack and pinion into its cavity locate it over top side slightly towards rear of emergency brake cable as shown in following image 3-63. Afterwards install left rear support bracket on its mounting studs then align pinion shaft with intermediate shaft U-joint. Put pinion into this U-joint, loosely install bolt there afterwards install lower mounting nuts loosing U-brackets together with cross-bracket followed by upper mounting nuts respectively finally tighten all these fasteners evenly to specified torque values as indicated below: Tighten (first) all four mountings (nuts) evenly and recheck torque in a cross-diagonal sequence, retighten if necessary. Check that the O-ring is in place on the pressure pipe for power steering units, install it to the adapter and connect return hose to its fitting; for non-power steering systems, slide pressure pipe into the socket on the column adapter. Moreover, torque U-joint bolt then remove screwdriver from intermediate shaft so that rubber boot again covers U-joint and fix tie rods into steering knuckles. Finally, place a wheel/tire assembly on each side lower vehicle down onto ground until tires begin contacting fl exible ramps lower vehicle onto ground by turning handle counterclockwise raise lift arms enough install wheels so they are nearly touching of surface release jack's hydraulic pressure . If required, bleed power steering system and perform an alignment if outer tie rods were taken off.

If one is to take off and reinstall rack and pinion assembly in a car, the process of removing the assembly and separating outer tie rods from inner tie rods would be first. After that, remove rubber boot seals and its shock dampener ring slides off from the inside tie rod housing. For you to disengage the inner tie rod assembly with a rack, wrench grip the rack and rotate the pivot housing of the tie rod counter clockwise. Next, screw off adjuster plug lock nut and separate adjuster plug by turning it anti- clockwise until it pulls out of its housing. Remove the rack bearing spring as well as rack bearing before taking away retaining ring on pinion shaft then dust cover at bottom of pinion housing. A ratchet wrench will be used to secure upper end of pinion shaft while lock nut is removed from lower end of shaft. Press threaded end of pinion shaft flush with ball bearing assembly using arbor press. Take out stub shaft dust seal, stub shaft seal plus needle bearing assembly. Align ends of rack equally from housing, mark position where pinion should leave housing and drive out pinion's shaft through press fit method using punch or drift tool positioned against outer edge surface only at location closest towards transmission case instead upwards towards oil pan on your transmission box side; however never on top part adjacent involving other gear teeth or outside wall between gears themselves themselves since this could damage those areas due rubbing against metal where contact might occur when shifting gears causing premature failure within gear engagement mechanisms like synchromesh sleeves. Remove retaining rings together valve body rings main driving force behind removal such items would usually have been use brass hammer hit out house till comes thereupon anything else pops up into place- now we can enjoy seeing what happens afterwards! Take bulkhead retaining ring off inner & outer bulkheads relating stuffs finally do same thing piston ring is taken down from above; which means either side left behind on its way down while still holding onto that part; otherwise both area need be replaced too. With appropriate device, knock out internal seal that surrounds whole rod housing so as access inside it without damaging the rest around or outside of such walls themselves within one movement. Carefully check all their conditions wear-off and damage ensuring any spoilt ones are taken off with new ones. Put together components ensuring right sealing, positioning according specified turning forces then apply fluid by means transmitted power steering system where necessity arises. Eventually, replace rack pinion assembly back into car.

First, remove the outer tie rods from the inner tie rods to remove the rack and pinion assembly from the car. Then, take out the rubber boot seals and slide off the shock dampener ring from the inner tie rod housing. Grasp wrench on rack while turning tie rod pivot housing counterclockwise towards separating inner tie rod assembly from rack. Remove adjuster plug locknut and turn adjuster plug counterclockwise to separate it from housing. Remove rack bearing spring and rack bearing. Pierce pinion seal and pry it out. Use internal snap-ring pliers to remove pinion retaining ring. Support pinion shaft in vise then tap on housing until pinion shaft separates from housing. Look at visually if damaged replace pinion roller bearing. Remove rack bushing retaining ring and use a puller to remove the bushing of the rack. Disengage rubber grommets from housing; wash all metal parts in solvent and inspect for wear or damage; if needed, replace pinion seal; reassemble by installing rubber grommets onto housing and pressing bushing into housing; install rack bushing retaining ring; press new roller bearing into housing; apply grease to teeth of rack, slide into housing; position the rack so that it is inserted into its bore for the pinion shaft, then install its retaining ring into place filled with grease in cavity of shaft hole; finally put new pinion seal in place then install spring &rack bearing . Install adjuster plug then adjust torque of pinion.Install adjuster plug locknut and torque to specs.Install inner tie rod onto rack then torque tie rod pivot housing.Stake both sides of pivoting cam over inner tube .Finally, reinstall rubber boot seals including outer tie rods before installing back again within vehicle a complete set of rake.

First, remove the outer tie rods from the inner tie rods to remove the rack and pinion assembly from the car. Then, take out the rubber boot seals and slide off the shock dampener ring from the inner tie rod housing. Grasp wrench on rack while turning tie rod pivot housing counterclockwise towards separating inner tie rod assembly from rack. Remove adjuster plug locknut and turn adjuster plug counterclockwise to separate it from housing. Remove rack bearing spring and rack bearing. Pierce pinion seal and pry it out. Use internal snap-ring pliers to remove pinion retaining ring. Support pinion shaft in vise then tap on housing until pinion shaft separates from housing. Look at visually if damaged replace pinion roller bearing. Remove rack bushing retaining ring and use a puller to remove the bushing of the rack. Disengage rubber grommets from housing; wash all metal parts in solvent and inspect for wear or damage; if needed, replace pinion seal; reassemble by installing rubber grommets onto housing and pressing bushing into housing; install rack bushing retaining ring; press new roller bearing into housing; apply grease to teeth of rack, slide into housing; position the rack so that it is inserted into its bore for the pinion shaft, then install its retaining ring into place filled with grease in cavity of shaft hole; finally put new pinion seal in place then install spring &rack bearing . Install adjuster plug then adjust torque of pinion.Install adjuster plug locknut and torque to specs.Install inner tie rod onto rack then torque tie rod pivot housing.Stake both sides of pivoting cam over inner tube .Finally, reinstall rubber boot seals including outer tie rods before installing back again within vehicle a complete set of rake.

Begin by prying back the plastic cover over the intermediate shaft to expose the U-joint which can be replaced. After that, loosen the locking bolt and nut that hold the joint to the steering shaft. Afterward, jack up the front of the car and support it on jackstands, and take off both front wheels. If it is a power steering unit, disconnect the tie rods from the steering knuckles; if not, disconnect only the pressure pipe and return hose from rack and pinion housing. Insert a screwdriver into a rubber boot covering a U-joint so as to hold it aside. Take out of position nuts from mounting studs of rack and pinion after removing intermediate shaft bolt secure it on a pinion shaft. Remove cross-bracket's upper mounting nuts and U-brackets at once then get rid of both cross-bracket and U-brackets from mounting studs by pulling them off with your hands one by one. You should also carefully remove rack and pinion along with tie rods from left side of car without causing damage to emergency brake cable, fuel inlet line or mounting stud threads. Remove rear support brackets from mounting studs. Among other repair options are buying a new rack and pinion assembly or having it rebuilt in shop or finding one in junkyard or rebuilding by yourself if you want. Put right rear support bracket over mounting studs first then push rack and pinion into its cavity locate it over top side slightly towards rear of emergency brake cable as shown in following image 3-63. Afterwards install left rear support bracket on its mounting studs then align pinion shaft with intermediate shaft U-joint. Put pinion into this U-joint, loosely install bolt there afterwards install lower mounting nuts loosing U-brackets together with cross-bracket followed by upper mounting nuts respectively finally tighten all these fasteners evenly to specified torque values as indicated below: Tighten (first) all four mountings (nuts) evenly and recheck torque in a cross-diagonal sequence, retighten if necessary. Check that the O-ring is in place on the pressure pipe for power steering units, install it to the adapter and connect return hose to its fitting; for non-power steering systems, slide pressure pipe into the socket on the column adapter. Moreover, torque U-joint bolt then remove screwdriver from intermediate shaft so that rubber boot again covers U-joint and fix tie rods into steering knuckles. Finally, place a wheel/tire assembly on each side lower vehicle down onto ground until tires begin contacting fl exible ramps lower vehicle onto ground by turning handle counterclockwise raise lift arms enough install wheels so they are nearly touching of surface release jack's hydraulic pressure . If required, bleed power steering system and perform an alignment if outer tie rods were taken off.

If one is to take off and reinstall rack and pinion assembly in a car, the process of removing the assembly and separating outer tie rods from inner tie rods would be first. After that, remove rubber boot seals and its shock dampener ring slides off from the inside tie rod housing. For you to disengage the inner tie rod assembly with a rack, wrench grip the rack and rotate the pivot housing of the tie rod counter clockwise. Next, screw off adjuster plug lock nut and separate adjuster plug by turning it anti- clockwise until it pulls out of its housing. Remove the rack bearing spring as well as rack bearing before taking away retaining ring on pinion shaft then dust cover at bottom of pinion housing. A ratchet wrench will be used to secure upper end of pinion shaft while lock nut is removed from lower end of shaft. Press threaded end of pinion shaft flush with ball bearing assembly using arbor press. Take out stub shaft dust seal, stub shaft seal plus needle bearing assembly. Align ends of rack equally from housing, mark position where pinion should leave housing and drive out pinion's shaft through press fit method using punch or drift tool positioned against outer edge surface only at location closest towards transmission case instead upwards towards oil pan on your transmission box side; however never on top part adjacent involving other gear teeth or outside wall between gears themselves themselves since this could damage those areas due rubbing against metal where contact might occur when shifting gears causing premature failure within gear engagement mechanisms like synchromesh sleeves. Remove retaining rings together valve body rings main driving force behind removal such items would usually have been use brass hammer hit out house till comes thereupon anything else pops up into place- now we can enjoy seeing what happens afterwards! Take bulkhead retaining ring off inner & outer bulkheads relating stuffs finally do same thing piston ring is taken down from above; which means either side left behind on its way down while still holding onto that part; otherwise both area need be replaced too. With appropriate device, knock out internal seal that surrounds whole rod housing so as access inside it without damaging the rest around or outside of such walls themselves within one movement. Carefully check all their conditions wear-off and damage ensuring any spoilt ones are taken off with new ones. Put together components ensuring right sealing, positioning according specified turning forces then apply fluid by means transmitted power steering system where necessity arises. Eventually, replace rack pinion assembly back into car.

Install the intermediate shaft seal and the intermediate shaft-to-stub shaft pinch bolt, then check and adjust the toe-in as necessary.

To install the steering gear, reverse the removal steps.

Install the bracket bolt to the crossmember under the air management pipe.

The Pitman shaft nut should be tightened to 180 ft. lbs. (244 Nm).

Remove the bracket bolt from the crossmember.

Raise the intermediate shaft seal and remove the intermediate shaft-to-stub shaft pinch bolt.

A jerky or lumpy sensation indicates worn or damaged bearings.

The hydraulic hoses must be disconnected from the steering gear housing.

The final step is to install the Pitman arm and reconnect the battery ground cable.

The drag represents the thrust bearing preload, which should meet the specified range; adjust the plug accordingly and torque-tighten the locknut.

The ends of the hoses should be plugged.

When installation is complete, bleed the system as outlined.

Finally, reinstall the Pitman arm and reconnect the battery ground cable along with the coupling shield if it was removed.

The steering gear is typically filled with lubricant for its entire lifespan, and unless a significant leak occurs that requires a complete overhaul, there is no need for refilling.