Steering Wheel & Steering Column: Removal & Installation Pontiac Sunfire I

Installation Procedure

Install the tilt lever (3) by turning the lever clockwise.

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Steering Wheel Replacement

Tools Required

1. J 1859-A Steering Wheel Puller
2. J 42578 Steering Wheel Puller Legs

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1. Disconnect the negative battery cable. CAUTION: «SIR CAUTION»(ref-175132-S12077789922005041500000) in Cautions and Notices.
2. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.
3. Remove the steering wheel inflatable restraint module. Refer to INFLATABLE RESTRAINT STEERING WHEEL MODULE REPLACEMENT in SIR.
4. Remove the steering wheel nut (1).
5. Remove the steering wheel using J 1859-A and J 42578. .
6. Remove the steering wheel (2) from the steering column (3).

Scheme 39

1. Install the steering wheel (2) to the column (3). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the steering wheel nut (1). Tighten Tighten the nut to 41 N.m (30 lb ft).
3. Install the inflatable restraint steering wheel module. Refer to INFLATABLE RESTRAINT STEERING WHEEL MODULE REPLACEMENT in SIR.
4. Enable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.
5. Connect the negative battery cable.

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1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. CAUTION: The tilt spring and the spring guide are under pressure. The tilt spring and the spring guide may become a projectile. Secure the spring with locking pliers during removal. Secure the spring with locking pliers during installation. Bodily Injury may result during removal and installation of the tilt spring and the spring guide. Always use caution during removal and installation of the tilt spring and the spring guide.
2. Use the tilt lever to move the tilt column into the UP position.
3. Pry the tilt spring (1) upward until a bulge occurs and most of the spring tension is removed.
4. Secure the tilt spring (1) until the tilt spring disengages from the post on the steering column support assembly, the steering column housing, and the bearing assembly.
5. Remove the tilt spring guide (1) from the tilt spring (2).

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1. Install the tilt spring guide to the tilt spring. CAUTION: The tilt spring and the spring guide are under pressure. The tilt spring and the spring guide may become a projectile. Secure the spring with locking pliers during removal. Secure the spring with locking pliers during installation Bodily injury may result during removal and Installation of the tilt spring and the spring guide. Always use caution during removal and Installation of the tilt spring and the spring guide.
2. Install the tilt spring (1) to the post on the steering column support assembly.
3. Secure the tilt spring (1) with locking pliers by performing the following steps: 3.1. While the end of the tilt spring is on the post, pull the center of the tilt spring (1) while pushing the tilt spring guide end to the post on the bearing and housing assembly. 3.2. With both ends installed on the post, push the tilt spring into position.
4. Enable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.

Steering Column Replacement

Tools Required

J 41352 Module Column Holding Fixture

Removal Procedure

Scheme 44

1. Disable the supplemental inflatable restraint (SIR) system. Refer toSIR DISABLING AND ENABLING ZONE 3 in SIR. NOTE: The vehicle's wheels must be in a straight-ahead position and the key must be in a straight-ahead position and the key must be in a LOCK position when removing or installing the steering column. Failure to do so may cause the SIR coil assembly to become uncentered and may result in unneeded SIR system Repair.
2. Remove the steering wheel. Refer to «STEERING WHEEL REPLACEMENT»(ref-189097-S36336226512005090600000) .
3. Remove the steering column trim covers. Refer to «STEERING COLUMN TRIM COVERS REPLACEMENT»(ref-189097-S09419078712005090600000) .
4. remove the linear shift cable by pushing in on the retaining tab and pulling downward on the cable.
5. Remove the upper pinch bolt for the intermediate steering shaft from the steering column. Refer to «INTERMEDIATE STEERING SHAFT REPLACEMENT»(ref-189097-S05193523782005090600000) .
6. Disconnect the electrical connectors from the steering column.
7. Remove the instrument panel cluster. Refer to INSTRUMENT PANEL CLUSTER (IPC) REPLACEMENT (CHEVROLET) or INSTRUMENT PANEL CLUSTER (IPC) REPLACEMENT (PONTIAC) .
8. Remove the upper mounting bolts (1) from the steering column (3).
9. Loosen the lower mounting bolts (4) from the steering column (3). NOTE: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on the end could collapse the steering shaft or loosen the plastic injections. Which maintain column rigidity. Leaning on the column assembly could cause the jacket to bend or deform. Any of the above damage could impair the columns collapsible design. Do NOT hammer on the end of the shaft, because hammering could loosen the plastic injections, which maintain column rigidity. If you need to remove the steering wheel, refer to the Steering Wheel Replacement procedure in this section.
10. Remove the steering column (3) from the vehicle.
11. Install the steering column onto J 41352 .

1. Tighten the steering column lower fasteners before you tighten the steering column upper fasteners Failure to do this can damage the steering column.
2. Tighten the steering column fasteners to the specified torque. Overtightening the upper steering column fasteners could affect the steering column collapse.

Scheme 45

1. Remove the steering column from J 41352.
2. Install the steering column (3) to the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Tighten the lower mounting bolts (4) to the steering column (3). Tighten Tighten the bolts to 27 N.m (20 lb ft).
4. Install the upper mounting bolts (1) to the steering column (3). Tighten Tighten the bolts to 27N.m (20 lb ft).
5. Install the instrument panel cluster. Refer to INSTRUMENT PANEL CLUSTER (IPC) REPLACEMENT (CHEVROLET) or INSTRUMENT PANEL CLUSTER (IPC) REPLACEMENT (PONTIAC) .
6. Connect the electrical connectors to the steering column (3).
7. Install the upper pinch bolt for the intermediate steering shaft to the steering column. Refer to «INTERMEDIATE STEERING SHAFT REPLACEMENT»(ref-189097-S05193523782005090600000) .
8. Install the steering column trim covers. Refer to «STEERING COLUMN TRIM COVERS REPLACEMENT»(ref-189097-S09419078712005090600000) .
9. Install the steering wheel. Refer to «STEERING WHEEL REPLACEMENT»(ref-189097-S36336226512005090600000) .
10. Install the steering wheel. Refer to «STEERING WHEEL REPLACEMENT»(ref-189097-S36336226512005090600000) .
11. Enable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.
12. Connect the negative battery cable.

Steering Column Jacket Replacement

Tools Required

J 21845-01 Pivot Pin Remover

Scheme 46

1. Disable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.
2. Remove the lock cylinder. Refer to «IGNITION LOCK CYLINDER REPLACEMENT (WITHOUT KEY)»(ref-189097-S41606253812005090600000) or «Ignition Lock Cylinder Replacement (With Key)»(ref-189097-S32904105872005090600000)
3. Remove the multifunction switch. Refer to «MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT»(ref-189097-S10706987812005090600000) .
4. Remove the windshield wiper and washer switch. Refer to WIPERS/WASHER SWITCH REPLACEMENT .
5. Remove the lock housing assembly. Refer to «STEERING COLUMN UPPER HOUSING REPLACEMENT»(ref-189097-S11615672702005090600000) .
6. Remove the ignition switch assembly. Refer to «IGNITION SWITCH REPLACEMENT»(ref-189097-S21401568632005090600000) .
7. Remove the tilt spring. Refer to «TILT SPRING REPLACEMENT»(ref-189097-S29937660222005090600000) .
8. Remove the lower shaft components. Refer to «STEERING SHAFT, LOWER BEARING, AND JACKET REPLACEMENT (TILT)»(ref-189097-S14136826682005090600000) or «STEERING SHAFT, LOWER BEARING, AND JACKET REPLACEMENT (STANDARD)»(ref-189097-S42444799752005090600000) .
9. Remove the 2 pivot pins using J 21854-01.
10. Remove the bearing and housing assembly.

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1. Install the bearing and housing assembly.
2. Lubricate the pivot with GM P/N 12346293 (Canadian P/N 992723).
3. Install the 2 pivot pins.
4. Stake the pivot pins in 3 locations.
5. Install the lower shaft components. Refer to «STEERING SHAFT, LOWER BEARING, AND JACKET REPLACEMENT (TILT)»(ref-189097-S14136826682005090600000) or «STEERING SHAFT, LOWER BEARING, AND JACKET REPLACEMENT (STANDARD)»(ref-189097-S42444799752005090600000) .
6. Install the tilt spring only. Refer to «TILT SPRING REPLACEMENT»(ref-189097-S29937660222005090600000) .
7. Install the Ignition switch assembly only. Refer to «IGNITION SWITCH REPLACEMENT»(ref-189097-S21401568632005090600000) .
8. Install the lock housing assembly. Refer to «STEERING COLUMN UPPER HOUSING REPLACEMENT»(ref-189097-S11615672702005090600000) .
9. Install the windshield wiper and washer switch. Refer to WIPERS/WASHER SWITCH REPLACEMENT .
10. Install the multifunction switch. Refer to «MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT»(ref-189097-S10706987812005090600000) .
11. Install the lock cylinder. Refer to «IGNITION LOCK CYLINDER REPLACEMENT (WITHOUT KEY)»(ref-189097-S41606253812005090600000) or «IGNITION LOCK CYLINDER REPLACEMENT (WITH KEY)»(ref-189097-S32904105872005090600000) .
12. Enable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.

Steering Shaft, Lower Bearing, and Jacket Replacement (Tilt)

Tools Required

J 41688 Centering Sphere Installer

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1. Disable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE in SIR.
2. Remove the steering column jacket. Refer to «STEERING COLUMN JACKET REPLACEMENT»(ref-189097-S13047046712005090600000) .
3. Remove the lower spring retainer (5) and discard.
4. Remove the lower bearing spring (4).
5. Remove the lower bearing seat (3).
6. Remove the adapter and bearing assembly (2) from steering column jacket assembly (1).
7. Remove the steering shaft assembly from the steering column jacket assembly.
8. Remove the 4 support screws and discard.
9. Remove the steering column support assembly from the steering column jacket assembly. IMPORTANT: Mark the upper shaft assembly and the lower steering shaft assembly to ensure proper assembly. Failure to assemble properly will cause the steering wheel to be turned 180 degrees.
10. Tilt the upper shaft assembly (1) 90 degrees to the lower steering shaft assembly (2) and disengage.
11. Insert the race and upper shaft assembly (1) into J 41688.
12. Insert J 41688 into a vise.
13. Rotate the driver 90 degrees in the counterclockwise direction in order to disengage the centering sphere from the race and upper shaft assembly.
14. Remove the race and upper shaft assembly (1) from J 41688.
15. Remove the shaft preload spring and the centering sphere from J 41688.
16. If necessary, discard the old centering sphere and the old shaft preload spring.
17. Remove the joint preload spring from the centering sphere.

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1. Lubricate the centering sphere (1) with GM P/N 12345718 (Canadian P/N 10953516).
2. Install the centering sphere (1) and the joint preload spring (2) into J 41688.
3. Compress the centering sphere and joint preload spring with J 41688.
4. Install the upper shaft assembly.
5. After the race and upper shaft assembly (1) is firmly attached to the centering sphere, rotate the shaft 90 degrees downward in order to lock the centering sphere in place.
6. Remove the centering sphere installer and the race and upper shaft assembly from the vise.
7. Disassembly J 41688 by separating the base. After the tool is disassembled, remove the race and upper shaft from J41688.
8. Lubricate the centering sphere with GM P/N 12345718 (Canadian P/N 10953516).
9. Using the alignment marks from the disassemble procedure, tilt the upper and lower shafts 90 degrees to each other and engage. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
10. Install the steering column support assembly to the steering column jacket assembly with the 4 support screws. Tighten Tighten the screws to 8 N.m (71 lb in).
11. Install the steering shaft assembly into the steering column support assembly.
12. Install the adapter and bearing assembly (2) to the steering column jacket assembly (1). Position the tab on the adapter and bearing assembly with the slot in steering column jacket assembly and push together.
13. Install the lower bearing seat (3).
14. Install the lower bearing spring (4).
15. Install the new lower spring retainers When installing, compress the lower bearing spring (4) to the length of 23.5 mm (0.93 in) between the lower bearing seat (3) and the lower spring retainer (5). CAUTION: Refer to «SIR INFLATOR MODULE COIL CAUTION»(ref-175132-S33913314732005041500000) in Cautions and Notices.
16. Install the steering column jacket. Refer to «STEERING COLUMN JACKET REPLACEMENT»(ref-189097-S13047046712005090600000) .
17. Enable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.

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1. Disable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.
2. Remove the steering column jacket. Refer to «STEERING COLUMN JACKET REPLACEMENT»(ref-189097-S13047046712005090600000) .
3. Remove and discard the 4 support screws (1).
4. Remove the support mounting adapter (2).
5. Remove and discard the lower spring retainer (6).
6. Remove the lower bearing spring (5).
7. Remove the lower bearing seat (4).
8. Remove the adapter and bearing assembly (3).
9. Remove and discard the bearing retainer (1).
10. Remove the steering shaft assembly (2) from the steering column jacket.

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1. Install the support mounting bracket (2).
2. Lubricate the new support screws (1) with LOCTITE® 242, GM P/N 123455382 (Canadian P/N 10953489). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install 4 new support screws (1). Tighten Tighten the screws to 8 N.m (71 lb in).
4. Install the steering shaft assembly (2) into the steering column jacket assembly. IMPORTANT: The bearing must be seated correctly on the steering shaft.
5. Install the new bearing retainer (1).
6. Install the adapter and bearing assembly (3).
7. Install the lower bearing seat (4). IMPORTANT: When installing, compress the lower bearing spring (5) to the length of 23.5 mm (0.93 inches ) between the lower bearing seat (4) and the lower spring retainer (6).
8. Install the lower bearing spring (5).
9. Install the new lower spring retainer (6). CAUTION: Refer to «SIR INFLATOR MODULE COIL CAUTION»(ref-175132-S33913314732005041500000) in Cautions and Notices.
10. Install the steering column jacket. Refer to «STEERING COLUMN JACKET REPLACEMENT»(ref-189097-S13047046712005090600000) .
11. Enable the SIR system. Refer to SIR DISABLING AND ENABLING ZONE 3 in SIR.

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Note. The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction.

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1. Verify the following conditions before centering the SIR coil: The wheels on the vehicle are straight ahead. The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. The ignition switch is in the LOCK position.
2. If the front (5) of the SIR coil has a centering window (4), and the backing side (2) has a spring service lock (1), perform the following steps: 2.1. Hold the coil with the face up. 2.2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 2.3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 2.4. Release the spring service lock between the locking tab. The SIR coil is now centered. 2.5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly.
3. If the front (4) of the SIR coil has a centering window (3) and the back side (1) has NO spring service lock, perform the following steps: 3.1. Hold the coil with the face up. 3.2. Rotate the coil hub clockwise until the coil ribbon stops. 3.3. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3.4. While holding the coil hub in the CENTER position, align the coil with the horn tower and slide the coil onto the steering shaft assembly.
4. If no centering window is present on the front side (3) of the SIR coil, but a spring service lock (1) is on the back side (2), perform the following steps: 4.1. Hold the coil with the back side up. 4.2. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 4.3. Still pressing the spring service lock, rotate the coil hub in the opposite direction 2 1/2 revolutions. 4.4. Release the spring service lock between the locking tabs. The SIR coil is now centered. 4.5. Align the centered coil with the horn tower and slide the coil onto the steering shaft assembly.
5. If no centering window appears on the front side (2) of the SIR coil and no spring service lock exists on the back side (1), perform the following steps: 5.1. Hold the coil with the face up. 5.2. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 5.3. Rotate the coil hub slowly, counterclockwise, for 2 1/2 revolutions. This is the CENTER position. 5.4. While maintaining the coil hub in the CENTER position, align the centered coil with the horn tower and slide the coil onto the steering shaft assembly.

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