Steering column — bulkhead (Opel Vectra A)

Fixed steering column

Bulkhead

1. If the steering column has not yet been removed from the vehicle, proceed as described in points 1-11 Chapters 33.

2. Using a screwdriver as a lever, remove the fuses from the ignition switch housing (see illustration), then turn the cover counterclockwise and remove it from the steering column.



3. To remove the bearing from the ignition switch housing, use a screwdriver to pry the two bearing fasteners out and push or tap it out by placing a tubular drift on the outer bearing race. When installing a new bearing, make sure the thrust washer and retaining springs are installed correctly) (see illustration).





4. The ignition switch is secured to the steering column lock housing with two countersunk screws. Remove the screws and remove the lock. It is recommended not to remove the switch and the lock cylinder at the same time, so that their relative positions are not lost.

5. If the steering column is in the vehicle, loosen and remove the upper pinch bolt of the steering shaft flexible coupling in the driver's footwell.

6. Remove the steering gear shaft from the steering column tube.

7. Install the temporary plastic centering washer supplied with the new steering column or steering gear shaft into the base of the steering column tube.

8. Insert the shaft into the steering column tube. If the steering column is in the car, connect the lower end of the shaft to the flexible coupling and install the upper pinch bolt, but do not tighten it at this stage.

9. Install the ignition switch and tighten the countersunk screws.

10. Install the ignition switch housing using new fuses.

11. If the steering column is in the vehicle, pull up the steering gear shaft to the bearing stop, then tighten the upper flex coupling pinch bolt. Make sure the wheels are still in the straight-ahead position and the upper flex coupling pinch bolt is horizontal.



12. Then install in the reverse order of removal. Install the steering wheel as described in Chapter 30.

13. Finally, take the vehicle for a test drive on a route with several turns and make sure the steering mechanism works properly.

Steering column with tilt adjustment

Note: When reassembling, use new shear bolts to secure the lock housing.

Bulkhead

14. If the steering column is in the vehicle, proceed as described in points 1-11 Chapters 33.

15. Remove the tilt adjuster spring using a screwdriver as a lever. Be careful as the spring may fly out.

16. The ignition switch is secured to the lock housing with two countersunk screws. Access to the countersunk screw is virtually impossible without removing the steering column. Remove it as described in Chapter 33.

17. The lock housing is secured to the bearing housing with two shear bolts, which must be punched, drilled out and removed using a special bolt puller (see illustration).



18. The upper steering column bearing race can be replaced after removing the snap ring, pressure rings and spring. Note that you may have to compress the spring to remove the snap ring. Be careful, as the spring may fly out after removing the snap ring.



19. To remove the bearing housing from the steering column, remove the pins using a nut and bolt. There is a special tool for this purpose, Opel KM-585 (see illustration).



20. The lower steering column bearing race can be removed from the shaft using a hammer and drift or flat chisel. Install the new race onto the shaft.

21. The main bearing rings of the steering column can only be replaced together with the casing.

22. If necessary, remove the universal joint shaft and tilt adjustment mechanism locks for replacement

23. Install the components in the reverse order of removal, paying attention to the following: (see illustration).



24. When installing the universal joint of the steering gear shaft, note that the spring clips must fit into the recesses of the joint halves (see illustration).





25. If the lock housing and bearing housing have been separated, clean out the mounting bolt holes using a special threaded plug. Apply blocking compound to the new shear bolts and tighten them until the heads break off.

26. After installing the bearing housing pins, secure each of them in three equally spaced places.

27. When replacing bearings, make sure that the clearances between the bearing housing and the buffers that limit upward movement are the same. Measure the clearances with a feeler gauge. There are buffer kits of different thicknesses available.