Steering gear — removal and installation (Opel Astra F)

Removal

Disconnect the negative battery terminal.

Set the front wheels straight ahead.

Where required, remove the air box from the top of the carburetor or throttle body (see chapter 4).

Remove the coolant expansion tank as described in chapter 3. On some models, the reservoir can be moved far enough to provide access to the steering gear without disconnecting the hoses.

Where required, disconnect the harness from the anti-theft device switch on the left side of the suspension head and move the harnesses away from the steering gear. Alternatively, the switch can be removed.

Remove the retaining plate from the bolts securing the tie rod to the steering gear, then unscrew and remove the bolts, remove the washers and intermediate plate.



On models with power steering, disconnect the hydraulic hoses from the pipes located on the left side of the engine compartment (next to the expansion tank of the cooling system). Remove the O-rings where necessary. Fluid leakage may occur, so close off any open ends of tubes and hoses to prevent contamination and fluid leakage.



In the driver's footwell, remove the clips and remove the lower trim panel.

Loosen and remove the upper clamp bolt securing the steering shaft to the flexible coupling.



In the engine compartment, unscrew the two clamps securing the steering gear to the bulkhead, then push the right end of the steering gear through the large rubber gasket in the right wheel arch and manipulate the steering gear upwards out of the engine compartment.

When removing the flexible coupling with rubber gaskets from the steering shaft at the same time as removing the steering gear, the help of an assistant may be required.

Installation

Installation is carried out in the reverse order of removal, taking into account the following.

Use new bolts for the steering gear to crossmember clamps.

Connect the flexible coupling to the steering shaft (with rack and steering wheel centering), so that the upper pinch bolt is positioned horizontally on the top side of the steering wheel shaft.

On models with power steering, replace the O-rings when connecting the hydraulic hoses to the pipes.

During installation, it is necessary to replace the fixing plate that secures the steering gear to the tie rod.



If necessary, after installing the expansion tank, add coolant to the required level.

On models with power steering, after finishing work, bleed the hydraulic system as described below in the section "Pumping...".

After completing the work, check the steering wheel alignment as described above in the relevant section.