Chevrolet 1980 Light Duty Truck Service Manual page 251

Fig. 3B 4 -63 --lnterm e diate S teering Shaft-P Series
Installation
See NOTICE on page 1 of this section
NOTICE:
regarding the fasteners referred to in steps 1, 3 and 4.
1. Install the intermediate shaft assembly onto the
steering shaft, aligning the flat on the shaft with the flat in
the coupling. Install the pot joint clamp bolt and torque to
specifications.
2. Lift the steering gear into position, guiding the
flexible coupling bolts into the shaft flange holes.
3. Install the steering gear to frame bolts and torque
to specifications.
4. Install the flexible coupling to steering shaft flange
bolt lockwashers and nuts. Check that the coupling
alignment pins are centered in the flange slots and then
torque the coupling bolts to specifications.
IN TER M ED IA TE STEERING SHAFT W IT H
UNIVERSAL JO IN T COUPLINGS
Removal (Fig. 3B4-63)
1. Set front wheels in straight ahead position. This can
be done by driving the vehicle a short distance on a flat
surface.
2. Mark upper universal joint yoke to steering shaft
relationship and lower yoke to steering gear wormshaft
relationship.
3. Remove both upper and lower universal yoke pinch
bolts.
4. Remove steering gear to frame bolts and lower the
gear. It is not necessary to disconnect the pitman arm from
the steering gear pitman shaft.
5. Remove the intermediate steering shaft and
universal joint assembly.
Disassembly
1. If the upper or lower half of the intermediate
steering shaft is to be replaced, proceed as follows:
a. With the shaft assembly on a bench, straighten the
tangs on the dust cap. Separate the upper and lower portions
of the shaft assembly.
STEERING CO LU M N S
b. Remove the felt washer, plastic washer and dust cap.
Discard the felt washer.
2. If the trunnion assemblies are to be replaced,
proceed as follows:
a. Remove the snap rings retaining the trunnion
bushings in one of the yokes.
b. Support the yoke on a bench vise and drive out one
bushing by tapping on the opposite bushing using a soft drift
and hammer.
c. Support the other side of the yoke and drive out the
remaining bushing as in Step b above.
d. Move the yoke on the trunnion as necessary to
separate the upper and lower yokes.
e. Remove the trunnion from the lower yoke as
outlined in Steps a through d above. Remove and discard
the seals.
Assembly
1. If the yoke trunnions were removed, reassemble as
follows:
a. Place the new trunnion into the lower yoke.
b. Place new seals onto the trunnion and then press the
new bushings into the yoke and over the trunnion hubs far
enough to install the snap rings.
c. Install the snap rings.
d. Repeat Steps a through c to attach the upper yoke
to the trunnion.
2. Reassemble the intermediate shaft assembly as
follows:
a. Place the dust cap, plastic washer and a new felt seal
over the shaft on the lower yoke assembly.
b. Align the arrow on the lower yoke assembly shaft
with the arrow on the upper yoke assembly tube and push
the two assemblies together.
c. Push the dust cap, plastic washer and felt washer into
position on the lower end of the upper yoke assembly and
bend the tangs of the dust cap down against the yoke tube.
Installation
See NOTICE on page 1 of this section
NOTICE:
regarding the fasteners referred to in steps 1, 3 and 4.
1. Align the marks made at removal and assemble the
intermediate shaft lower yoke onto the steering gear
wormshaft. Install the pinch bolt
specifications. The pinch bolt must pass through the shaft
undercut. If a new yoke was installed, the slit in the yoke
should be in the 12 o'clock position.
2. Raise the steering gear into position while guiding
the upper yoke assembly onto the steering shaft.
The marks on the coupling and steering shaft must
align. If a new yoke was installed, assemble the upper yoke
to the steering shaft with the steering wheel in straight ahead
position (gear must be on high point).
3. Install the steering gear to frame bolts and torque
to specifications.
4. Install the upper yoke to steering shaft pinch bolt
and torque to specifications.
NOTICE: The pinch bolt must pass through the shaft
undercut, or damage may occur to the components.
3B 4-37
and torque to
LIG H T T R U C K SER V IC E M AN UAL