G-Body Manual Steering Box Conversion⁚ A Comprehensive Guide
This guide details converting your G-body’s power steering to manual. We’ll cover selecting the right manual steering box, compatible G-body models, and the step-by-step installation process. We’ll also discuss performance, handling, and potential drawbacks.
Choosing the Right Manual Steering Box
Selecting the appropriate manual steering box is crucial for a successful G-Body conversion. Popular choices include the Saginaw 525 box, known for its 25⁚1 ratio (6.25 turns lock-to-lock) and 3-13/16″ long input shaft with 3/4″ 30-splines. Consider the Borgeson manual steering conversion box, specifically designed for 1978-88 GM G-Bodies, offering a balance of performance and reliability. Speedway Motors also offers a 25⁚1 ratio manual box, ideal for drag racing applications where weight reduction is paramount. Before purchasing, verify the input shaft length and spline count compatibility with your G-Body’s steering column. Checking dimensions is essential to ensure a proper fit and prevent installation issues. Remember to account for the steering ratio; a quicker ratio will provide more responsive steering but may require more effort.
Compatible G-Body Models and Years
The manual steering box conversion is applicable to a wide range of GM G-Body models spanning the years 1978-1988. This includes popular models such as the Chevrolet Monte Carlo, Malibu, and El Camino, as well as the Buick Regal and Oldsmobile Cutlass. While the core components are largely interchangeable across these models, slight variations might exist in the mounting brackets or linkage configurations; Always double-check compatibility with your specific year and model to avoid unexpected fitting problems. Online forums and communities dedicated to G-Body restoration and modifications are valuable resources for verifying compatibility and gathering insights from experienced enthusiasts. Consult these resources before purchasing any parts to ensure a smooth conversion. Remember that some kits might be specifically designed for drag racing applications, which might not be ideal for street driving.
Pitman Arm Selection and Compatibility
Selecting the correct pitman arm is crucial for a successful G-body manual steering conversion. The pitman arm’s dimensions and spline count must precisely match both the manual steering box and the steering linkage. Using an incorrect pitman arm can lead to improper steering geometry, causing issues like binding, poor handling, and even damage to the steering components. The original power steering pitman arm is generally incompatible with a manual steering box due to differences in shaft diameter and spline configuration. A common solution is to source a pitman arm from a manual steering G-body model of the same generation. Alternatively, some aftermarket conversion kits include a compatible pitman arm. Before purchasing, carefully compare the specifications of the pitman arm with those of your manual steering box and existing steering linkage. Consult online resources and forums for guidance on identifying the correct pitman arm for your specific G-body year and model. Incorrect selection can result in poor handling and potential safety hazards.
Installation Process⁚ A Step-by-Step Guide
This section provides a detailed, step-by-step guide for installing your new manual steering box, ensuring a smooth and successful conversion in your G-body.
Removing the Power Steering System
Before commencing the manual steering box installation, the existing power steering system must be meticulously removed; Begin by disconnecting the battery’s negative terminal to prevent accidental short circuits. Next, locate and detach the power steering pump’s belt, carefully noting its routing for reinstallation if needed later. Drain the power steering fluid using a suitable container, ensuring complete fluid removal to prevent spills and environmental contamination. Disconnect the high-pressure and low-pressure power steering hoses at the steering gear and the pump, keeping the ends elevated to minimize fluid loss. Once the hoses are detached, carefully remove the power steering pump assembly along with any mounting brackets or associated components. Remember to take photos of the process for future reference. Finally, remove the power steering gear box itself, taking note of any mounting bolts, brackets, or linkages that must be reattached during the manual steering installation. Properly dispose of the used power steering fluid according to local regulations.
Installing the Manual Steering Box
With the power steering system removed, prepare for the manual steering box installation. Carefully examine the new manual steering box, comparing it to the original power steering unit to ensure proper alignment and mounting. Using the original power steering box mounting points as a guide, securely attach the new manual steering box to the vehicle’s frame, ensuring that all bolts are tightened to the manufacturer’s specifications. Double-check alignment to prevent binding or stress on the steering components. If any shims or spacers were used with the power steering box, ensure their proper placement is replicated with the manual unit. Take care to avoid over-tightening the bolts, as this could damage the steering box or its mounting points. Once the manual steering box is securely mounted, visually inspect its position to verify proper fitment and alignment with the steering column and pitman arm. Before proceeding to the next step, ensure everything is correctly positioned to avoid future issues.
Connecting the Pitman Arm and Steering Linkage
Once the manual steering box is securely mounted, the next crucial step is connecting the pitman arm and steering linkage. Begin by carefully aligning the pitman arm splines with the output shaft of the manual steering box. Ensure that they are properly seated before tightening the retaining nut or bolt. Over-tightening can damage the components, so use a torque wrench to achieve the manufacturer’s recommended specification. Next, connect the steering linkage to the pitman arm, ensuring a snug and secure fit. Any play or looseness in the connection will negatively impact steering precision and responsiveness. Double-check all connections before proceeding. A improperly connected pitman arm can lead to difficult or imprecise steering, and potentially damage the steering box or other components. Use the appropriate tools to ensure the connections are secure and aligned correctly. After connecting, carefully test the steering system by turning the steering wheel to check for proper alignment and free movement throughout the entire range of motion. Address any binding or stiffness immediately.
Performance and Handling Considerations
This section explores the impact of a manual steering conversion on your G-body’s handling, including steering ratio, weight reduction, and potential drawbacks like increased steering effort.
Steering Ratio and Feel
The steering ratio significantly impacts the feel and responsiveness of your G-body. A lower ratio (fewer turns lock-to-lock) provides quicker, more direct steering, enhancing agility, especially beneficial for performance driving or autocross. However, a lower ratio might make low-speed maneuvering slightly less effortless. Conversely, a higher ratio offers more stability at higher speeds but requires more turns of the steering wheel for the same amount of turning. The choice depends on your priorities. Some aftermarket manual steering boxes offer adjustable ratios, allowing customization to your preferences. Consider your driving style and the intended use of your vehicle when selecting a steering box with an appropriate ratio. Many find the quicker ratio of a manual setup preferable to the often sluggish feel of the original power steering, providing a more connected driving experience. The difference in feel is quite noticeable, offering a more direct and engaging interaction with the road.
Weight Reduction Benefits
One primary advantage of converting to manual steering is weight reduction. Removing the power steering pump, its associated brackets, hoses, and fluid significantly lightens the front end of your G-body. This weight savings translates to improved handling, quicker acceleration, and better braking performance. For drag racing or other performance applications where minimizing weight is critical, this conversion offers a substantial benefit. Even a few pounds saved from the front end can make a noticeable difference in a car’s responsiveness and overall performance. The reduction in unsprung weight, specifically the weight not supported by the suspension, is especially beneficial for handling, improving the car’s ability to react to changes in the road surface and driver input. While the weight savings might not be massive, the performance gains are often worthwhile for those focused on optimizing their G-body for speed and handling. Remember to weigh your vehicle before and after the conversion to quantify the precise weight reduction achieved.
Potential Drawbacks of Manual Steering
While offering weight reduction and a potentially more direct steering feel, converting to manual steering in a G-body also presents some drawbacks. The most significant is the increased effort required to turn the steering wheel, especially at low speeds and during parking maneuvers. This can be fatiguing, particularly in city driving or during long trips. The lack of power assist also means that the car will be less forgiving on uneven roads or when encountering unexpected bumps or obstacles; steering can become more difficult and require greater physical exertion. Furthermore, the absence of power assist might negatively impact low-speed maneuverability, making parking and tight turns more challenging. While a quicker steering ratio is often a benefit, it can also lead to a less stable feel at higher speeds. Consider these trade-offs carefully before undertaking this conversion. The choice depends heavily on your priorities and intended use of the vehicle. For purely track use where weight reduction is paramount, the drawbacks might be acceptable; however, for everyday driving, the increased effort could prove significant.