Power Steering System Chevrolet Chevy Express G3500

Fastener Tightening Specifications

Fastener Tightening Specifications

Power Steering Pump Specifications

Power Steering Pump Specifications

Scheme 1

Scheme 2

Scheme 3

Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Power Steering System in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Review the system description and operation in order to familiarize yourself with the system functions. Refer to Power Steering System Description and Operation (w/o Electro-Hydraulic Steering) .

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the power steering system.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Inspect the power steering reservoir for the proper power steering fluid level and condition.

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Power Steering Fluid Leaks»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-fluid-leaks)
2. «Rattle, Clunk, or Shudder Noise from the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system)
3. «Whine or Growl Noise from the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system)
4. «Steering Effort Hard in One or Both Directions»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__steering-effort-hard-in-one-or)
5. «Steering Effort Too Easy in One or Both Directions»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__steering-effort-too-easy-in-one)

Scheme 4

Scheme 5

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 5: This step tests the system for restrictions.
2. 7: This step tests the following components for the following conditions: The pump for internal leaks The power steering pipes for kinks
3. 8: This step tests the ability of the pump to regulate flow at maximum pressure.
4. 10: This step tests the ability of the pump to regulate flow under normal operating conditions.
5. 12: This step tests the internal components of the pump and the gear.

Power Steering System Test Procedure

Power Steering Fluid Leaks

Power Steering Fluid Leaks

Rattle, Clunk, or Shudder Noise from the Power Steering System

Whine or Growl Noise from the Power Steering System

Steering Effort Hard in One or Both Directions

Steering Effort Hard in One or Both Directions

Steering Effort Too Easy in One or Both Directions

Steering Effort Too Easy in One or Both Directions

Tools Required

1. J 35555 Metal Mityvac. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 43485 Power Steering Bleeder Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

1. Verify that the hoses do not touch any other part of the vehicle.
2. Verify that all hose connections are tight.
3. Remove the pump reservoir cap.
4. Fill the pump reservoir with fluid to the FULL COLD level.
5. Attach the J 43485 to the J 35555 or equivalent. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Place the J 43485 on or in the pump reservoir filler neck. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Apply a vacuum of 68 kPa (20 in Hg) maximum.
8. Wait 5 minutes. Typical vacuum drop is 7-10 kPa (2-3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis at the end of this procedure.
9. Remove the J 43485 and the J 35555 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
10. Reinstall the pump reservoir cap.
11. Start the engine. Allow the engine to idle.
12. Turn off the engine.
13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes.
14. Start the engine. Allow the engine to idle.
15. Turn the steering wheel 180-360 degrees in both directions 5 times.
16. Switch the ignition off.
17. Verify the fluid level.
18. Remove the pump reservoir cap.
19. Attach the J 43485 to the J 35555 or equivalent. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
20. Place the J 43485 on or in the pump reservoir filler neck. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
21. Apply a vacuum of 68 kPa (20 in Hg) maximum.
22. Wait 5 minutes.
23. Remove the J 43485 and the J 35555 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
24. Verify the fluid level.
25. Reinstall the pump reservoir cap.

Scheme 6

1. If the vacuum continues to drop, remove the pressure and return hose from the pump.
2. Install the plugs (1, 2) supplied with the J 43485 into the pressure and return port. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Attach the J 43485 to the J 35555 or equivalent. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
4. Place the J 43485 on or in the pump reservoir filler neck. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
5. Apply a vacuum of 68 kPa (20 in Hg) maximum.
6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system.
7. Observe the fluid.
8. If condition persists, replace the following parts: The return hose clamps The return hose O-rings The pressure hose O-rings The gear cylinder line O-rings The reservoir to pump O-ring
9. Repeat the bleed procedure from the beginning.
10. Drive the vehicle approximately 16 km (10 mi) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface.
11. Verify the following conditions: There is smooth power assist. The vehicle operates quietly. The pump maintains the proper fluid level. There is not any leaking in the steering system. The fluid is free of foam or discoloration.

Checking and Adding Power Steering Fluid

Note. When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.

1. If the power steering system has been serviced, bleed the power steering system to remove any trapped air from the system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. Fully charge the hydro-boost accumulator using the following procedure: Start the engine. Firmly apply the brake pedal 2 to 3 times. Turn the engine Off.
3. Clean the area surrounding the reservoir cap.
4. Remove the reservoir cap.
5. Inspect the power steering pump fluid level at regular intervals. Add fluid when required. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/chevy-express-g3500/1996-2012/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) in Maintenance and Lubrication.
6. If the fluid level is low, add power steering fluid to the proper level.
7. Install the reservoir cap.
8. When checking the fluid level after servicing the steering system, bleed the air from the system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

1. Turn off the engine.
2. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Place a large container under the fluid return hose in order to collect the draining fluid.
4. Remove the fluid return hose at the power steering pump reservoir inlet connection.
5. Plug the reservoir return hose inlet connection on the power steering pump.
6. Run the engine at idle while an assistant maintains the fluid level at FULL COLD in the reservoir using new approved power steering fluid.
7. Turn off the engine.
8. Turn the steering wheel fully to the left and to the right.
9. Remove the plug from the pump reservoir inlet connection.
10. Install the fluid return hose to the pump reservoir.
11. Maintain the fluid level at FULL COLD.
12. Operate the engine at idle for approximately 15 minutes.
13. Repeat steps 3-5.
14. Inspect the power steering fluid for the following indications of contamination: Milky fluid - water Brown fluid - burnt Plastic debris or dirt chunks
15. If the fluid is contaminated, repeat steps 6-12 in order to complete a third flush.
16. Remove the plug from the pump reservoir inlet connection.
17. Install the fluid return hose to the pump reservoir.
18. Clean any spilled fluid.
19. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system)

Removal Procedure

1. Siphon the power steering fluid from the reservoir.
2. Disconnect the reservoir outlet hose from the reservoir.
3. Remove the reservoir inlet hose (3) from the reservoir.
4. Remove the power steering pump remote reservoir mounting nuts (4).
5. Remove the power steering pump remote reservoir (3).

Installation Procedure

1. Install the power steering pump remote reservoir (3) to the vehicle.
2. Install the power steering pump remote reservoir (4) mounting nuts. Tighten: Tighten the nuts to 7 N.m (58 lb in).
3. Install the reservoir inlet hose (3) to the reservoir.
4. Connect the reservoir outlet hose to the reservoir.
5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Power Steering Pulley Replacement

Tools Required

1. J 25033-C Power Steering Pump Pulley Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 25034-C Power Steering Pump Pulley Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 7

1. Remove the upper fan shroud. Refer to «Fan Shroud Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-43l) in Engine Mechanical 4.3L or «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) or «Drive Belt Replacement - Air Conditioning»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) in Engine Mechanical 4.8L, 5.3L, and 6.0L.
3. Remove the power steering pump pulley using the J 25034-C . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 8

1. Place the power steering pump pulley on the end of the power steering pump shaft.
2. Install the power steering pump pulley using J 25033-C . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Ensure that the power steering pump pulley is flush against the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 in).
4. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-43l) in Engine Mechanical 4.3L or «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) or «Drive Belt Replacement - Air Conditioning»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical/#engine-mechanical-removal-installation-1-of-3-48l-53l-60l) in Engine Mechanical 4.8L, 5.3L, and 6.0L.
5. Install the upper fan shroud. Refer to «Fan Shroud Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

Scheme 9

1. Place a drain pan below under the vehicle.
2. Remove the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
5. Disconnect the reservoir outlet hose from the power steering pump through the wheel well.
6. Disconnect the power steering gear outlet hose or cooler hose from the power steering pump through the wheel well.
7. Disconnect the power brake booster inlet hose (2) from the power steering pump (1) through the wheel well.
8. Cap the ends of the hose and the power steering pump in order to prevent the entrance of dirt.
9. Lower the vehicle.
10. Remove the power steering pump mounting bolts and the nuts.
11. Remove the accessory mounting bracket mounting bolts and nut.
12. Pull the accessory bracket forward.
13. Remove the power steering pump from the vehicle.
14. Remove the power steering pump rear bracket mounting nuts.
15. Remove the power steering pump rear bracket.

1. Install the rear bracket to the power steering pump.
2. Install the power steering pump rear bracket mounting nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the power steering pump to the vehicle.
4. Install the power steering pump front mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Reposition the accessory mounting bracket and install the mounting bolts and nut. Tighten: Tighten the bolts and nut to 50 N.m (37 lb ft).
6. Install the power steering pump lower and rear mounting nuts. Tighten: Tighten the nuts to 41 N.m (30 lb ft).
7. Uncap the power steering hoses.
8. Raise the vehicle.
9. Install the power brake booster inlet hose (2) to the power steering pump through the wheel well. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
10. Install the power steering gear outlet hose or cooler hose to the power steering pump through the wheel well.
11. Install the reservoir outlet hose to the power steering pump through the wheel well.
12. Lower the vehicle.
13. Install the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement) .
14. Bleed the system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
15. Remove the drain pan from under the vehicle.

Scheme 10

1. Place a drain pan below under the vehicle.
2. Remove the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement) .
3. Remove the lower intermediate shaft to the power steering gear retaining bolt.
4. Disconnect the lower intermediate shaft from the power steering gear.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
7. Disconnect the reservoir outlet hose from the power steering pump through the wheel well.
8. Disconnect the power steering gear outlet hose or cooler hose the power steering pump through the wheel well.
9. Disconnect the power brake booster inlet hose (2) from the power steering pump through the wheel well.
10. Cap the ends of the hose and the pump in order to prevent the entrance of dirt.
11. Lower the vehicle.
12. Remove the rear power steering pump mounting bolt.
13. Remove the front power steering pump mounting bolts.
14. Remove the power steering pump from the vehicle.
15. Remove the power steering pump rear bracket mounting nuts.
16. Remove the power steering pump rear bracket from the power steering pump.

Scheme 11

1. Install the power steering pump rear bracket to the power steering pump.
2. Install the power steering pump rear bracket mounting nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Install the power steering pump to the vehicle.
4. Install the front power steering pump mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the rear power steering pump mounting bolt. Tighten: Tighten the bolt to 41 N.m (30 lb ft).
6. Uncap the power steering hoses.
7. Raise the vehicle.
8. Install the power brake booster inlet hose (2) to the power steering pump through the wheel well. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
9. Install the power steering gear outlet hose or cooler hose to the power steering pump through the wheel well.
10. Install the reservoir outlet hose to the power steering pump through the wheel well.
11. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
12. Lower the vehicle.
13. Connect the lower intermediate shaft to the power steering gear.
14. Install the lower intermediate shaft to the power steering gear retaining bolt. Tighten: Tighten the bolt to 61 N.m (45 lb ft).
15. Install the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-pulley-replacement) .
16. Bleed the system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
17. Remove the drain pan from under the vehicle.

Scheme 12

1. Drain the power steering fluid from the power steering pump.
2. Remove the pump mounting studs (2).
3. Remove the connector and fitting assembly (4).
4. Remove the O-ring seal (3) from the connector and fitting assembly (4).
5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly. Refer to «Power Steering Pump Flow Control Valve Replacement - Off Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Remove the reservoir assembly (1) from the pump housing assembly (2).
7. Remove the O-ring seals (1), (4) and (5).
8. Remove the magnet (3).
9. Clean the magnet (3).
10. Inspect the welch plug in the power steering pump housing (2). Do not remove. If the welch plug is deformed or dislodged, replace the power steering pump.

Scheme 13

1. Lubricate the O-ring seals (1, 4 and 5) with power steering fluid.
2. To install the control valve assembly and flow control spring to the pump housing assembly (2). Refer to «Power Steering Pump Flow Control Valve Replacement - Off Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Install the O-ring seals (1, 4 and 5) to the pump housing assembly (2).
4. Install the magnet (3) to the pump housing assembly (2).
5. Connect the reservoir assembly (1) to the pump housing assembly (2).
6. Install the O-ring seal.
7. Install the connector and fitting assembly (4) to the pump housing (1).
8. Install the pump mounting studs (2) to the pump housing (1). Tighten Tighten the pump mounting studs (2) to 58 N.m (43 lb ft). Tighten the connector and fitting assembly (4) to 75 N.m (55 lb ft).

Scheme 14

1. Drain the oil from the reservoir (1).
2. Remove the connector and fitting assembly (2).
3. Remove the control valve assembly (4) from the pump housing (1). Make sure the flow control spring (5) does not fall out of the pump housing (1).
4. Remove and discard the O-ring seal (3) from the connector and fitting assembly (2).

Assembly Procedure

1. Install the flow control spring (5), if removed from the pump housing (1).
2. Lubricate the new O-ring seal (3) with power steering fluid.
3. Install the O-ring seal (3) onto the connector and fitting assembly (2).
4. Install the control valve assembly (4).
5. Install the connector and fitting assembly (2). Tighten: Tighten the connector and fitting assembly to 75 N.m (55 lb ft).

Pitman Shaft Seal Replacement (Non Rack and Pinion)

Tools Required

1. J 4245 Internal Snap Ring Pliers. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 6278 Pitman Shaft Bearing Remover and Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 15

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Mark the position of the pitman arm to the pitman shaft.
3. Remove the Pitman Arm. Refer to «Pitman Arm Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/steering-linkage/#steering-linkage-non-rack-pinion__pitman-arm-replacement) in Steering Linkage (Non-Rack and Pinion).
4. Drain the power steering fluid from the system.
5. Remove the pitman shaft and side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Clean the exposed end of the pitman shaft.
7. Clean the steering gear housing.
8. Use a wire brush to clean the pitman shaft splines.
9. Remove the dust seal (1).
10. Remove the retaining ring using J 4245 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
11. Use a screwdriver to pry the backup washer (3) and the double lip seal (2) from the power steering gear housing (1).
12. Inspect the power steering gear housing (1) for burrs.
13. Remove the power steering gear housing (1) if necessary.
14. Insert the J 6278 through the hole in the top of the power steering gear housing (1). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
15. Drive out the needle bearing (2).

Scheme 16

1. Coat the double lip seal (2) and the washer (3) with grease.
2. Install the needle bearing (2) to the power steering gear housing (1) using J 6278 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Install the double lip seal (2).
4. Install the backup washer (3).
5. Install the retaining ring using the J 4245 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Install the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Install the dust seal (1).
8. Install the Pitman Arm. Refer to «Pitman Arm Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/steering-linkage/#steering-linkage-non-rack-pinion__pitman-arm-replacement) in Steering Linkage (Non-Rack and Pinion).
9. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
10. Lower the vehicle.

Tools Required

J 34028 Inner Tie Rod Wrench. See Special Tools and Equipment .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the rack and pinion boot. Refer to «Rack and Pinion Boot Replacement - On Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
4. Remove the shock dampener (2) from the inner tie rod (5).
5. Slide the shock dampener (2) back onto the power steering gear (1).
6. Remove the inner tie rod (2) from the power steering gear (4) as follows: Place J 34028 on the flats of the inner tie rod housing (3). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Rotate the inner tie rod housing (3) counterclockwise until the inner tie rod (2) separates from the power steering gear.
7. Remove the old Loctite® from the threads of the power steering gear (1).

1. Apply Loctite® 262 or equivalent to the inner tie rod threads (2).
2. Install the inner tie rod (3) to the power steering gear (1).
3. Install a torque wrench (1) to the J 34028 to tighten the inner tie rod (2). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Tighten: Tighten the inner tie rod to 100 N.m (74 lb ft).
4. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener bottoms out against the inner tie rod housing.
5. Install the rack and pinion boot. Refer to «Rack and Pinion Boot Replacement - On Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
7. Lower the vehicle.
8. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

J 24319-B Steering Linkage and Tie Rod Puller. See Special Tools and Equipment .

Scheme 17

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the outer tie rod stud retaining nut.
4. Loosen the jam nut (2) on the inner tie rod (1).
5. Disconnect the outer tie rod from the steering knuckle using J 24319-B . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Remove the outer tie rod (3) from the inner tie rod (1).

Scheme 18

1. Connect the outer tie rod (3) to the inner tie rod (1). Do not tighten the jam nut (2).
2. Connect the outer tie rod to the steering knuckle.
3. Install the outer tie rod retaining nut. Tighten: Tighten the nut to 63 N.m (47 lb ft).
4. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

J 22610 Keystone Clamp Pliers. See Special Tools and Equipment .

Scheme 19

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the outer tie rod. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Remove the hexagon jam nut (2) from the inner tie rod (1).
4. Remove the tie rod end clamp (2) from the rack and pinion boot (1).
5. Remove the boot clamp (1) from the rack and pinion boot with side cutters.
6. Discard the boot clamp (1).
7. Disconnect the breather tube from the rack and pinion boot (1). Remove the rack and pinion boot (1) from the power steering gear.

Scheme 20

1. Prior to the rack and pinion boot installation, apply grease to the inner tie rod (2) and the power steering gear (1).
2. Install the rack and pinion boot (3) onto the inner tie rod (2).
3. Install the breather tube while aligning the breather tube with the mark made during removal and the molded nipple of the rack and pinion boot.
4. Install the rack and pinion boot onto the power steering gear (1) until the rack and pinion boot (3) is seated in the power steering gear groove.
5. Install the boot clamp (1) on the rack and pinion boot (2).
6. Crimp the boot clamp (1) using the J 22610 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Install the new boot clamp (2) onto the rack and pinion boot (1).
8. Install the hexagon jam nut (2) to the inner tie rod (1).
9. Install the outer tie rod. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
10. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Power Steering Cooler Pipe/Hose Replacement (GT4)

Note. Refer to Power Steering Hose Disconnected Notice in Cautions and Notices.

Scheme 21

1. Install drain pan under vehicle.
2. Disconnect the power steering cooler hose from the power steering pump.
3. Disconnect the power steering cooler hose from the power steering gear.
4. Cap the power steering cooler ends in order to prevent the entry of dirt.
5. Remove the power steering cooler mounting bolts.
6. Remove the power steering cooler from the vehicle.

1. Install the power steering cooler to the vehicle.
2. Install the power steering cooler mounting bolts. Tighten: Tighten the bolts to 5 N.m (44 lb in).
3. Connect the power steering cooler hose to the power steering gear. Tighten: Tighten the hose fitting to 33 N.m (24 lb in).
4. Connect the power steering cooler hose to the power steering pump.
5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Remove the drain pan from under the vehicle.

Power Steering Cooler Pipe/Hose Replacement (GT5)

Note. Refer to Power Steering Hose Disconnected Notice in Cautions and Notices.

Scheme 22

1. Install drain pan under the vehicle.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Disconnect the power steering cooler hose from the power steering pump.
4. Disconnect the power steering cooler hose from the power steering gear.
5. Cap the power steering pipes and cooler ends in order to prevent the entry of dirt.
6. Remove the power steering cooler mounting nuts.
7. Remove the power steering cooler from the vehicle.

1. Install the power steering cooler to the vehicle.
2. Install the power steering cooler mounting nuts. Tighten: Tighten the nuts to 28 N.m (21 lb ft).
3. Connect the power steering cooler hose to the power steering gear. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
4. Connect the power steering cooler hose to the power steering pump.
5. Lower the vehicle.
6. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Remove the drain pan from under the vehicle.

Scheme 23

1. Install a drain pan under the vehicle.
2. Siphon the fluid from the reservoir to prevent excessive spillage.
3. Remove the reservoir inlet hose (3) from the power brake booster (2).
4. Remove the reservoir inlet hose (3) from the reservoir.
5. Remove the reservoir inlet hose from the vehicle.

1. Route the hose in the same position the hose occupied prior to removal.
2. Install the reservoir inlet hose (3) to the reservoir.
3. Install the reservoir inlet hose (3) to the power brake booster (2).
4. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
5. Remove the drain pan from under the vehicle.

Power Steering Reservoir Outlet Pipe/Hose Replacement

Note. Refer to Power Steering Hose Disconnected Notice in Cautions and Notices.

1. Siphon the power steering fluid from the reservoir.
2. Disconnect the power steering reservoir outlet hose from the power steering pump.
3. Disconnect the power steering reservoir outlet hose from the power steering gear remote reservoir.
4. Remove the power steering reservoir outlet hose from the vehicle.

1. Install the power steering reservoir outlet hose to the vehicle
2. Install the power steering reservoir outlet hose to the power steering pump.
3. Install the power steering reservoir outlet hose to the power steering gear remote reservoir.
4. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 24

1. Install a drain pan under the vehicle.
2. Siphon the power steering fluid from the reservoir to prevent excessive spillage.
3. Remove the power steering outlet hose from the power steering pump.
4. Remove the power steering gear outlet hose from the power steering gear.
5. Remove the power steering gear outlet hose from the vehicle.

1. Route the hose in the same position the hose occupied prior to removal.
2. Install the steering gear outlet hose to the power steering gear. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
3. Install the power steering outlet hose to the power steering pump.
4. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
5. Remove the drain pan from under the vehicle.

Scheme 25

1. Install a drain pan under the vehicle.
2. Siphon the power steering fluid from the reservoir to prevent excessive spillage.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
5. Remove the power brake booster inlet hose (2) from the power steering pump (1) through the wheelwell.
6. Lower the vehicle.
7. Remove the power brake booster inlet hose (1) from the power brake booster (2).
8. Remove the power brake booster inlet hose from the vehicle.

1. Route the hose in the same position the hose occupied prior to removal.
2. Install the power brake booster inlet hose (1) to the power brake booster (2). Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
3. Raise the vehicle.
4. Install the power brake booster inlet hose (2) to the power steering pump (1) through the wheelwell. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
5. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
6. Lower the vehicle.
7. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
8. Remove the drain pan from under the vehicle.

1. Install a drain pan under the vehicle.
2. Siphon the power steering fluid from the reservoir to prevent excessive spillage.
3. Remove the power brake booster outlet hose (1) from the power brake booster (2).
4. Remove the power brake booster outlet hose from the power steering gear (2).
5. Remove the power brake booster outlet hose from the vehicle.

1. Route the hose in the same position the hose occupied prior to removal.
2. Install the power brake booster outlet hose (1) to the power brake booster (2). Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
3. Install the power brake booster outlet hose to the power steering gear (2). Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
4. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
5. Remove the drain pan from under the vehicle.

Power Steering Gear Replacement (Non-Rack and Pinion)

Tools Required

1. J 6632-01 Pitman Arm Puller. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 24319-B Steering Linkage and Tie Rod Puller. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. J 29107-A Pitman Arm Puller. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Place a drain pan under the vehicle.
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
4. Disconnect the lower intermediate shaft from the power steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(/chevrolet/chevy-express-g3500/1996-2012/remont/ignition-switchsteering-lock/#steering-wheel-steering-column) in Steering Wheel and Column.
5. Disconnect the power brake booster outlet hose (4) and power steering gear outlet hose or the power steering cooler hose (1) from the power steering gear (2).
6. Cap the ends of the hoses and the power steering gear fittings in order to prevent the entrance of dirt.
7. Remove the pitman arm to relay rod retaining nut.
8. Disconnect the pitman arm from the relay rod using J 24319-B . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
9. Remove the power steering gear mounting bolts.
10. Remove the power steering gear from the vehicle.
11. Remove the pitman arm to power steering gear retaining nut and washer.
12. Remove the pitman arm from the power steering gear using J 6632-01 or J 29107-A . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 26

1. Install the pitman arm to the power steering gear.
2. Install the pitman arm to power steering gear retaining nut and washer. Tighten: Tighten the nut to 250 N.m (184 lb ft).
3. Install the power steering gear to the vehicle.
4. Install the power steering gear to the frame mounting bolts. Tighten: Tighten the bolts to 150 N.m (111 lb ft).
5. Install the pitman arm to relay rod.
6. Install the pitman arm to relay rod retaining nut. Tighten: Tighten the nut to 63 N.m (47 lb ft).
7. Remove the caps from the steering gear and hoses.
8. Connect the power brake booster outlet hose (4) and power steering gear outlet hose or the power steering cooler hose (1) to the power steering gear (2). Tighten: Tighten the hose fittings to 33 N.m (24 lb ft).
9. Connect the lower intermediate shaft to the power steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(/chevrolet/chevy-express-g3500/1996-2012/remont/ignition-switchsteering-lock/#steering-wheel-steering-column) in Steering Wheel and Column.
10. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
11. Lower the vehicle.
12. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
13. Remove the drain pan from under the vehicle.

J 24319-B Steering Linkage and Tie Rod Puller. See Special Tools and Equipment .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Place a drain pan under the vehicle.
3. Remove the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
4. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
5. Remove the outer tie rods retaining nuts.
6. Disconnect the outer tie rods from the steering knuckles using J 24319-B . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Disconnect the lower intermediate shaft from the power steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(/chevrolet/chevy-express-g3500/1996-2012/remont/ignition-switchsteering-lock/#steering-wheel-steering-column) in Steering Wheel and Column.
8. Disconnect the power brake booster outlet hose (2) and power steering gear outlet hose (1) or the power steering cooler hose (1) from the power steering gear (3).
9. Cap the ends of the hoses and the power steering gear fittings in order to prevent the entrance of dirt.
10. Remove the power steering gear mounting bolts.
11. Remove the power steering gear from the vehicle.

Scheme 27

1. Install the power steering gear to the vehicle.
2. Install the power steering gear to the frame mounting bolts. Tighten: Tighten the bolts to 150 N.m (111 lb ft).
3. Remove the caps from the steering gear and hoses.
4. Connect the power brake booster outlet hose (2) and power steering gear outlet hose (1) or the power steering cooler hose (1) to the power steering gear (3). Tighten: Tighten the hose fittings to 33 N.m (24 lb ft).
5. Connect the lower intermediate shaft to the power steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(/chevrolet/chevy-express-g3500/1996-2012/remont/ignition-switchsteering-lock/#steering-wheel-steering-column) in Steering Wheel and Column.
6. Install the outer tie rods retaining nuts. Tighten: Tighten the nuts to 63 N.m (47 lb ft).
7. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
8. Install the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
9. Lower the vehicle.
10. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
11. Remove the drain pan from under the vehicle.
12. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Scheme 28

1. Loosen the adjuster plug lock nut (1).
2. Turn the adjuster plug clockwise until the adjuster plug bottoms in the gear assembly.
3. Turn the adjuster plug back 50 degrees to 70 degrees (approximately one flat).
4. Install the adjuster plug lock nut (1) to the adjuster plug. Tighten: Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 68 N.m (50 lb ft).

J 22610 Keystone Clamp Pliers. See Special Tools and Equipment .

Disassembly Procedure

1. To remove the outer tie rod. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. Remove the hexagon jam nut (2) from the inner tie rod assembly (1).
3. Remove the tie rod end clamp (2) from the rack and pinion boot (1).
4. Remove the boot clamp (1) from the rack and pinion boot with side cutters.
5. Discard the boot clamp (1).
6. Remove the rack and pinion boot (1) and the breather tube, if present, from the rack and pinion gear assembly.

1. Install the new boot clamp (1) onto the rack and pinion boot (3).
2. Prior to rack and pinion boot installation, apply grease to the inner tie rod assembly (2) and the rack and pinion gear assembly (1).
3. Install the rack and pinion boot (3) onto the inner tie rod assembly (2).
4. If present, install the breather tube while aligning the breather tube with the mark made during removal and the molded nipple of the rack and pinion boot.
5. Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3) is seated in the gear assembly groove.
6. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Crimp the boot clamp (1).
8. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end clamp.
9. Install the tie rod end clamp (2) onto the rack and pinion boot (1).
10. Install the hexagon jam nut (2) to the inner tie rod assembly (1).
11. To assemble the outer tie rod assembly. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

J 34028 Inner Tie Rod Wrench. See Special Tools and Equipment .

1. To remove the rack and pinion boot and the breather tube. Refer to «Rack and Pinion Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. Place the gear in a vise.
3. Remove the shock dampener (4) from the inner tie rod housing (6).
4. Slide the shock dampener (4) back on the rack (5).
5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (6).
6. Place a wrench on the flats of the inner tie rod housing (6).
7. Rotate the inner tie rod housing (6) counterclockwise, while holding the rack stationary, until the inner tie rod separates from the rack (5).
8. Remove the shock dampener (3) from the inner tie rod housing (2).
9. Slide the shock dampener (3) back on the rack (5).
10. Place a pipe wrench on the rack.
11. Place a wrench on the flats of the inner tie rod housing (2).
12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary, until the inner tie rod (1) separates from the rack (5).
13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE® from the threads (2) of the inner tie rod and the rack. If male rack (5) and female inner tie rod (4) LOCTITE® will not be present.

Scheme 29

1. Slide the shock dampener (4) forward onto the rack (3).
2. If female rack (3) and male inner tie rod (2), apply LOCTITE® 262, or equivalent, to the inner tie rod threads.
3. Attach the inner tie rod onto the rack (3).
4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2).
5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Tighten: Tighten the inner tie rod to 100 N.m (74 lb ft).
6. Slide the shock dampener (2) forward onto the rack.
7. If female rack and male inner tie rod (1), apply LOCTITE® 262, or equivalent, to the inner tie rod threads.
8. Attach the inner tie rod (1) onto the rack.
9. Place a pipe wrench on the rack next to the inner tie rod housing (4).
10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Tighten: Tighten the inner tie rod to 100 N.m (74 lb ft).
11. Place the inner tie rod assembly (2) in a vise.
12. Stake both sides of the female inner tie rod assembly housing to the male rack.
13. Insert a 0.010 inch gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler (1) must not pass between the rack and the housing stake.
14. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener (2) bottoms against the inner tie rod housing (3).
15. To assemble the rack and pinion boot and the breather tube. Refer to «Rack and Pinion Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 30

1. Loosen both cylinder line fittings on the cylinder end of the gear assembly.
2. Loosen both fittings on the cylinder line assemblies (1) at the valve end of the gear assembly.
3. Remove both cylinder line assemblies (1) from the rack and pinion gear assembly (2).
4. Remove the O-ring seals (1) from the valve end of line.
5. Discard the O-ring seals (1).

1. Inspect the cylinder lines (1) for the following items: Cracks Dents Damage to the threads
2. Replace the parts as needed.
3. Install the new O-ring seals (1) to the valve end of the cylinder lines.
4. Install the cylinder line assemblies (1) to the gear assembly (2). Tighten Tighten the valve end fittings to 17 N.m (13 lb ft) Tighten the cylinder end fittings to 27 N.m (20 lb ft)

J 29810 Stub Shaft Seal Protector. See Special Tools and Equipment .

Scheme 31

1. Remove the steering gear from the vehicle, refer to «Power Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-gear-replacement-non-rack-and) or «Power Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. Remove the adjuster plug lock nut (5) from the adjuster plug (4).
3. Remove the adjuster plug (4) from the gear assembly (1).
4. Remove the adjuster spring (3) and the rack bearing (2).
5. Remove the spool shaft boot (1) from the rack and pinion gear assembly.
6. Remove the retaining ring (2) from the valve bore of the rack and pinion gear assembly.
7. Remove the dust cover (4) from the bottom of the rack and pinion gear assembly.
8. Remove the hex lock nut (3) from the lower end of the pinion and valve assembly while holding the stub shaft with a 14 mm crowfoot wrench.
9. Using an arbor press (1), press on the threaded end of the pinion until removal of the following items is possible: The stub shaft (4) The stub shaft seal (2) The stub shaft bearing annulus assembly (3)

Scheme 32

1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft. Tighten: Tighten the nut to 30 N.m (22 lb ft).
2. Install the dust cover (2) to the rack and pinion gear assembly.
3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2).
4. Install J 29810 onto the valve stub shaft. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
5. Lubricate the stub shaft seal (3) with grease.
6. Install the stub shaft seal (3) into the rack and pinion gear assembly.
7. Install the retaining ring (2) into the groove in the rack and pinion gear assembly.
8. Install the spool shaft boot (1) onto the rack and pinion gear assembly.
9. Lubricate the following items with lithium base grease: The rack bearing (2) The adjuster spring (3) The adjuster plug (4)
10. Install the following items into the gear assembly: The rack bearing (2) The adjuster spring (3) The adjuster plug (4)
11. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster plug (1) back 50 degrees to 70 degrees.
12. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 N.m (16 lb in).
13. Install the adjuster plug lock nut (5) to the adjuster plug (4). Finger tighten the adjuster plug lock nut (5) while holding the adjuster plug (4) stationary. Tighten: Tighten the nut to 68 N.m (50 lb ft).
14. Install the steering gear into the vehicle, refer to «Power Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__power-steering-gear-replacement-non-rack-and) or «Power Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
15. Refer to «Bleeding the Power Steering System»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)

Tools Required

1. J 42882 Adjuster Nut Socket. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 43435 Adjuster Lock Nut Wrench. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 33

1. Rotate the stub shaft back and forth in order to drain the power steering fluid.
2. Remove the coupling shield retainer and the lock nut from the steering gear housing using J 43435 and a torque wrench. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Turn the adjuster nut assembly (1) clockwise using J 42882 until the adjuster nut assembly (1) and the thrust support assembly (2) are firmly bottomed in the steering gear housing (3). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Tighten: Tighten the adjuster nut assembly (1) to 30 N.m (22 lb ft).
4. Place an index mark (1) on the steering gear housing (4) parallel with one of the holes (3) in the adjuster nut assembly (2).
5. Measure back counterclockwise 13 mm (1/2 in).
6. Place a second mark (2) on the steering gear housing (1).
7. Using J 42882 and a torque wrench, turn the adjuster nut assembly (1) counterclockwise 15-25 degrees to align the hole (2) in the adjuster nut assembly (1) with the second mark (4) on the steering gear housing (3). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
8. Install the coupling shield retainer and the lock nut.
9. Hold the adjuster nut assembly in position to maintain alignment of the marks.
10. Tighten the coupling shield retainer and the lock nut using J 43435 and a torque wrench. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Tighten: Tighten the coupling shield retainer and the lock nut to 109 N.m (80 lb ft).
11. To adjust the pitman shaft, refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 34

Scheme 35

1. Adjust the worm shaft and valve, refer to «Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__worm-thrust-bearing-preload-adjustment) .
2. Rotate the stub shaft (3) back and forth to drain the power steering fluid.
3. Loosen the adjuster lock nut (4).
4. Turn the pitman shaft adjuster screw (1) counterclockwise until the screw is fully extended.
5. Turn the pitman shaft adjuster screw (1) clockwise 1 full turn.
6. Rotate the stub shaft (3) from stop to stop using a 12-point socket while counting the number of turns.
7. Starting at either stop, turn the stub shaft (3) back half of the total number of turns. This is the center of the gear.
8. Make sure that the gear is centered by checking the following items: The flat on the stub shaft (3) faces upward. The flat on the stub shaft (3) is parallel with the side cover (2).
9. Align the master spline (5) on the pitman shaft (4) with the adjuster screw (1).
10. Place a torque wrench on the stub shaft (2) with the handle in the vertical position.
11. Rotate the stub shaft (2) 45 degrees from each side of the center of the stub shaft. The stub shaft (2) must rotate smoothly.
12. Record the worm bearing preload measured on or near the center (1). The recorded bearing preload must be 1.2 N.m (10.5 lb in) with the worm and the ball nut installed. If the torque is outside of this range, readjust or repair the steering gear assembly as required.
13. To obtain the correct preload torque, adjust the over-center torque by turning the pitman shaft adjuster screw clockwise.
14. Add 0.9 N.m (8 lb in) torque to the previously measured worm bearing preload torque. Tighten: Tighten the adjuster lock nut to 44 N.m (32 lb ft). Prevent the adjuster screw from turning while tightening the adjuster lock nut.

Scheme 36

1. Remove the nut (3).
2. Remove the lock washer (2).
3. Clean the exposed end of the pitman shaft.
4. Clean the steering gear housing (1).
5. Use a wire brush to clean the pitman shaft splines.
6. Loosen the adjuster lock nut (1).
7. Remove the bolts (2).
8. Remove the nut.
9. Rotate the stub shaft (6) using a 12-point socket to center the steering gear (7).
10. Remove the following items as an assembly: The side cover (8) The gasket (3) The pitman shaft (4)
11. Remove the pitman shaft (4) from the side cover (8).

Scheme 37

1. Screw the pitman shaft (4) to the side cover (8) until it fully seats to the side cover (8).
2. Install the adjuster lock nut (1). Do not tighten the adjuster lock nut (1) until the pitman shaft adjustment is completed.
3. Install the pitman shaft assembly (4) and the side cover (8) to the steering gear housing (7).
4. Install the bolts (2). Tighten: Tighten the bolts (2) to 60 N.m (45 lb ft).
5. Install the lock washer (2).
6. Install the nut (3).
7. If necessary, adjust the pitman shaft. Refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) to adjust the pitman shaft.

Scheme 38

1. Rotate the stub shaft back and forth to drain the fluid.
2. Insert a punch into the housing access hole to unseat the retaining ring (1).
3. Remove the plug (2).
4. Remove the O-ring seal (3).

1. Lubricate the O-ring seal (3) with power steering fluid.
2. Install the O-ring seal (3) into the steering gear housing (5).
3. Install the plug (2).
4. Install the retaining ring (1). Ensure that the retaining ring open end is approximately 25 mm (1 in) from the access hole in the steering gear housing (5).

Scheme 39

1. Remove the thrust support assembly. Refer to «Steering Gear Thrust Support Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__steering-gear-thrust-support-replacement) .
2. Remove the stub shaft (1) and the valve assembly (2) from the steering gear housing.
3. If necessary, remove the stub shaft (1) from the valve assembly (2) in the following manner: Tap the stub shaft (1) lightly on a wood block in order to loosen the cap. Pull the cap and the valve spool out from valve body (2) 6 mm (1/4 in). Disengage the stub shaft pin (3) from the hole in the valve spool (4).
4. If the valve assembly needs repair, disassemble the valve in the following manner: Simultaneously pull and rotate the valve spool (1) from the valve body (3). Remove the valve spool O-ring seal (2). Alternately remove the valve body teflon rings (5) and the O-ring seals (4).

Scheme 40

1. If disassembled, reassemble the valve assembly in the following manner: Alternately install the valve body teflon rings (5) and the O-ring seals (4). Install the valve spool O-ring seal (2) to the valve spool (1). Lubricate the valve spool (1) and O-ring seal (2) with power steering fluid.
2. Simultaneously push and rotate the valve spool (2) into the valve body (1) until the hole (3) in the valve spool (2) for the stub shaft pin is accessible from the opposite end of the valve body (1).
3. If necessary, install the stub shaft to the valve spool in the following manner: Lubricate the stub shaft assembly (3). Insert the stub shaft (3) into the valve spool. Insert the pin. IMPORTANT: Make sure that the shaft cap notch (1) is mated with the valve body pin before installing the valve body into the steering gear assembly. The notch in the cap (1) must fully engage the valve body pin (2). Seat the cap against the valve body shoulder.
4. Install the stub shaft (7) and valve assembly (6) to the worm shaft (5). Ensure the pin fits in the worm shaft to the slot in the valve assembly.
5. Install the thrust support assembly. Refer to «Steering Gear Thrust Support Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__steering-gear-thrust-support-replacement) .

Rack Piston and Worm Shaft Replacement - Off Vehicle (700 Gear)

Tools Required

1. J 21552 Rack Piston Arbor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 8947 Rack Piston Teflon Ring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 41

1. Remove the pitman shaft seals and bearing. Refer to «Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__pitman-shaft-seals-and-bearing-replacement) .
2. Remove the housing end plug. Refer to «Steering Gear Housing End Plug Replacement - Off Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Turn the stub shaft counterclockwise until the rack piston (2) begins to come out of the steering gear housing (3).
4. Remove the rack piston plug (1).
5. Insert J 21552 into the bore of the rack piston (2). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Hold J 21552 tightly against the worm shaft while turning the stub shaft counterclockwise. Turning the stub shaft forces the rack piston (2) onto J 21552 . The rack piston balls remain in place. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Remove the following items as an assembly from the steering gear housing (9): The rack piston (4) The rack piston screws (8), clamp (7), ball guide (6) and balls (5) J 21552 See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
8. Remove the spool valve assembly. Refer to «Steering Gear Valve Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
9. Remove the worm shaft (14).
10. Remove the thrust bearing (12) and the flat races (11, 13).
11. Remove J 21552 from the rack piston (4). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
12. Remove the rack piston balls (5).
13. Remove the following items from the rack piston (4): The screws (8) The clamp (7) The ball guide (6) The remaining rack piston balls (5) in the ball guide (6)
14. Remove the teflon ring (2).
15. Remove the O-ring seal (3).
16. Clean all of the disassembled parts.
17. Inspect all of the disassembled parts for wear.
18. Replace the parts if necessary.

Scheme 42

1. Install the O-ring seal (3) and the teflon ring (2).
2. Lubricate both parts with power steering fluid.
3. Install the worm shaft (14) to the rack piston (4) outside of the steering gear housing (9). Fully seat the worm shaft to the rack piston.
4. Align the worm shaft spiral groove with the rack piston ball return guide hole (1).
5. Lubricate the rack piston balls with power steering fluid.
6. Insert the rack piston balls through the ball return guide hole (1) while turning worm shaft (2) counterclockwise in order to install the rack piston balls into the rack piston. Install the black and the silver rack piston balls alternately into the rack piston and the ball guide to maintain the rack piston to the worm shaft preload.
7. Install the remaining rack piston balls (3) into the ball guide (1) using grease at each end (2) to retain the rack piston balls (3).
8. Install the ball guide (3) to the rack piston (2).
9. Install the ball guide clamp (4).
10. Install the screws (5). Tighten: Tighten the screws (5) to 6 N.m (53 lb in).
11. Insert J 21552 into the bore of the rack piston while turning the worm shaft counterclockwise. The turning of the worm shaft forces the rack piston onto J 21552 . The rack piston balls remain in place. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
12. Install the flat races (2, 4) and the thrust bearing (3) onto the worm shaft (1).
13. Install the worm shaft (4) to the steering gear housing (3).
14. Install the spool valve. Refer to «Steering Gear Valve Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
15. Install the rack piston (2) to the worm (4) from J 21552 using J 8947 to compress the seals. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
16. Hold J 21552 tightly against the worm shaft (4). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
17. Turn the stub shaft clockwise until the rack piston (2) is seated on the worm shaft (4).
18. Remove J 21552 from the rack piston (1). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
19. Install the rack piston plug (1). Tighten: Tighten the rack piston plug to 150 N.m (111 lb ft).
20. Install the housing end plug. Refer to «Steering Gear Housing End Plug Replacement - Off Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
21. Install the pitman shaft seals and bearing. Refer to «Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__pitman-shaft-seals-and-bearing-replacement) .
22. To adjust the steering gear; refer to one of the following procedures: «Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__worm-thrust-bearing-preload-adjustment) «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system)

Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)

Tools Required

1. J 6278 Pitman Shaft Bearing Remover and Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 4245 Internal Snap Ring Pliers. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 43

1. Remove the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. Remove the pitman arm (3) from the steering gear (1).
3. Remove the pitman shaft boot (2).
4. Remove the dust seal (1).
5. Remove the retaining ring using the J 4245 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Use a screwdriver to pry the backup washer (3) and the double lip seal (2) from the steering gear housing (1).
7. Inspect the steering gear housing (1) for burrs.
8. Insert J 6278 through the hole in the top of the steering gear housing (1). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
9. Drive out the needle bearing (2).

Scheme 44

1. Install the needle bearing (2) to the steering gear housing (1) using the J 6278 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. Coat the double lip seal (2) and the washer (3) with grease.
3. Install the double lip seal (2).
4. Install the backup washer (3).
5. Install the retaining ring using the J 4245 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
6. Install the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
7. Install the dust seal (1).
8. Install the pitman shaft boot (2).
9. Install the pitman arm (3) to the steering gear (1).
10. Install the lock washer (4).
11. Install the nut (5). Tighten: Tighten the pitman arm nut to 250 N.m (184 lb ft).
12. Refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) to adjust the pitman shaft.

Scheme 45

Remove the check valve (1) from the steering gear housing (2) using a small screwdriver.

Scheme 46

Install the check valve (1) using a 9.52mm inch diameter piece of tubing 100 mm (4 in) long to drive into the steering gear housing.

Steering Gear Thrust Support Replacement - Off Vehicle (700 Gear)

Tools Required

1. J 42882 Adjuster Nut Socket. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
2. J 43435 Adjuster Lock Nut Wrench. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .

1. Rotate the stub shaft back and forth in order to drain the power steering fluid.
2. Remove the coupling shield retainer and the lock nut from the steering gear housing using J 43435 and a torque wrench. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
3. Remove the adjuster nut assembly (2) from the steering gear housing (1) using J 42882 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
4. Remove the thrust support assembly (2) from the steering gear housing (1).
5. Remove the O-ring seal (3) from the thrust support assembly (2).

Scheme 47

1. Lubricate the new O-ring seal (3).
2. Install the new O-ring seal (3) on the thrust support assembly (2).
3. Install the thrust support assembly (2).
4. Connect the adjuster nut assembly (2) to the steering gear housing (1) using J 42882 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) .
5. Install the coupling shield retainer and the lock nut (1) to the adjuster nut assembly.
6. Refer to «Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system__worm-thrust-bearing-preload-adjustment) to adjust the thrust bearing preload.
7. Hold the adjuster nut assembly in position to maintain alignment of the marks.
8. Tighten the coupling shield retainer and the lock nut using J 43435 and a torque wrench. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/manual-power-steering/#power-steering-system) . Tighten: Tighten the retainer and the lock nut to 109 N.m (80 lb ft).

The hydraulic power steering pump is a constant displacement vane-type pump that provides hydraulic pressure and flow for the power steering gear. The hydraulic power steering pumps are either belt-driven or direct-drive, cam-driven.

The power steering fluid reservoir holds the power steering fluid and may be integral with the power steering pump or remotely located. The following locations are typical locations for the remote reservoir

1. Mounted to the front of the dash panel
2. Mounted to the inner fender
3. Mounted to a bracket on the engine

The 2 basic types of power steering gears are listed below

1. A recirculating ball system
2. A rack and pinion system

In the recirculating ball system, a worm gear converts steering wheel movement to movement of a sector shaft. A pitman arm attached to the bottom of the sector shaft actually moves one tie rod and an intermediate rod move the other tie rod.

In the rack and pinion system, the rack and the pinion are the 2 components that convert steering wheel rotation to lateral movement. The steering shaft is attached to the pinion in the steering gear. The pinion rotates with the steering wheel. Gear teeth on the pinion mesh with the gear teeth on the rack. The rotating pinion moves the rack from side to side. The lateral action of the rack pushes and pulls the tie rods in order to change the direction of the vehicle's front wheels.

The power steering pressure hose connects the power steering pump union fitting to the power steering gear and allows pressurized power steering fluid to flow from the pump to the gear.

The power steering return hose returns fluid from the power steering gear back to the power steering fluid reservoir. The power steering return line may contain an integral fin-type or line-type power steering fluid cooler.

In a typical power steering system, a pump generates hydraulic pressure, causing fluid to flow, via the pressure hose, to the steering gear valve assembly. The steering gear valve assembly regulates the incoming fluid to the right and left chambers in order to assist in right and left turns.

Turning the steering wheel activates the valve assembly, which applies greater fluid pressure and flow to 1 side of the steering gear piston, and lower pressure and flow to the other side of the piston. The pressure assists the movement of the gear piston. Tie rods transfer this force to the front wheels, which turn the vehicle right or left.

Special Tools

Special Tools Illustration Tool Number/ Description J 4245 Internal Snap Ring Pliers J 6278 Pitman Shaft Bearing Remover and Installer J 6632-01 Pitman Arm Puller J 8947 Rack Piston Teflon Ring Compressor J 21552 Rack Piston Arbor J 22610 Keystone Clamp Pliers J 24319-B Steering Linkage and Tie Rod Puller J 25033-C Power Steering Pump Pulley Installer J 25034-C Power Steering Pump Pulley Remover J 29107-A Pitman Arm Puller J 29810 Stub Shaft Seal Protector J 34028 Inner Tie Rod Wrench J 35555 Mity Vac J 39570 Chassis Ear J 42882 Adjuster Nut Socket J 43435 Adjuster Lock Nut Wrench J 43485 Power Steering Bleeder Adapter J 44721 Power Steering System Analyzer

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

See also:
• Hydraulic Brake Booster Replacement
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Excessive Wear Diagnosis
• Steering Linkage Inspection (Steering Linkage Inspection)
• Steering Linkage Inspection (Idler Arm Inspection)
• Drive Belt Tensioner Replacement - Accessory
• Diagnostic Starting Point - Suspension General Diagnosis
• Intermediate Steering Shaft Replacement - Upper
• Fluid and Lubricant Recommendations
• Lifting and Jacking the Vehicle
• Fastener Notice
• Fan Shroud Replacement
• Tire and Wheel Removal and Installation
• Pitman Arm Replacement
• Measuring Wheel Alignment
• Power Steering Hose Disconnected Notice
• Engine Protection Shield Replacement
• Symptoms - Power Steering System
• Power Steering Fluid Leaks
• Steering Effort Hard in One or Both Directions
• Steering Effort Too Easy in One or Both Directions
• Checking and Adding Power Steering Fluid
• Power Steering Pump Specifications
• Power Steering Gear Replacement (Non-Rack and Pinion)
• Fastener Tightening Specifications
• Power Steering Cooler Pipe/Hose Replacement (GT4)
• Power Steering Cooler Pipe/Hose Replacement (GT5)
• Power Steering Reservoir Outlet Pipe/Hose Replacement
• Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)
• Power Steering Pulley Replacement
• Steering Gear Thrust Support Replacement - Off Vehicle (700 Gear)
• Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)