Editing Swapping to rack and pinion steering (section)
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====Pressure relief valving==== Most older GM pumps will have a pressure rating as high as 1350 psi. The '82–'94 Chevy S10 has the lowest rating at around 1100 psi. The Cavalier rack was designed for a pressure of ~1,000 psi. You can adjust the pressure with a simple shim kit from Borgeson. The pressure relief valve is located behind the high pressure output fitting on the back of the pump. You may need a small magnet to pull it out of the recess. The shim kit comes with a tool to help with removing the end nut, a new O-ring for the outer fitting, and several shims with a guide on how many shims to use to attain the desired pressures. Basically, adding shims reduces the pressure on the spring, allowing the bypass to open sooner and recirculate the fluid, rather than force it to the rack- thus making the pressure lower. The kit allows for reduction to about 750 psi, suitable for a Mustang II rack, which allows you to get well below the normal range for a Cavalier rack. Reduce the sensitivity to what suits you. In most cases, the pressure reduction valve can be removed and replaced with the pump in the car. Yes, you have to drain and refill the pump each time, but that’s pretty minor.
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