If you own a Pontiac with a "manual" steering system, you've likely retained it for three possible reasons: 1) Your Pontiac is a race car and you enjoy the advantages of less weight, parasitic drag, and maintenance compared to a power-steering system, 2) Your Pontiac is restored to factory stock and you don't want to add options that didn't come with it, 3) You really enjoy the upper body workout it provides without having to resort to ordering exercise equipment from late-night infomercials.
Your Pontiac's Saginaw manual steering box has probably performed dependably for years-decades even. But as the miles pile up, you may start to notice a bit of play that wasn't there before. You can adjust the lash between the worm and sector gears, but that may only make things worse if the bushing and bearing wear are what's actually causing the play.
Refer to this diagram as you...
Refer to this diagram as you read the story to get a better understanding of the location of the parts.
The good news is that rebuilding a manual box is relatively easy and inexpensive using a rebuild kit (PN H1010) from Harry's Steering Gear Repair that costs about $60, and you don't need many specialized tools. You need pullers to remove the Pitman arm and races, drivers to install races and a bushing, and an in-lb torque wrench, but these are readily available for loan or rent at auto-parts stores. The rebuild can easily be accomplished over a weekend, including the removal and reinstallation of the box.
The Saginaw manual steering box first appeared in GM cars in '55, and variations of that venerable box were used for decades. Our particular box has a 24:1 ratio with six turns to lock, and was used in various GM cars of the '60s and '70s. Regardless of what year Pontiac you're driving, if it has a manual Saginaw recirculating-ball steering box, the following instructions should provide the guidance you need for a successful rebuild.
Before getting your hands dirty, take a look at the diagrams included with this article. The recirculating-ball steering box isn't difficult to work on, but it's a bit peculiar in that the "threads" for the ball nut are made up of small steel balls. Ball threads provide two key advantages over cut threads-they last longer and require less driver effort.
Hopefully a new set of bearings, a new bushing, and some fresh lube will get your steering box working good as new, but if the wormshaft, ball nut, or Pitman shaft are pitted or severely worn, they will also need to be replaced. Harry's Steering Gear Repair carries a large parts inventory and can, for instance, supply you with a new wormshaft/ball-nut assembly for about $60. If you have the slightest doubt about the durability of your parts, don't hesitate to opt for replacements.
Before you start the rebuild, you must remove the box from your Pontiac. Begin by disconnecting the rag joint with a 9/16-inch wrench. Next, unscrew the Pitman arm's 15/16-inch-head retaining nut; you will probably need either a breaker bar or an impact wrench unless you are really pumped. Use a puller to remove the arm. Remove the three 5/8-inch-head bolts that secure the box to the frame. Finally, remove the rag joint from the end of the wormshaft.
Now let's get to the rebuild.
Remove the lash adjuster nut...
Remove the lash adjuster nut and then the three 9/16-inch head bolts that retain the housing side cover.
Unthread the adjuster stud...
Unthread the adjuster stud clockwise to remove the side cover.
Next, pull the Pitman shaft...
Next, pull the Pitman shaft from the case using the lash-adjuster stud as a handle. If it won't come freely, a tap from a rubber or plastic-headed mallet will do the trick (but I don't think the mallet will be necessary).