Fastener Tightening Specifications
| Application | Specification | |
|---|---|---|
| Metric | English | |
| Adjuster Plug Locknut | 70 N.m | 52 lb ft |
| Ball Joint Hex Nut | 45 N.m | 33 lb ft |
| Crossmember-to-Underbody Bolts | 150 N.m | 111 lb ft |
| Outer Tie Rod Hex Nuts | 45 N.m | 33 lb ft |
| Outer Tie Rod Lock Nuts | 54 N.m | 40 lb ft |
| Pinion Preload | 0.9-1.7 N.m | 8-15 lb in |
| Stabilizer Shaft-to-Knuckle Bolts | 45 N.m | 33 lb ft |
| Steering Gear Retaining Bracket Nuts | 50 N.m | 37 lb ft |
Fastener Tightening Specifications
Manual Steering Specifications
| Application | Specification | |
|---|---|---|
| Metric | English | |
| Gear Type | Power Rack and Pinion | |
| Oil Capacity | 1.1 liter | 1.2 quart |
| Overall Gear Ratio | ||
| Manual Steering | 21.5:1 | |
| Power Steering | 16:1 | |
| Wheel Diameter | ||
| With Air Bag | 380 mm | 15.0 in |
| Without Air Bag | 370 mm | 14.5 in |
| Lubricant | Lithium-Base Grease No. 1051344 or Equivalent | |
Manual Steering Specifications
Symptoms - Manual Steering Gear
| Checks | Actions |
|---|---|
| Check the steering gear adjustment. | Perform the straight-ahead check. |
| Check the wheel bearing for wear or damage. | Replace the wheel bearing. |
| Check the outer tie rods for improper installation. | Tighten the tie rods. |
Too Much Play in Steering System
| Checks | Actions |
|---|---|
| Check the steering gear for improper and insufficient lubrication. | Lubricate the rack assembly. Lubricate the pinion assembly. |
| Check the steering gear mounting for improper installation. | Tighten the steering gear mounting bolts and the nuts. |
| Check the outer tie rods for improper installation. | Tighten the tie rods. |
Rattle in Rack and Pinion Steering Gear
Hard Steering
| Checks | Actions |
|---|---|
| Inspect for a lack of lubrication of the ball joints, the tie rods and the steering gear. | Lubricate the ball joints, the tie rods, and the steering gear. Replace the ball joints, the tie rods, and the steering gear as needed. |
| Check the front-wheel alignment. | Align the front wheels. |
| Check the steering gear adjustment. | Adjust the steering gear. |
Hard Steering
Poor Returnability
| Checks | Actions |
|---|---|
| Inspect for a lack of lubrication of the ball joints, the tire rods and the steering gear. | Lubricate the ball joints, the tie rods, and the steering gear. Replace the ball joints, the tie rods, and the steering gear as needed. |
| Inspect for binding in the ball joints. | Replace the ball joints. |
| Inspect for binding in the steering column. | Lubricate the steering column. Replace the steering column as needed. |
| Inspect for a lack of lubrication in the steering gear. | Lubricate the steering gear. Repair or replace the steering gear as needed. |
| Check the front-wheel alignment. | Align the front wheels. |
| Check the steering gear preload adjustment. | Perform a rack bearing preload on-vehicle adjustment. |
Poor Returnability
Scheme 6
After all the necessary operations on the steering gear are completed, check the exact straight-ahead position of the steering in each case.
With the vehicle on the floor, place the steering wheel in the straight-ahead position. Mark the centerline of both tires on the floor. Turn the steering wheel all the way to the right and mark the new centerline of both tires on the floor.
| Angle | Specified Value |
|---|---|
| Inner Angle (B) | 35°5'+/-1°30' |
| Outer Angle (A) | 34°+/-1°30' |
Straight-Ahead Tire Specifications
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Place the steering wheel in the straight-ahead position. Is the wheel in the correct position? | Go to Step 2 | |
| 2 | Is the steering coupling flange pinch bolt lying horizontally? | Go to Step 3 | Go to Step 4 |
| 3 | Is the steering wheel off center by more than 5 degrees? | Go to Step 5 | Go to Step 6 |
| 4 | The pinion is displaced on the rack. The steering pinion position must be corrected. Is the repair complete? | Go to Step 2 | |
| 5 | Remove steering wheel and center on the spindle splines. Is the repair complete? | Go to Step 3 | |
| 6 | Turn the steering wheel all the way to the right. Measure the inner and the outer angles of the tire centerline compared to the straight-ahead centerline. Refer to the Straight-Ahead Tire Specifications table. Do the angles match the values specified in the Straight-Ahead Tire Specifications table? | System OK | Go to Step 7 |
| 7 | The rack assembly was not assembled correctly. Repair as needed. Is the repair complete? | Go to Step 6 |
Straight Ahead Diagnosis
Adjustment Procedure
Note. Refer to Fastener Notice in Cautions and Notices.
Note: Make the rack bearing adjustment with the front wheel raised and the steering wheel centered. Be sure to check the returnability of the steering wheel to center after the adjustment.
- Loosen the locknut and turn the adjuster plug clockwise until a torque of 10 N.m (88 lb-in) is obtained.
- Back the adjuster plug off by 55-65 degrees. Check the pinion preloaded torque is within the range 0.9-1.7 N.m (8 to 15 lb in).
- Tighten the adjuster plug locknut while holding the adjuster plug stationary. Tighten: Tighten the adjuster plug locknut to 70 N.m (52 lb ft).
Tools Required
KM-507-C Ball Joint Remover
Removal Procedure
- Remove the outer tie rod hex nut and disconnect the outer tie rod from the steering knuckle using the special tool KM-507-C .
- Loose the tie rod lock nuts and remove the outer tie rod.
Installation Procedure
- Install the outer tie rod by tightening the lock nuts to 54 N.m (40 lb ft).
- Install the outer tie rod by tightening the hex nut to 45 N.m (33 lb ft).
KM-507-C Ball Joint Remover
- Disconnect the negative battery cable.
- Position the tires straight ahead by turning the steering wheel.
- Remove the intermediate shaft.
- Remove the front tires.
- Remove the outer tie rod hex nuts. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#power-steering-system) in Power Steering System.
- Remove the ball joint hex nuts and disconnect the stabilizer shaft from the knuckle by removing the stabilizer shaft link assembly. Refer to «Stabilizer Shaft Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) in Front Suspension.
- Remove the cross member by removing the nuts and bolts to the underbody.
- Remove the rack and pinion assembly by disconnecting the steering gear retaining bracket nuts.
- Install the rack and pinion assembly by connecting the steering gear retaining bracket nuts. Tighten: Tighten the steering gear retaining bracket nuts to 50 N.m (37 lb ft).
- Install the cross member by tightening the nuts and bolts to the underbody. Tighten: Tighten the cross member by tightening the nuts and bolts to the underbody to 150 N.m (111 lb ft).
- Install the ball joint hex nuts and connect the stabilizer shaft to the knuckle by tightening the bolt with stabilizer shaft link assembly. Refer to «Stabilizer Shaft Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) in Front Suspension. Tighten: Tighten the ball joint hex nuts to knuckle to 45 N.m (33 lb ft). Tighten the bolts of stabilizer shaft to the knuckle to 45 N.m (33 lb ft).
- Install the outer tie rod hex nuts. Tighten: Tighten the outer tie rod hex nuts to 45 N.m (33 lb ft).
- Install the front tires. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
- Install the intermediate shaft.
- Install the steering wheel and column.
- Connect the negative battery cable. IMPORTANT: After all the operations with the steering gear, be sure to check the exact straight-ahead position of the steering in each case. Refer to Straight-Ahead Inspection.
Manual Steering Gear Description and Operation
The manual rack and pinion steering system consists of two main components: the rack and the pinion. The motion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack, which moves the rack. The force is then transmitted through the arms on the struts, which turn the wheels.
Special Tools
Special Tools Illustration Tool Number/ Description KM-507-C Ball Joint Remover