Saturn S Series Sedan SL, SL1, and SL2

Rack and pinion: general rebuild info

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Old Jan 14, 2025 | 08:34 PM
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loadedkaraage's Avatar
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Post Rack and pinion: general rebuild info

I can't make a write up for rebuilding your rack and pinion ( SL2 Saturn 99' ), but I have some info that may be helpful.
I wish I could give some definitive pictures and breakdown of the innerds, but I can't be 100% certain so I'm not posting here. I am posting mistakes I made though.

First, the boot that covers the universal joint, and connects to the rack and {pinion} shaft, cannot be purchased anywhere. Probably a junkyard find. Here are some general dimensions if you think you can find something that'll work
Intermediate steering shaft boot, firewall side
Intermediate steering shaft boot, firewall side
That's all that was left of mine.

The only identifiable marking I could find stamped on the rack and pinion was "126GM9/A1" if that is of any use.

Bushing on main shaft. If you managed to pop the seal off to this point, better check your rebuild kit { seals }, because that 30mm inner diameter lip you see is also a part of the seal that needs removed. Tried pushing the new one on on top of it already, it dont work.
Bushing on main shaft. If you managed to pop the seal off to this point, better check your rebuild kit { seals }, because that 30mm inner diameter lip you see is also a part of the seal that needs removed. Tried pushing the new one on on top of it already, it no fit.

Here are the two bearings that dont come in the rebuild kit. If you want to track them down, heres the dimensions and relative info. Mine looked good, I dont think they needed replaced, though I didnt open them up, spun with no binding. Could have been original rack and pinion if that tells you about millage you can get out of them
Here are the two bearings that don't come in the rebuild kit. If you want to track them down, here's the dimensions and relative info. Mine looked good, I don't think they needed replaced, though I didn't open them up, spun with no binding. Could have been original rack and pinion if that tells you about millage you can get out of them

25/26mm not relevant to this pic, but heres the inner shaft. Dont quote me on if this is the correct orientation either. When you pull yours apart, you better be documenting everything. Even better if you take pictures. In any case, that left bushing has 2 seals on it. An outer teflon and inner rubber
25/26mm not relevant to this pic, but here's the inner shaft. Don't quote me on if this is the correct orientation either. When you pull yours apart, you better be documenting everything. Even better if you take pictures. In any case, that left bushing has 2 seals on it. An outer teflon and inner rubber

And if you have gotten to this point, you will still need the bushing on the inside of your rack and steering shaft. You will need a 25mm and maybe 26mm diameter washer or bearing pusher set! I can't remember if 26mm wouldn't fit, but whatever the case, it will only barely catch the lip of the seal you need to push out. You will probably won't be able to push it out on the first go. You're going to have to work with it for a bit.

Also, the bushing that you fish out of the shaft, this goes on the rack ( the long thing you take out of the shaft ) rather than pushing it in first. You may have luck seating it first and then shoving the shaft through, but as for me, I need to replace that seal. The problem is it needs to seat or else it won't hold any fluid. Internet says to seat the seal before inserting shaft. Whatever you do, good luck.

Not a very difficult job, but stressful if you didn't take pics right away. Maybe you should try seating the bearing first like everyone else. After all, mine is leaking. In any case, rebuilding yourself is a viable option. Minimal tools required.

Oh, and the teflon seals ( not rubber ) need compressed before installation into shaft. Look this procedure up, you can use a plastic 2 liter and some zip ties, worked flawlessly.

Plenty of videos on the tube if you are wondering if you want to take on this job.

Cheers
 
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