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Home/Chevrolet/Chevy Express H1500/Chevrolet Chevy Express H1500 (2003-2012)/Repair manual/Manual & Power Steering/Power Steering System
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Power Steering System Chevrolet Chevy Express H1500

Manual & Power Steering 13 illustrations ~8558 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Accessory Mounting Bracket Bolts and Nut50 N.m37 lb ft
Adjuster Lock Nut49 N.m36 lb ft
Adjuster Plug Lock Nut68 N.m50 lb ft
Cylinder Lines to Gear Fitting-Cylinder End27 N.m20 lb ft
Cylinder Lines to Gear Fitting-Valve End17 N.m13 lb ft
Hydraulic Brake Booster Inlet and Outlet Hose Fittings33 N.m24 lb ft
Inner Tie Rod to Power Steering Gear100 N.m74 lb ft
Lower Intermediate Steering Shaft to Steering Gear Retaining Bolt61 N.m45 lb ft
Outer Tie Rod to Steering Knuckle Retaining Nut63 N.m47 lb ft
Pitman Arm to Power Steering Gear Mounting Nut250 N.m184 lb ft
Pitman Arm to Relay Rod Retaining Nut63 N.m47 lb ft
Pitman Shaft Side Cover Bolts62 N.m46 lb ft
Power Steering Cooler Hose to Power Steering Gear33 N.m24 lb ft
Power Steering Cooler Mounting Bolts (GT4)5 N.m44 lb in
Power Steering Cooler Mounting Nuts (GT5)28 N.m21 lb ft
Power Steering Gear End Housig Bolts62 N.m46 lb ft
Power Steering Gear Mounting Bolts150 N.m111 lb ft
Power Steering Gear Outlet Hose to the Steering Gear33 N.m24 lb ft
Power Steering Pump Flow Control Valve to Power Steering Pump75 N.m55 lb ft
Power Steering Pump Front Mounting Bolts50 N.m37 lb ft
Power Steering Pump Lower and Rear Mounting Nuts (4.3L)41 N.m30 lb ft
Power Steering Pump Mounting Studs58 N.m43 lb ft
Power Steering Pump Rear Bracket Mounting Nuts50 N.m37 lb ft
Power Steering Pump Rear Mounting Bolt (4.8L, 5.3L, 6.0L, and 6.6L)41 N.m30 lb ft
Power Steering Remote Reservoir Retaining Nuts11 N.m97 lb in

Fastener Tightening Specifications

Power Steering Pump Specifications

VehicleEngine CodeEngine SizeHigh Flow (Liters per Minute)High Flow (Gallons per Minute)Pressure Relief(kPa)Pressure Relief (PSI)
G 15/25/35 Series 7200/8600 GVWLU3 LR4 LM7 LQ4 LLY4.3L 4.8L 5.3L 6.0L 6.6L12.2/14.02.7/3.19825/105141425/1525

Power Steering Pump Specifications

Scheme 1

Scheme 1: Power Steering Gear Disassembled View (680 Gear)
Scheme 1: Power Steering Gear Disassembled View (680 Gear)
CalloutComponent Name
1Stub Shaft Housing Bolt
2Stub Shaft Housing
3Stub Shaft Housing O-Ring
4Stub Shaft Housing O-Ring
5Steering Gear Pitman Shaft Housing Cover O-Ring
6Steering Gear Pitman Shaft and Housing Cover
7Steering Gear Pitman Shaft Lash Adjuster Nut
8Steering Gear Pitman Shaft Housing Cover Bolt
9Steering Gear Pitman Shaft Bearing
10Steering Gear Pitman Shaft Seal
11Steering Gear Pitman Shaft Washer
12Steering Gear Pitman Shaft Seal Retaining Ring
13Dust Seal
14Pitman Arm Boot
15Pitman Arm
16Pitman Arm Washer
17Pitman Arm Nut
18Steering Gear Housing

Scheme 2

Scheme 2: Power Steering Gear Disassembled View (700 Gear)
Scheme 2: Power Steering Gear Disassembled View (700 Gear)
CalloutComponent Name
1Retaining Ring
2Plug
3O-ring Seal
4Side Cover
5Adjuster Lock Nut
6Bolt
7Gasket
8Pitman Shaft
9Steering Gear Housing End Plug
10Teflon Ring
11O-ring Seal
12Rack Piston
13Balls
14Ball Guide
15Clamp
16Screw
17Housing
18Check Valve
19Flat Race
20Thrust Bearing
21Flat Race
22Worm Shaft
23Needle Bearing
24Pitman Shaft Seal
25Backup Washer
26Retaining Ring
27Dust Seal
28Pitman Shaft Boot
29Pitman Shaft Arm
30Lock Washer
31Nut
32Seal
33Stub Shaft
34Valve Spool
35Seal
36Valve Body
37O-ring Seal
38Valve Body Ring
39O-ring Seal
40Valve Body Ring
41O-ring Seal
42Valve Body Ring
43Coupling Shield Retainer and Lock Nut
44Adjuster Nut Assembly
45O-ring Seal
46Thrust Support Assembly

Scheme 3

Scheme 3: Power Steering Pump Disassembled View
Scheme 3: Power Steering Pump Disassembled View
CalloutComponent Name
1O-ring Seal
2Hydraulic Pump Housing Assembly
3Magnet
4Rectangular Section Seal
5Rectangular Section Seal
6Control Valve Assembly
7Flow Control Spring
8Hydraulic Pump Reservoir Assembly
9Pump Mounting Studs
10O-ring Seal
11Connector and Fitting Assembly

Begin the system diagnosis by reviewing the system Description and Operation. Refer to Power Steering System Description and Operation (w/o Electro-Hydraulic Steering) . 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.

IMPORTANTThe following steps must be completed before using the symptom tables.

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 for leaking power steering components. If necessary, refer to «Power Steering Fluid Leaks»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-fluid-leaks) .
  4. Verify the power steering fluid level per operating specification. Refer to «Checking and Adding Power Steering Fluid»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__checking-and-adding-power-steering-fluid)
  5. Inspect the power steering fluid for the following indications of contamination: Milky fluid - water Brown fluid - burnt Debris in fluid - plastic or dirt
  6. If necessary, flush the power steering system. Refer to «Power Steering System Flushing»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .

Symptoms List

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

  1. «Power Steering Fluid Leaks»(/chevrolet/chevy-express-h1500/2003-2012/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-h1500/2003-2012/remont/manual-power-steering/#power-steering-system)
  3. «Whine or Growl Noise from the Power Steering System»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system)
  4. «Steering Effort Hard in One or Both Directions»(/chevrolet/chevy-express-h1500/2003-2012/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-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-effort-too-easy-in-one)

Scheme 4

Scheme 4: Power Steering System Test
Scheme 4: Power Steering System Test
CalloutComponent Name
1Power Steering Return Hose
2Power Steering Pressure Hose

Scheme 5

Scheme 5
Scheme 5
CalloutComponent Name
1Power Steering Return Hose
2Power Steering Pressure Hose

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.
StepActionValue(s)YesNo
DEFINITION: The Power Steering System Test Procedure will perform the following functions: Test the operation of the hydraulic power steering system. Test the operation of the power steering pump and power steering gear. Identify restrictions in the system.
1Inspect the power steering fluid for the following indications of contamination: Milky fluid - water Brown fluid - burnt Debris in fluid - plastic or dirt Is the fluid free of contamination?Go to Step 3Go to Step 2
2Flush the power steering system. Refer to Power Steering System Flushing . Did you complete the procedure?Go to Step 3
3IMPORTANT: In order to accurately diagnose the system, the malfunction must be present during the test procedure. Attempt to duplicate the condition.Is the condition present?Go to Step 4System OK
4Turn the ignition switch to the OFF position. Place a drain pan under the vehicle in order to catch any power steering fluid. Disconnect the power steering pressure pipe/hose from the power steering pump or the power steering gear as necessary. Install the J 44721 Power Steering System Analyzer. See Special Tools . Fill the power steering system. Refer to Checking and Adding Power Steering Fluid . Did you complete the installation?Go to Step 5
5Fully open the J 44721 valve. See Special Tools . Start the engine. NOTE: Refer to STEERING WHEEL IN THE FULL TURN POSITION NOTICE . Turn the steering wheel and BRIEFLY hold the steering wheel against the steering stop in order to release any trapped air from the system. Inspect and ensure that all of the power steering pipe/hose connections are not leaking. Make sure the steering wheel is OFF the steering stop, observe the pressure reading. Is the pressure reading greater than the specified value?1525 kPa (221 psi)Go to Step 6Go to Step 7
6IMPORTANT: A restriction may be present in the power steering system. Turn OFF the engine IMMEDIATELY. Locate and repair the restriction.Did you complete the repair?Go to Step 18
7Allow the engine to run until the engine reaches full operating temperature. Record the pressure reading and flow reading. Partially close the J 44721 valve until the system pressure reaches the specified value, then record the FLOW reading. See Special Tools . Subtract second flow reading from the first flow reading. Is the flow DECREASE greater than 3.8 L (1 gal) per minute?4827 kPa (700 psi)Go to Step 13Go to Step 8
8NOTE: Do not leave the valve fully closed for more than 5 seconds, or the pump could be damaged internally. Fully close then open the J 44721 valve 3 times. See Special Tools . Record all of the high pressure readings. Refer to Power Steering Pump Specifications for power steering system pressure relief specifications.Are the 3 high pressure readings within specifications?Go to Step 9Go to Step 15
9Are the three high pressure readings within 245 kPa (50 psi) of each other?Go to Step 10Go to Step 14
10Increase the engine speed to approximately 1,500 RPM. Record the flow reading. Refer to Power Steering Pump Specifications for power steering system pressure specifications. Is the actual flow reading within specifications?Go to Step 11Go to Step 13
11Is the difference between the actual flow reading and the maximum flow specification more than 3.8 L (1 gal) per minute?Go to Step 16Go to Step 12
12NOTE: Refer to STEERING WHEEL IN THE FULL TURN POSITION NOTICE Turn the steering wheel from steering stop to steering stop and record the FLOW readings at each stop.Is the flow LOWER than 3.8 L (1 gal) per minute?Go to Step 18Go to Step 17
13Replace the power steering pump. Refer to Power Steering Pump Replacement (4.3L) or Power Steering Pump Replacement (4.8L, 5.3L, 6.0L) or Power Steering Pump Replacement (6.6L Diesel) . Did you complete the replacement?Go to Step 18
14Remove the power steering pump flow control valve. Refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle . Inspect the flow control valve. If any burrs or scratches are noticed on the flow control valve, replace the flow control valve. Do NOT attempt to clean the flow control valve. Refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle . Inspect the flow control valve bore. If any burrs or scratches are present in the control valve bore, replace the power steering pump. Refer to Power Steering Pump Replacement (4.3L) or Power Steering Pump Replacement (4.8L, 5.3L, 6.0L) or Power Steering Pump Replacement (6.6L Diesel) . Did you complete the repair?Go to Step 18
15Replace the power steering pump flow control valve. Refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle . Did you complete the replacement?Go to Step 18
16Remove the power steering pump flow control valve and inspect for any wear or damage. Do NOT disassemble the flow control valve. If the flow control valve is worn damaged, replace the flow control valve. Refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle . Did you complete the repair?Go to Step 18
17The power steering gear is leaking across the piston or bypassing the valve circuit. Replace the power steering gear. Refer to Steering Gear Replacement (Non-Rack and Pinion) or Steering Gear Replacement (Rack and Pinion) . Did you complete the replacement?Go to Step 18
18Test the power steering system for the original condition. Does the original condition still exist?Go to Step 5Go to Step 19
19Disconnect and remove the J 44721 from the vehicle. See Special Tools . Connect the vehicle power steering pipes/hoses. Bleed the power steering system and add fluid as necessary. Refer to Power Steering System Bleeding . Did you complete the repair?System OK
IMPORTANT
In order to accurately diagnose the system, the malfunction must be present during the test procedure.
IMPORTANT
A restriction may be present in the power steering system. Turn OFF the engine IMMEDIATELY.
NOTE
Do not leave the valve fully closed for more than 5 seconds, or the pump could be damaged internally.

Power Steering System Test

Power Steering Fluid Leaks

StepActionYesNo
1Did you review the Power Steering System General Description?Go to Step 2Go to Power Steering System Description and Operation (w/o Electro-Hydraulic Steering)
2Inspect the power steering system for the following: Inspect the power steering fluid level and condition. Inspect for aftermarket devices which could affect the operation of the power steering system. Inspect the power steering system components for obvious damage or conditions which could cause leaks. If necessary, clean the power steering system components, start the engine, and rotate the steering wheel from stop to stop. Turn the engine off and inspect all power steering system components for leaks. Is the power steering system leaking?Go to Step 3Go to Step 15
3Inspect the power steering system fittings. Are the fittings leaking?Go to Step 9Go to Step 4
4Inspect the power steering hoses. Are the hoses leaking?Go to Step 10Go to Step 5
5Inspect the following power steering pump components for leaks. Flow control valve seal Power Steering Pump Shaft Seal Power Steering Pump Reservoir and Seals Power Steering Pump Is the power steering pump components leaking?Go to Step 11Go to Step 6
6Inspect the following power steering gear components for leaks. Power Steering Cylinder Lines and/or Seals Power Steering Gear Stub Shaft Seals Power Steering Gear Pitman Shaft and/or seals Is the power steering gear components leaking?Go to Step 12Go to Step 7
7Inspect the power steering cooler for leaks. Is the power steering cooler leaking?Go to Step 13Go to Step 8
8Inspect the hydraulic brake booster assembly for leaks. Refer to Power Brake Booster Leak Inspection . Is the hydraulic brake booster assembly leaking?Go to Step 14Go to Step 15
9IMPORTANT: If fitting is still to leaking after tightening, inspect for damage to the fitting and seals. Replace the damaged component as necessary. Tighten the fittings. Refer to Fastener Tightening Specifications .Did you complete the repair?Go to Step 15
10Replace the leaking power steering hoses. Refer to the appropriate procedure(s): Power Steering Reservoir Inlet Pipe/Hose Replacement Power Steering Fluid Reservoir Outlet Hose Replacement Power Steering Gear Outlet Pipe/Hose Replacement Power Brake Booster Inlet Hose Replacement Power Brake Booster Outlet Hose Replacement Did you complete the repair?Go to Step 15
11Replace the leaking power steering pump component. Refer to the appropriate procedure(s): Power Steering Pump Flow Control Valve Replacement - Off Vehicle Power Steering Pump Shaft Seal Replacement Power Steering Fluid Reservoir Replacement - Off Vehicle Power Steering Pump Replacement (4.3L) or Power Steering Pump Replacement (4.8L, 5.3L, 6.0L) or Power Steering Pump Replacement (6.6L Diesel) Did you complete the repair?Go to Step 15
12Replace the leaking power steering gear component. Refer to the appropriate procedure(s): Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle (Quiet Valve) Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle . Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle Steering Gear Replacement (Non-Rack and Pinion) or Steering Gear Replacement (Rack and Pinion) . Did you complete the repair?Go to Step 15
13Replace the power steering cooler. Refer to Power Steering Cooler Pipe/Hose Replacement (GT4) or Power Steering Cooler Pipe/Hose Replacement (GT5) . Did you complete the repair?Go to Step 15
14Replace the hydraulic brake booster assembly. Refer to Power Brake Booster Replacement . Did you complete the repair?Go to Step 15
15Start the vehicle and rotate the steering wheel from stop to stop and verify the system is not leaking. Did you correct the condition?System OKGo to Step 2
IMPORTANT
If fitting is still to leaking after tightening, inspect for damage to the fitting and seals. Replace the damaged component as necessary.

Power Steering Fluid Leaks

StepActionYesNo
1Did you review the Power Steering System General Description and perform the necessary inspections?Go to Step 2Go to Symptoms - Power Steering System
2Verify that a rattle, clunk, or shudder noise is present. Is a rattle, clunk, or shudder noise present?Go to Step 3System OK
3Inspect the power steering hoses for proper routing and clearance. Is the routing or clearance of the power steering hoses incorrect?Go to Step 11Go to Step 4
4Inspect the engine drive belt for cracking or excessive wear. Refer to Drive Belt Falls Off and Excessive Wear Diagnosis for the 4.3L engine. Drive Belt Falls Off and Excessive Wear Diagnosis for the 4.8L, 5.3L, and 6.0L engines. Is the drive belt cracked or excessively worn?Go to Step 12Go to Step 5
5Inspect the power steering pump pulley for damage. Is the power steering pump pulley damaged?Go to Step 13Go to Step 6
6Inspect the power steering pump and the power steering mounting bracket/brace for the proper installation. Refer to Power Steering Pump Replacement (4.3L) or Power Steering Pump Replacement (4.8L, 5.3L, 6.0L) or Power Steering Pump Replacement (6.6L Diesel) . Is the power steering pump installation incorrect?Go to Step 14Go to Step 7
7Inspect the power steering gear for the proper installation. Refer to Steering Gear Replacement (Non-Rack and Pinion) or Steering Gear Replacement (Rack and Pinion) . Is the power steering gear installation incorrect?Go to Step 15Go to Step 8
8Inspect the steering linkage. Refer to Steering Linkage Inspection . Is the steering linkage worn?Go to Step 16Go to Step 9
9Inspect the suspension. Is the suspension worn?Go to Step 17Go to Step 10
10Inspect the intermediate shaft. Is the intermediate shaft worn?Go to Step 18Go to Step 3
11Adjust or replace the hoses. Refer to the appropriate procedure: Power Steering Cooler Pipe/Hose Replacement (GT4) or Power Steering Cooler Pipe/Hose Replacement (GT5) Power Steering Reservoir Inlet Pipe/Hose Replacement Power Steering Fluid Reservoir Outlet Hose Replacement Power Steering Gear Outlet Pipe/Hose Replacement Power Brake Booster Inlet Hose Replacement Power Brake Booster Outlet Hose Replacement Did you complete the repair?Go to Step 19
12Replace the engine drive belt. Refer to Drive Belt Replacement for the 4.3L engine, Drive Belt Tensioner Replacement - Accessory or Drive Belt Tensioner Replacement - Air Conditioning for the 4.8L, 5.3L, and 6.0L engine. Did you complete the repair?Go to Step 19
13Replace the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement . Did you complete the repair?Go to Step 19
14Install the power steering pump correctly. Refer to Power Steering Pump Replacement (4.3L) or Power Steering Pump Replacement (4.8L, 5.3L, 6.0L) or Power Steering Pump Replacement (6.6L Diesel) . Did you complete the repair?Go to Step 19
15Install the power steering gear correctly. Refer to Steering Gear Replacement (Non-Rack and Pinion) or Steering Gear Replacement (Rack and Pinion) . Did you complete the repair?Go to Step 19
16Replace the worn steering linkage. Refer to Steering Linkage Inspection . Did you complete the repair?Go to Step 19
17Replace the worn suspension components. Refer to Diagnostic Starting Point - Suspension General Diagnosis . Did you complete the repair?Go to Step 19
18Replace the intermediate shaft. Refer to Upper Intermediate Steering Shaft Replacement or Lower Intermediate Steering Shaft Replacement . Did you complete the repair?Go to Step 19
19Operate the system in order to verify the repair. Did you correct the condition?System OKGo to Step 3

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

StepActionYesNo
1Did you review the Power Steering System General Description and perform the necessary inspections?Go to Step 2Go to Symptoms - Power Steering System
2Verify that a whine or growl noise is present. Is a whine or growl noise present?Go to Step 3System OK
3Inspect the power steering fluid for the following indication of contamination: Milky fluid - water Brown fluid - burnt Debris in fluid - plastic or dirt Is the fluid free of contamination?Go to Step 5Go to Step 4
4Flush the power steering system. Refer to Power Steering System Bleeding Did you complete the procedure?Go to Step 11Go to Step 5
5Inspect the power steering gear for a whine or growl noise using J 39570 Chassis Ear. See Special Tools . Is the noise present at the power steering gear?Go to Step 8Go to Step 6
6Inspect the power steering pump for a whine or growl noise using J 39570 . See Special Tools . Is the noise present at the power steering pump?Go to Step 9Go to Step 7
7Inspect the power steering hoses for a whine or growl noise using J 39570 . See Special Tools . Is the noise present at the power steering hoses?Go to Step 10Go to Step 2
8Replace the power steering gear. Refer to Steering Gear Replacement (Non-Rack and Pinion) or Steering Gear Replacement (Rack and Pinion) . Did you complete the repair?Go to Step 11
9Replace the power steering pump. Refer to Power Steering Pump Replacement (4.3L) or Power Steering Pump Replacement (4.8L, 5.3L, 6.0L) or Power Steering Pump Replacement (6.6L Diesel) . Did you complete the repair?Go to Step 11
10Adjust the routing of the power steering hoses. Did you complete the repair?Go to Step 11
11Operate the system in order to verify the repair. Did you correct the condition?System OKGo to Step 3

Whine or Growl Noise from the Power Steering System

Poor Return of Steering Wheel

StepActionYesNo
DEFINITION: After completing a turn, extra steering input is required for the steering wheel to return to center.
1Did you review the General Description and perform the necessary inspections?Go to Step 2Go to Power Steering System Description and Operation (w/o Electro-Hydraulic Steering)
2Verify that poor return of the steering wheel is present. Does the system operate normally?System OKGo to Step 3
3Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Lubricate the tie rod ends and ball joints, if applicable. Inspect the suspension system for worn or damaged components. Repair as necessary. Did you find and correct the condition?Go to Step 12Go to Step 4
4Rotate the steering wheel ONE revolution in both directions. Rotate the steering wheel back to the original position. Was the steering wheel abnormally difficult to rotate in either direction?Go to Step 5Go to Step 10
5IMPORTANT: Position the wheels straight ahead. Do NOT rotate the steering wheel more than one complete revolution from center. Disconnect the intermediate shaft from the steering column. Note the position of the steering wheel and rotate the steering wheel ONE revolution in both directions. Rotate the steering wheel back to the original position. Was the steering wheel abnormally difficult to rotate in either direction?Go to Step 11Go to Step 6
6Inspect the intermediate shaft for stiff or loose joints. Repair or replace as necessary. Did you find and complete the repair?Go to Step 12Go to Step 7
7Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation . Disconnect both outer tie rod ends from the steering knuckles. Use your hands in order to move the tie rod end studs. If abnormally difficult to move, replace the tie rod end. If equipped with recirculating ball steering, ensure that idler and pitman arm joints are not to stiff. Repair as necessary. Did you find and complete the repair?Go to Step 12Go to Step 8
8Use your hands to rotate the steering knuckle inboard and outboard in order to inspect for a binding strut bearings, ball joints, or axle. Repair or replace any abnormally stiff or loose components. Did you find and complete the repair?Go to Step 12Go to Step 9
9Inspect for binding in the steering gear. If a binding is present repair or replace the steering gear. Did you find and complete the repair?Go to Step 12Go to Step 10
10Inspect the wheel alignment and adjust as necessary. Refer to Measuring Wheel Alignment . Did you find and complete the repair?Go to Step 12
11Inspect the steering column for a binding. If a binding is present, repair or replace the steering column as necessary. Did you find and complete the repair?Go to Step 12
12Operate the system in order to verify the repair. Did you correct the condition?System OK
IMPORTANT
Position the wheels straight ahead. Do NOT rotate the steering wheel more than one complete revolution from center.

Poor Return of Steering Wheel

Steering Effort Too Easy in One or Both Directions

StepActionYesNo
1Did you review the Power Steering System Description and perform the necessary inspections?Go to Step 2Go to Symptoms - Power Steering System
2Verify that the steering effort is too easy in one or both directions. Does the system operate normally?System OKGo to Step 3
3Perform the power steering test procedure. Refer to Power Steering System Test . Did you complete the procedure?Go to Step 4
4Operate the system in order to verify the repair. Did you correct the condition?System OKGo to Step 3

Steering Effort Too Easy in One or Both Directions

Steering Effort Hard in One or Both Directions

StepActionYesNo
1Did you review the Power Steering System General Description and perform the necessary inspections?Go to Step 2Go to Symptoms - Power Steering System
2Verify that the steering effort is hard in one or both directions. Does the system operate normally?System OKGo to Step 3
3Perform the power steering test procedure. Refer to Power Steering System Test . Did you complete the procedure?Go to Step 4
4Operate the system in order to verify the repair. Did you correct the condition?System OKGo to Step 3

Steering Effort Hard in One or Both Directions

  1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator.
  2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: Start the engine. Firmly apply the brake pedal 10-15 times. Turn the engine OFF.
  3. Raise the vehicle until the front wheels are off the ground. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. Vehicles equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops.
  5. Verify power steering fluid level per operating specification. Refer to «Checking and Adding Power Steering Fluid»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__checking-and-adding-power-steering-fluid) .
  6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining).
  7. Verify the fluid level. Repeat the bleed procedure, if necessary.

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 «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/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 pedel 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-h1500/2003-2012/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
  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 «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
IMPORTANTDo not reuse any drained power steering fluid regardless of appearance or condition.
  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-h1500/2003-2012/remont/hoistjack/#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. With the key on engine off, turn the steering wheel fully to the left and to the right while an assistant maintains the minimum fluid level in the reservoir using new approved power steering fluid. Continue until the fluid from the return hose runs clear.
  7. Remove the plug from the pump reservoir inlet connection and install the fluid return hose to the pump reservoir.
  8. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  9. Inspect the power steering fluid for the following indications of contamination: Milky fluid - water Brown fluid - burnt Plastic debris or dirt chunks
  10. If the fluid is contaminated, repeat steps 2-9.
  11. Lower the vehicle and check the Power Steering system for leaks.

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 11 N.m (97 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 «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .

Power Steering Pump Pulley Replacement

Tools Required

  1. J 25033-C Power Steering Pump Pulley Installer. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  2. J 25034-C Power Steering Pump Pulley Remover. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. Remove the drive belt. Refer to «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4) , or to «Air Conditioning Compressor Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4) for the 4.8L, 5.3L, 6.0L engine, or to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) for the 6.6L engine.
  3. Remove the power steering pump pulley using the J 25034-C . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  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-h1500/2003-2012/remont/mechanical/#engine-mechanical-43l) for the 4.3L engine, or to «Drive Belt Replacement - Accessory»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4) , or to «Air Conditioning Compressor Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4) for the 4.8L, 5.3L, 6.0L engine, or to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) for the 6.6L engine.
  5. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  1. Place a drain pan below under the vehicle.
  2. Remove the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  4. Disconnect the reservoir outlet hose from the power steering pump through the wheel well.
  5. Disconnect the power steering gear outlet hose or cooler hose from the power steering pump through the wheel well.
  6. Disconnect the power brake booster inlet hose (2) from the power steering pump (1) through the wheel well.
  7. Cap the ends of the hose and the power steering pump in order to prevent the entrance of dirt.
  8. Remove the power steering pump mounting bolts and the nuts.
  9. Remove the power steering pump from the vehicle.
  10. Remove the power steering pump rear bracket mounting nuts.
  11. 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. Uncap the power steering hoses.
  6. 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).
  7. Install the power steering gear outlet hose or cooler hose to the power steering pump through the wheel well.
  8. Install the reservoir outlet hose to the power steering pump through the wheel well.
  9. Install the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement) .
  10. Bleed the system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  11. Remove the drain pan from under the vehicle.
  1. Place a drain pan below under the vehicle.
  2. Remove the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-pump-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-h1500/2003-2012/remont/hoistjack/#general-information) .
  6. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-tire-system/#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 from 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.
  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. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-tire-system/#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 Pump Pulley Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement) .
  16. Bleed the system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  17. Remove the drain pan from under the vehicle.
  1. Place a drain pan below under the vehicle.
  2. Remove the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement) .
  3. Disconnect the reservoir outlet hose from the power steering pump through the wheel well.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  5. Disconnect the power steering gear outlet hose or cooler hose at the power steering pump through the wheel well.
  6. Disconnect the power brake booster inlet hose from the power steering pump through the wheel well.
  7. Cap the ends of the hose and the pump in order to prevent the entrance of dirt.
  8. Remove the rear power steering pump bracket bolts from the bracket through the wheel well.
  9. Lower the vehicle.
  10. Remove the power steering pump and bracket bolts (1).
  11. Remove the power steering pump bracket (2) from the pump.
  12. Remove the power steering pump (2) from the vehicle.
  13. Remove the rear power steering pump bracket nuts (1) from the pump.
  14. Remove the rear power steering pump bracket (2) from the pump (3).
  1. Install the rear power steering pump bracket (2) to the pump (3).
  2. Install the power steering pump rear bracket nuts (1) to the pump studs. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  3. Position the power steering pump (2) to the vehicle.
  4. Position the front power steering pump bracket (2) to the pump.
  5. Install the power steering pump bracket bolts (1) to the bracket and pump. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  6. Raise the vehicle.
  7. Install the power steering pump rear bracket bolts (1) to the bracket. Tighten: Tighten the bolts to 41 N.m (30 lb ft).
  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. Lower the vehicle.
  11. Install the reservoir outlet hose to the power steering pump through the wheel well.
  12. Install the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement) .
  13. Bleed the system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  14. Remove the drain pan from under the vehicle.

Disassembly Procedure

  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-h1500/2003-2012/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.

Assembly Procedure

  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-h1500/2003-2012/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).
  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).
  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).
  1. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (6.6L Diesel)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  2. Cut the seal with a chisel in order to remove it.
  1. Lubricate the seal with power steering fluid.
  2. Install the seal using a deep socket.
  3. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) or «Power Steering Pump Replacement (6.6L Diesel)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .

Pitman Shaft Seal Replacement (Non Rack and Pinion)

Tools Required

  1. J 4245 Internal Snap Ring Pliers
  2. J 6278 Pitman Shaft Bearing Remover and Installer
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#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-h1500/2003-2012/remont/steering-linkage/#steering-linkage__pitman-arm-replacement) .
  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»(/chevrolet/chevy-express-h1500/2003-2012/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 .
  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).
  15. Drive out the needle bearing (2).
  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 .
  3. Install the double lip seal (2).
  4. Install the backup washer (3).
  5. Install the retaining ring using the J 4245 .
  6. Install the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/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-h1500/2003-2012/remont/steering-linkage/#steering-linkage__pitman-arm-replacement) .
  9. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  10. Lower the vehicle.

Tools Required

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

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-tire-system/#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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  6. Remove the outer tie rod (3) from the inner tie rod (1).
  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-h1500/2003-2012/remont/wheel-alignment/#wheel-alignment-system__measuring-wheel-alignment) .

J 22610 Keystone Clamp Pliers

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the outer tie rod. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/chevy-express-h1500/2003-2012/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.
  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 .
  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-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  10. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-alignment/#wheel-alignment-system__measuring-wheel-alignment) .
  1. Install drain pan under the vehicle.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#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 cooler ends in order to prevent the entry of dirt.
  6. Remove the power steering cooler mounting bolts.
  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 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. Lower the vehicle.
  6. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  7. Remove the drain pan from under the vehicle.
  1. Install drain pan under the vehicle.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#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 «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  7. Remove the drain pan from under the vehicle.
  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). DO NOT reuse clamps.
  4. Remove the reservoir inlet hose (3) from the reservoir. DO NOT reuse clamps.
  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. Reposition and secure clamps.
  3. Install the reservoir inlet hose (3) to the power brake booster (2). Reposition and secure clamps.
  4. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  5. Remove the drain pan from under the vehicle.
  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 «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  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-h1500/2003-2012/remont/hoistjack/#general-information) .
  4. Remove the power steering outlet hose from the power steering pump.
  5. Remove the power steering gear outlet hose from the power steering gear.
  6. 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. Lower the vehicle.
  5. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  6. Remove the drain pan from under the vehicle.

Steering Gear Replacement (Non-Rack and Pinion)

Tools Required

  1. J 6632-01 Pitman Arm Puller. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  2. J 24319-B Steering Linkage and Tie Rod Puller. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  3. J 29107-A Pitman Arm Puller. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#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-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  4. Disconnect the lower intermediate shaft from the power steering gear. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/steering-column-switches/#steering-wheel-steering-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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  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 «Lower Intermediate Steering Shaft Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
  10. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  11. Lower the vehicle.
  12. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/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 .

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#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-h1500/2003-2012/remont/wheel-tire-system/#tires-and-wheels) .
  4. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/frames-subframes-crossmembers/#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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  7. Disconnect the lower intermediate shaft from the power steering gear. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/steering-column-switches/#steering-wheel-steering-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.
  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 «Lower Intermediate Steering Shaft Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/steering-column-switches/#steering-wheel-steering-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-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  8. Install the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-tire-system/#tires-and-wheels) .
  9. Lower the vehicle.
  10. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/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-h1500/2003-2012/remont/wheel-alignment/#wheel-alignment-system__measuring-wheel-alignment) .

Steering Gear Rack Bearing Preload Adjustment - Off Vehicle (Rack and Pinion)

  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.

  1. To remove the outer tie rod. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/chevy-express-h1500/2003-2012/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 .
  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-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .

J 34028 Inner Tie Rod Wrench. See Special Tools .

  1. To remove the rack and pinion boot, refer to «Steering Gear Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  2. Place the gear in a vise.
  3. Remove the shock dampener (6) from the inner tie rod housing (4).
  4. Slide the shock dampener (6) back on the rack (5).
  5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (4).
  6. Place a wrench on the flats of the inner tie rod housing (4).
  7. Rotate the inner tie rod housing (4) 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 (3) and the rack (1). If male rack (5) and female inner tie rod (4) LOCTITE® will not be present.
  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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) . 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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) . 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 (1).
  13. Insert a 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler gage (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. Refer to «Steering Gear Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  1. Remove the rack and pinion boot. Refer to «Steering Gear Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/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 assembly (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.
  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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) . 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»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) . 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 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler gage (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. Refer to «Steering Gear Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  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).

Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (670/680 Gear)

  1. Remove the steering gear. Refer to «Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-non-rack-and-pinion) or «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  2. Loosen the steering gear pitman shaft lash adjuster nut (4).
  3. Turn the steering gear pitman shaft lash adjuster screw (1) counterclockwise until fully extended.
  4. Turn the steering gear pitman shaft lash adjuster screw (1) clockwise one full turn.
  5. Rotate the steering gear stub shaft (3) from stop to stop, using a 12-point socket while counting the number of turns.
  6. Starting at either stop, turn the steering gear stub shaft (3) back half the total number of turns counted previously. This is the centered position.
  7. Make sure the steering gear pitman shaft is centered by checking the following items: The flat on the steering gear stub shaft (2) faces upward. The flat on the steering gear stub shaft is parallel with the steering gear side cover. The master spline (3) on the steering gear pitman shaft is in line with the steering gear pitman shaft lash adjuster screw (1).
  8. Place a torque wrench on the stub shaft with the handle in the vertical position.
  9. Rotate the steering gear stub shaft 45 degrees from each side of the center of the steering gear stub shaft. The steering gear stub shaft must rotate smoothly and must not stick or bind.
  10. Record the steering gear worm bearing preload measured on or near the center.
  11. Recorded steering gear worm bearing preload must be 0.8-7.1 N.m (7.1-15.1 lb in), with the steering gear pitman shaft lash adjuster nut installed. If the torque is outside this range, readjust or repair the steering gear assembly as required.
  12. To obtain the correct reload torque, adjust the over center preload by turning the steering gear pitman shaft lash adjuster screw clockwise.
  13. Add increments of 0.7-1.1 N.m (6-10 lb in) torque to the previously measured steering gear worm bearing preload torque. Tighten: Tighten the nut to 49 N.m (36 lb ft).
  14. Install the steering gear. Refer to «Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-non-rack-and-pinion) or «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  1. Remove the steering gear. Refer to «Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-non-rack-and-pinion) or «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  2. Remove the pitman arm nut (3).
  3. Remove the pitman arm washer (2).
  4. Clean the exposed end of the pitman shaft.
  5. Clean off the steering gear housing (1).
  6. Use a wire brush to clean the steering gear pitman shaft splines.
  7. To center the steering gear stub shaft: Rotate the steering gear stub shaft (1) with a wrench from stop to stop. Count the number of turns. Rotate the steering gear stub shaft back 1/2 of the total amount of turns.
  8. Remove the steering gear pitman shaft housing cover bolts (1). Remove the steering gear pitman shaft lash adjuster nut (2).
  9. Remove the steering gear pitman shaft housing cover (3).
  10. Remove the steering gear pitman shaft housing cover O-ring (4).
  1. Install the new steering gear pitman shaft housing cover O-ring (4).
  2. Install the steering gear pitman shaft housing cover (3).
  3. Install the steering gear pitman shaft lash adjuster nut (2).
  4. Install the steering gear pitman shaft housing cover bolts (1). Tighten: Tighten the bolts to 62 N.m (46 lb ft).
  5. Install the pitman arm washer (2).
  6. Install the pitman arm nut (3). Tighten: Tighten the nut to 250 N.m (184 lb ft).
  7. If necessary adjust the steering gear pitman shaft over-center preload. Refer to «Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (670/680 Gear)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-pitman-shaft-over-center-preload) .
  8. Install the steering gear. Refer to «Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-non-rack-and-pinion) or «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .

Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle

Tools Required

  1. J 6278 Pitman Shaft Bearing Remover and Installer
  2. J 6219 Pitman Shaft Oil Seal Installer. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  3. J 4245 Internal Snap Ring Pliers
  1. Remove the steering gear. Refer to «Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-non-rack-and-pinion) or «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  2. Remove the steering gear pitman shaft and housing cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  3. Remove the pitman arm (4) from the steering gear (1). Refer to «Pitman Arm Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/steering-linkage/#steering-linkage__pitman-arm-replacement) .
  4. Remove the pitman arm boot (3) from the steering gear housing (1).
  5. Remove the dust seal (2) from the steering gear housing (1).
  6. Remove the steering gear pitman shaft seal retaining ring (2) from the steering gear housing (1) using pliers J 4245 .
  7. Remove the steering gear pitman shaft washer (3) from the steering gear housing (1).
  8. Pry the steering gear pitman shaft seal (2) from the steering gear housing (1) using a screwdriver.
  9. Inspect the housing for burrs and replace if necessary.
  10. Insert remover/installer J 6278 through the hole in the top of the steering gear housing (1).
  11. Drive out the steering gear pitman shaft bearing (2) from the steering gear housing (1).
  1. Install the steering gear pitman shaft bearing into the steering gear housing (1) using remover/installer J 6278 .
  2. Drive the steering gear pitman shaft bearing into the steering gear housing until the shoulder seats properly.
  3. Coat the steering gear pitman shaft seal (2) and steering gear pitman shaft washer (3) with grease.
  4. Install the steering gear pitman shaft seal (2) into the steering gear housing (1) using installer J 6219 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__special-tools) .
  5. Install the steering gear pitman shaft washer (3) onto the steering gear housing (1).
  6. Install the steering gear pitman shaft seal retaining ring (2) into the steering gearing housing (1) using pliers J 4245 .
  7. Coat the dust seal (2) with grease and install it into the steering gear housing (1).
  8. Install the pitman arm boot (3) onto the steering gear housing (1).
  9. Install the steering gear pitman shaft and housing cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  10. Install the pitman arm (4) to the steering gear (1). Refer to «Pitman Arm Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/steering-linkage/#steering-linkage__pitman-arm-replacement) .
  11. Adjust the steering gear pitman arm shaft over center pre-load as needed. Refer to «Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (670/680 Gear)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-pitman-shaft-over-center-preload) .
  12. Install the steering gear. Refer to «Steering Gear Replacement (Non-Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-non-rack-and-pinion) or «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .

Scheme 6

Scheme 6: Disassembly Procedure
Scheme 6: Disassembly Procedure
IMPORTANTDo not to damage the threads of the steering gear housing when removing the check valve.

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

Scheme 7

Scheme 7: Assembly Procedure
Scheme 7: Assembly Procedure

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.

Scheme 8

Scheme 8: Stub Shaft Housing Replacement
Scheme 8: Stub Shaft Housing Replacement
CalloutComponent Name
Preliminary Procedures: Remove the power steering gear. Refer to Steering Gear Replacement (Non-Rack and Pinion) or Steering Gear Replacement (Rack and Pinion) .
1Stub Shaft Housing Bolt (Qty: 4) NOTE: Refer to Fastener Notice . Tighten: 62 N.m (46 lb ft)
2Stub Shaft Housing
3Stub Shaft Housing O-Ring (Qty: 2) Tip: Grease the stub shaft housing O-Rings with the special grease supplied in the service kit.
NOTE
Refer to Fastener Notice .

Stub Shaft Housing Replacement

  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-h1500/2003-2012/remont/hoistjack/#general-information) .
  4. Remove the power brake booster inlet hose (2) from the power steering pump (1) through the wheel well.
  5. Lower the vehicle.
  6. Remove the power brake booster inlet hose (1) from the power brake booster (2).
  7. 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). Hand tighten.
  3. Raise the vehicle.
  4. Install the power brake booster inlet hose (2) to the power steering pump (1) through the wheel well. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
  5. Lower the vehicle.
  6. Tighten the power brake booster inlet hose to the power brake booster. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
  7. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/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. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  4. Through the wheel well, disconnect the power brake booster outlet hose (1) from the power steering gear (2).
  5. Lower the vehicle.
  6. Remove the water deflector from the fender.
  7. Remove the power brake booster outlet hose (1) from the power brake booster (2).
  8. 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). Hand tighten.
  3. Raise the vehicle.
  4. Through the wheel well, connect the power brake booster outlet hose to the power steering gear (2). Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
  5. Lower the vehicle.
  6. Tighten the power brake booster outlet hose at the power brake booster. Tighten: Tighten the hose fitting to 33 N.m (24 lb ft).
  7. Install the water deflector to the fender.
  8. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/chevy-express-h1500/2003-2012/remont/manual-power-steering/#power-steering-system) .
  9. Remove the drain pan from under the vehicle.

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 6219 Pitman Shaft Oil Seal Installer J 6278 Bearing Remover and Installer J 6632-01 Pitman Arm Puller J 22610 Keystone Clamp Pliers J 24319-B Steering Linkage and Tie Rod Puller J 25033-C Pulley Installer J 25034-C Pulley Remover J 29107-A Pitman Arm Puller J 34028 Inner Tie Rod Wrench J 39570 Chassis Ear J 44721 Power Steering System Analyzer

Scheme 9

Scheme 9: Special Tools
Scheme 9: Special Tools

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

See also:
• STEERING WHEEL IN THE FULL TURN POSITION NOTICE
• Power Brake Booster Leak Inspection
• Power Brake Booster Replacement
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Steering Linkage Inspection
• Drive Belt Tensioner Replacement - Accessory
• Diagnostic Starting Point - Suspension General Diagnosis
• Upper Intermediate Steering Shaft Replacement
• Lifting and Jacking the Vehicle
• Tire and Wheel Removal and Installation
• Measuring Wheel Alignment
• Fluid and Lubricant Recommendations
• Fastener Notice
• Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)
• Drive Belt Replacement
• Pitman Arm Replacement
• Power Steering Hose Disconnected Notice
• INSTALLING HOSES WITHOUT TWISTS OR BENDS NOTICE
• Engine Protection Shield Replacement
• PIPE WRENCH POSITIONING NOTICE
• Power Steering System Description and Operation (w/o Electro-Hydraulic Steering)
• Power Steering Fluid Leaks
• Checking and Adding Power Steering Fluid
• Steering Effort Hard in One or Both Directions
• Steering Effort Too Easy in One or Both Directions
• Special Tools
• Power Steering Pump Specifications
• Steering Gear Replacement (Non-Rack and Pinion)
• Fastener Tightening Specifications
• Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle
• Power Steering Pump Pulley Replacement
• Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (670/680 Gear)