Power Steering System Chevrolet Express G2500

Fastener Tightening Specifications

Fastener Tightening Specifications

Power Steering Pump Specifications

Power Steering Pump Specifications

Scheme 1

Scheme 2

Scheme 3

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/express-g2500/2013-2013/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/express-g2500/2013-2013/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/express-g2500/2013-2013/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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__power-steering-fluid-leaks)
2. «Rattle, Clunk, or Shudder Noise from the Power Steering System»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system)
3. «Whine or Growl Noise from the Power Steering System»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system)
4. «Steering Effort Hard in One or Both Directions»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-effort-hard-in-one-or)
5. «Steering Effort Too Easy in One or Both Directions»(/chevrolet/express-g2500/2013-2013/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 NOTE: Power steering hoses may not look kinked, but have a layer separation causing the inner hose to collapse and restrict power steering fluid flow. The power steering pipes and hoses 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

Power Steering Fluid Leaks

Special Tools

GE-28431-6 Fluorescent Dye

For equivalent regional tools, refer to Special Tools .

Note. If fluid is found on a manual steering gear or on an electronic power steering gear, do not replace steering gear. Vehicles equipped with these systems do not use hydraulic power steering fluid. The fluid may be assembly fluid or another system fluid. Clean the components and identify the sources of the leaks before attempting to repair or replace any power steering components. Clearly mark all locations of leaks with paint, marker, or equivalent for warranty identification and engineering root cause analysis.

Some customers may comment on a fluid LEAK or NOISY power steering pump. Upon inspection, the technician may find power steering fluid leaking from the hydraulic power steering system. Use the following inspection procedure in order to diagnose the source of the leak and take appropriate action to correct the condition.

1. Inspect the fluid level in the power steering fluid reservoir. Refer to «Checking and Adding Power Steering Fluid»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__checking-and-adding-power-steering-fluid) . If the fluid level is NOT low, a careful analysis of the condition is necessary to confirm that the type of fluid is actually power steering fluid.
2. Visually inspect the power steering system and components where the fluid has accumulated.
3. Use a clean towel or a rag in order to completely clean off all residual fluid from the power steering components.
4. Add 30 cc (1 oz) of GE-28431-6 dye to the power steering fluid.
5. Start the vehicle and warm the steering system by turning to the left steering stop and to the right steering stop 10 times with the weight of the vehicle on the front tires.
6. Turn vehicle engine OFF.
7. Shine a black light on the area where the residual fluid accumulated. Identify the sources of the leaks. If equipped with hydroboost, refer to «Hydraulic Brake Booster Leak Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
8. Mark all locations of leaks with paint, marker, or equivalent.
9. Repair or replace all affected components.

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

Whine or Growl Noise from the Power Steering System

Poor Return of Steering Wheel

Poor Return of Steering Wheel

Steering Effort Too Easy in One or Both Directions

Steering Effort Too Easy in One or Both Directions

Steering Effort Hard in One or Both Directions

Steering Effort Hard in One or Both Directions

Steering Linkage Inner Tie Rod Inspection

Special Tools

J-8001 Dial Indicator Set

For equivalent regional tools, refer to Special Tools .

1. Turn the ignition key to the on position with the engine off.
2. With the aid of an assistant, turn the steering wheel to the full stop position and hold the steering wheel in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. If there is not a good location for the J-8001 Dial Indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the J-8001 Dial Indicator pointer.
5. Install the J-8001 Dial Indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing.
6. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash.
7. Zero the J-8001 Dial Indicator.
8. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash.
9. Record the measurement seen on the J-8001 Dial Indicator.
10. If the measured value exceeds 1.0 mm (0.04 in), replace the inner tie rod. Refer to «Steering Linkage Inner Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-inner-tie-rod-replacement) .
11. Repeat the procedure for the other side.

Steering Linkage Outer Tie Rod Inspection

Special Tools

J-8001 Dial Indicator Set

For equivalent regional tools, refer to Special Tools .

1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod end. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-outer-tie-rod-replacement) .
2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
3. Install the J-8001 Dial Indicator between the outer tie rod end and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the dial indicator position.
4. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash.
5. Zero the J-8001 Dial Indicator.
6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash.
7. Record the measurement seen on the J-8001 Dial Indicator.
8. If the measured value exceeds 1 mm (0.04 in) then replace the outer tie rod. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-outer-tie-rod-replacement) .
9. Repeat the procedure for the other side.

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/express-g2500/2013-2013/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/express-g2500/2013-2013/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

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/express-g2500/2013-2013/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/express-g2500/2013-2013/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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .

Note. Do not reuse any drained power steering fluid regardless of appearance or condition.

1. Raise the vehicle until the front wheels are off the ground. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Place a large drain pan under the vehicle in order to collect the draining fluid.
3. Remove the fluid return hose at the power steering fluid reservoir or the pump inlet connection, as applicable.
4. Plug the reservoir return hose inlet connection on the power steering fluid reservoir or the pump, as applicable.
5. Have an assistant maintain the minimum fluid level in the reservoir using clean, new power steering fluid. Refer to «Checking and Adding Power Steering Fluid»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__checking-and-adding-power-steering-fluid) .
6. With the key in the ON position and with the engine OFF, turn the steering wheel fully to the left and to the right. Continue until the fluid from the return hose runs clear.
7. Remove the plug and install the fluid return hose to the power steering fluid reservoir or the pump inlet connection, as applicable.
8. Bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/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 3-9.
11. Remove the drain pan.
12. Lower the vehicle.

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 and tighten 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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .

Power Steering Pump Pulley Replacement (4.3L)

Special Tools

1. J-25033-C Pulley Installer
2. J-25034-C Pulley Remover

For equivalent regional tools, refer to Special Tools .

1. Remove the engine coolant fan upper shroud, if equipped. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(/chevrolet/express-g2500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the accessory drive belt. Refer «Drive Belt Replacement»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-43l-lu3) .
3. Use the J-25034-C remover in order to remove the power steering pump pulley.

1. Place the power steering pump pulley on the end of the power steering pump shaft.
2. Use the J-25033-C installer in order to install the power steering pump pulley.
3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2) with an allowable variance of 0.25 mm (0.010 in).
4. Install the accessory drive belt. Refer to «Drive Belt Replacement»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-43l-lu3) .
5. Install the engine coolant fan upper shroud, if equipped. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(/chevrolet/express-g2500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .

Power Steering Pump Pulley Replacement (4.8L, 5.3L, 6.0L, or 6.2L)

Special Tools

1. J-25033-C Pulley Installer
2. J-25034-C Pulley Remover

For equivalent regional tools, refer to Special Tools .

1. Remove the engine coolant fan upper shroud, if equipped. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(/chevrolet/express-g2500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions-on-vehicle) .
3. Use the J-25034-C remover in order to remove the power steering pump pulley.

1. Place the power steering pump pulley on the end of the power steering pump shaft.
2. Use the J-25033-C installer in order to install the power steering pump pulley.
3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2) with an allowable variance of 0.25 mm (0.010 in).
4. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions-on-vehicle) .
5. Install the engine coolant fan upper shroud, if equipped. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(/chevrolet/express-g2500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .

Power Steering Pump Pulley Replacement (6.6L)

Special Tools

1. J-25033-C Pulley Installer
2. J-25034-C Pulley Remover

For equivalent regional tools, refer to Special Tools .

1. Remove the accessory drive belt. Refer to «Drive Belt Replacement»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
2. Use the J-25034-C remover in order to remove the power steering pump pulley.

1. Place the power steering pump pulley on the end of the power steering pump shaft.
2. Use the J-25033-C installer in order to install the power steering pump pulley.
3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2) with an allowable variance of 0.25 mm (0.010 in).
4. Install the accessory drive belt. Refer to «Drive Belt Replacement»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Remove the power steering pump pulley . Refer to «Power Steering Pump Pulley Replacement (4.3L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement-43l) .
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Disconnect the reservoir outlet hose from the power steering pump through the wheel well.
6. Disconnect the power steering gear outlet hose or the 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. Remove the power steering pump mounting bolts and the nuts.
10. Remove the power steering pump from the vehicle.
11. Remove the power steering pump rear bracket mounting nuts.
12. Remove the power steering pump rear bracket from the power steering pump.

1. Install the rear bracket to the power steering pump.
2. Install the power steering pump rear bracket mounting nuts and tighten to 50 N.m (37 lb ft).
3. Position the power steering pump in the vehicle.
4. Install the power steering pump front mounting bolts 50 N.m (37 lb ft).
5. Install the power steering pump lower and rear nuts and tighten to 41 N.m (30 lb ft).
6. Uncap the power steering hoses.
7. Connect the power brake booster inlet hose (2) to the power steering pump through the wheel well and tighten 34 N.m (25 lb ft).
8. Connect the power steering gear outlet hose or the cooler hose to the power steering pump through the wheel well.
9. Connect the reservoir outlet hose to the power steering pump through the wheel well.
10. Lower the vehicle.
11. Install the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement (4.3L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement-43l) .
12. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
13. Clean any excess power steering fluid from the vehicle.
14. Remove the drain pans from under the vehicle.

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Remove the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement (4.8L, 5.3L, 6.0L, or 6.2L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement-48l) .
4. Remove the lower intermediate shaft to the power steering gear retaining bolt.
5. Disconnect the lower intermediate shaft from the power steering gear.
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
7. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. Disconnect the reservoir outlet hose from the power steering pump through the wheel well.
9. Disconnect the power steering gear outlet hose or the cooler hose from the power steering pump through the wheel well.
10. Disconnect the power brake booster inlet hose (2) from the power steering pump through the wheel well.
11. Cap the ends of the hose and the pump in order to prevent the entrance of dirt.
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 and tighten to 50 N.m (37 lb ft).
3. Position the power steering pump in the vehicle.
4. Install the front power steering pump mounting bolts and tighten to 50 N.m (37 lb ft).
5. Install the rear power steering pump mounting bolt and tighten to 41 N.m (30 lb ft).
6. Uncap the power steering hoses.
7. Connect the power brake booster inlet hose (2) to the power steering pump through the wheel well and tighten to 34 N.m (25 lb ft).
8. Connect the power steering gear outlet hose or the cooler hose to the power steering pump through the wheel well.
9. Connect the reservoir outlet hose to the power steering pump through the wheel well.
10. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
11. Connect the lower intermediate shaft to the power steering gear.
12. Install the lower intermediate shaft to the power steering gear retaining bolt and tighten to 61 N.m (45 lb ft).
13. Lower the vehicle.
14. Install the power steering pump pulley. Refer to «Power Steering Pump Pulley Replacement (4.8L, 5.3L, 6.0L, or 6.2L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__power-steering-pump-pulley-replacement-48l) .
15. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
16. Clean any excess power steering fluid from the vehicle.
17. Remove the drain pans from under the vehicle.

Scheme 6

Power Steering Pump Replacement (LGH)

Scheme 7

Power Steering Fluid Reservoir Replacement - Off Vehicle (LGH)

Disassembly Procedure

1. Remove the power steering pump and reservoir as an assembly. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
2. Drain the power steering fluid from the power steering pump.
3. Remove the pump mounting studs (2).
4. Remove the connector and fitting assembly (4).
5. Remove the O-ring seal (3) from the connector and fitting assembly.
6. If replacement is necessary, 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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
7. Remove the reservoir assembly (1) from the pump housing assembly (2).
8. Remove the O-ring seals (1, 4, 5).
9. Remove the magnet (3).
10. Clean the magnet.
11. Inspect the welch plug in the power steering pump housing (2). Do not remove the welch plug. If the welch plug is deformed or dislodged, replace the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (LGH)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .

Assembly Procedure

1. Lubricate the NEW O-ring seals (1, 4, 5) with power steering fluid.
2. Install the O-ring seals to the pump housing assembly.
3. 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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
4. Install the magnet (3) to the pump housing assembly.
5. Connect the reservoir assembly (1) to the pump housing assembly (2).
6. Install the O-ring seal (3).
7. Install the connector and fitting assembly (4) to the pump housing (1). Hand tighten the connector and fitting assembly. CAUTION: Refer to «Fastener Caution»(/chevrolet/express-g2500/2013-2013/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
8. Install the pump mounting studs (2) to the pump housing and tighten to 58 N.m (43 lb ft).
9. Tighten the connector and fitting assembly to 62 N.m (46 lb ft).
10. Install the power steering pump and reservoir as an assembly. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .

1. Drain the power steering fluid from the power steering pump housing (1).
2. Remove the connector and fitting assembly (2).
3. Remove the control valve assembly (4) from the pump housing. Ensure the flow control spring (5) does not fall out of the pump housing.
4. Remove the O-ring seal (3) from the connector and fitting assembly. Discard the O-ring seal.

1. Ensure the flow control spring (5) does not fall out of the pump housing (1).
2. Lubricate the NEW O-ring seal (3) with power steering fluid.
3. Install the O-ring seal onto the connector and fitting assembly (2).
4. Install the control valve assembly (4).
5. Install the connector and fitting assembly (2) and tighten to 62 N.m (46 lb ft).

1. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (LGH)»(/chevrolet/express-g2500/2013-2013/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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (4.8L, 5.3L, 6.0L)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) , «Power Steering Pump Replacement (LGH)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .

Steering Linkage Outer Tie Rod Replacement

Special Tools

J 24319-B Steering Linkage and Tie Rod Puller

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
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 steering linkage and tie rod puller.
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 and tighten to 63 N.m (47 lb ft).
4. Check the wheel alignment. Refer to «Wheel Alignment Measurement»(/chevrolet/express-g2500/2013-2013/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-measurement) .

Steering Gear Boot Replacement

Tools Required

J 22610 Keystone Clamp Pliers

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the outer tie rod. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-outer-tie-rod-replacement) .
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 keystone clamp pliers.
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 «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-outer-tie-rod-replacement) .
10. Check the wheel alignment. Refer to «Wheel Alignment Measurement»(/chevrolet/express-g2500/2013-2013/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-measurement) .

1. Place drain pans under the vehicle.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the left front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
4. From the left front wheel well, loosen the hose clamp (2) and disconnect the power steering cooler hose (1) from the power steering pump (3).
5. Disconnect the power steering cooler hose (2) from the steering gear (1).
6. Cap the power steering cooler ends in order to prevent the entry of dirt.
7. Remove the power steering cooler mounting bolts.
8. Remove the power steering cooler from the vehicle.

1. Position the power steering cooler in the vehicle.
2. Install the power steering cooler mounting bolts and tighten to 5 N.m (44 lb in).
3. Connect the power steering cooler hose (2) to the steering gear (1) and tighten the fitting to 34 N.m (25 lb in).
4. From the left front wheel well, connect the power steering cooler hose (1) to the power steering pump (3) and secure with the hose clamp (2).
5. Install the left front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Lower the vehicle.
7. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
8. Clean any excess power steering fluid from the vehicle.
9. Remove the drain pans.

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. Disconnect the power steering cooler hose from the power steering pump.
5. Disconnect the power steering cooler hose from the power steering gear.
6. Cap the power steering cooler ends in order to prevent the entry of dirt.
7. Remove the power steering cooler mounting bolts.
8. Remove the power steering cooler from the vehicle.

1. Position the power steering cooler in the vehicle.
2. Install the power steering cooler mounting bolts and tighten to 5 N.m (44 lb in).
3. Connect the power steering cooler hose to the power steering gear and tighten to 34 N.m (25 lb in).
4. Connect the power steering cooler hose to the power steering pump.
5. Lower the vehicle.
6. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
7. Clean any excess power steering fluid from the vehicle.
8. Remove the drain pans from under the vehicle.

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. Disconnect the power steering cooler hose from the power steering pump.
5. Disconnect the power steering cooler hose from the power steering gear.
6. Cap the power steering pipes and cooler ends in order to prevent the entry of dirt.
7. Remove the power steering cooler mounting nuts.
8. Remove the power steering cooler from the vehicle.

1. Position the power steering cooler in the vehicle.
2. Install the power steering cooler mounting nuts and tighten to 28 N.m (21 lb ft).
3. Connect the power steering cooler hose to the power steering gear and tighten to 34 N.m (25 lb ft).
4. Connect the power steering cooler hose to the power steering pump.
5. Lower the vehicle.
6. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
7. Clean any excess power steering fluid from the vehicle.
8. Remove the drain pans 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/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
5. Remove the drain pan from under the vehicle.

Scheme 8

Power Steering Fluid Reservoir Outlet Hose Replacement (LGH)

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. If necessary, remove the left front wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Disconnect the power steering fluid reservoir outlet hose from the power steering pump.
6. Disconnect the power steering fluid reservoir outlet hose from the reservoir.
7. Remove the power steering fluid reservoir outlet hose from the vehicle.

1. Position the power steering fluid reservoir outlet hose in the vehicle.
2. Connect the power steering fluid reservoir outlet hose to the power steering pump.
3. Connect the power steering fluid reservoir outlet hose to the reservoir.
4. If you removed the left front wheelhouse splash shield, install the splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
6. Clean any excess power steering fluid from the vehicle.
7. Remove the drain pans from under the vehicle.
8. Lower the vehicle.

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. Disconnect the power steering gear outlet hose from the power steering pump.
5. Disconnect the power steering gear outlet hose from the power steering gear.
6. Remove the power steering gear outlet hose from the vehicle.

1. Position the power steering gear outlet hose in the vehicle.
2. Connect the power steering gear outlet hose to the power steering gear and tighten to 34 N.m (25 lb ft).
3. Connect the power steering gear outlet hose to the power steering pump.
4. Lower the vehicle.
5. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
6. Clean any excess power steering fluid from the vehicle.
7. Remove the drain pans from under the vehicle.

Steering Gear Replacement (Rack and Pinion)

Special Tools

1. J-24319-B Steering Linkage and Tie Rod Puller
2. J-42640 Steering Column Anti-rotation Pin

For equivalent regional tools, refer to Special Tools .

1. Install the J-42640 pin to the steering column lower access hole in order to lock the steering column in the straight ahead position.
2. Place drain pans under the vehicle.
3. Remove as much power steering fluid from the reservoir as possible.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the front tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Remove the outer tie rod retaining nuts.
8. Use the J-24319-B puller in order to disconnect the outer tie rods from the steering knuckles.
9. Disconnect the lower intermediate shaft from the power steering gear. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/steering-column-switches/#steering-wheel-and-steering-column) .
10. 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).
11. Cap the ends of the hoses and the power steering gear fittings in order to prevent the entrance of dirt.
12. Remove the power steering gear mounting bolts.
13. Remove the power steering gear from the vehicle.

1. Position the power steering gear in the vehicle.
2. Install the power steering gear to the frame mounting bolts and tighten 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 the hose fittings to 34 N.m (25 lb ft).
5. Connect the lower intermediate shaft to the power steering gear. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/steering-column-switches/#steering-wheel-and-steering-column) .
6. Connect the outer tie rods to the steering knuckles.
7. Install the outer tie rods retaining nuts and tighten to 63 N.m (47 lb ft).
8. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
9. Install the front tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
10. Lower the vehicle.
11. Remove the J-42640 pin from the steering column lower access hole.
12. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
13. Clean any excess power steering fluid from the vehicle.
14. Remove the drain pans from under the vehicle.
15. Measure and adjust the front toe. Refer to «Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment»(/chevrolet/express-g2500/2013-2013/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-steering-wheel-angle) .

Steering Gear Replacement (Recirculating Ball)

Special Tools

1. J-6632-01 Pitman Arm Puller
2. J-24319-B Steering Linkage and Tie Rod Puller
3. J-29107-A Pitman Arm Puller
4. J-42640 Steering Column Anti-rotation Pin

For equivalent regional tools, refer to Special Tools .

1. Install the J-42640 pin to the steering column lower access hole in order to lock the steering column in the straight ahead position.
2. Place drain pans under the vehicle.
3. Remove as much power steering fluid from the reservoir as possible.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Disconnect the lower intermediate shaft from the power steering gear. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/steering-column-switches/#steering-wheel-and-steering-column) .
7. Disconnect the power brake booster outlet hose (4) and power steering gear outlet hose (1) or the power steering cooler hose (1) from the power steering gear (2).
8. Cap the ends of the hoses and the power steering gear fittings in order to prevent the entrance of dirt.
9. Remove the pitman arm to relay rod retaining nut.
10. Disconnect the pitman arm from the relay rod using the J-24319-B puller.
11. Remove the stabilizer shaft insulator clamp nuts (3) and/or studs.
12. Move the stabilizer shaft (2) down in order to disconnect the stabilizer shaft from the frame and access the lower steering gear bolts.
13. Support the stabilizer shaft in order to avoid stress on the stabilizer shaft links.
14. Remove the power steering gear mounting bolts.
15. Remove the power steering gear from the vehicle.
16. Remove the pitman arm to power steering gear retaining nut and washer.
17. Remove the pitman arm from the power steering gear using the J-6632-01 puller or the J-29107-A puller.

1. Install the pitman arm to the power steering gear.
2. Install the pitman arm to power steering gear retaining nut and washer and tighten to 250 N.m (184 lb ft).
3. Position the power steering gear in the vehicle.
4. Install the power steering gear to the frame mounting bolts and tighten to 150 N.m (111 lb ft).
5. Connect the stabilizer shaft and the insulator clamps to the frame. Refer to «Stabilizer Shaft Insulator Replacement»(/chevrolet/express-g2500/2013-2013/remont/suspension-front/#front-suspension-system) .
6. Install the pitman arm to relay rod.
7. Install the pitman arm to relay rod retaining nut and tighten to 63 N.m (47 lb ft).
8. Remove the caps from the steering gear and hoses.
9. Connect the power brake booster outlet hose (4) and power steering gear outlet hose (1) or the power steering cooler hose (1) to the power steering gear (2). Tighten the hose fittings to 34 N.m (25 lb ft).
10. Connect the lower intermediate shaft to the power steering gear. Refer to «Lower Intermediate Steering Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/steering-column-switches/#steering-wheel-and-steering-column) .
11. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
12. Lower the vehicle.
13. Remove the J-42640 pin from the steering column lower access hole.
14. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
15. Clean any excess power steering fluid from the vehicle.
16. Remove the drain pans from under the vehicle.
17. Measure and adjust the front toe. Refer to «Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment»(/chevrolet/express-g2500/2013-2013/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-steering-wheel-angle) .

Steering Gear Rack Bearing Preload Adjustment - Off Vehicle

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. Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 68 N.m (50 lb ft).

Steering Gear Boot and Breather Tube Replacement - Off Vehicle

Tools Required

J 22610 Keystone Clamp Pliers

1. To remove the outer tie rod. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-outer-tie-rod-replacement) .
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 keystone clamp pliers.
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 «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-linkage-outer-tie-rod-replacement) .

Steering Linkage Inner Tie Rod Replacement

Special Tools

J-34028 Inner Tie Rod Wrench

1. Remove the steering gear from the vehicle. Refer to «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-rack-and-pinion) , «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .
2. Remove the 2 steering gear boots and breather tubes from the steering gear. Refer to «Steering Gear Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-boot-and-breather-tube) .
3. Place the steering gear in a vise.
4. Slide the left shock dampener (4) from the left inner tie rod housing (6) to the rack (5).
5. Place a pipe wrench on the rack next to the left inner tie rod housing.
6. Place a wrench on the flats of the left inner tie rod housing.
7. Rotate the left inner tie rod housing counterclockwise, while holding the rack stationary, until the left inner tie rod separates from the rack.
8. Slide the right shock dampener (3) from the right inner tie rod housing (2) to the rack (5).
9. Place a pipe wrench on the left side of the rack.
10. Place a wrench on the flats of the right inner tie rod housing.
11. Rotate the right inner tie rod housing counterclockwise, while holding the rack stationary, until the right inner tie rod (1) separates from the rack.
12. If the steering gear has a female rack (1) and a male inner tie rod (3), remove the old LOCTITE® from the threads (2) on the inner tie rod and from the threads on the rack. If the steering gear has a male rack (5) and a female inner tie rod (4), LOCTITE® will not be present.

1. If the steering gear has a female rack (1) and a male inner tie rod (3), apply LOCTITE® 262, or equivalent, to the threads (2) on the left inner tie rod.
2. Install the left inner tie rod to the rack (3).
3. Place a pipe wrench on the rack next to the left inner tie rod housing (2).
4. Place a torque wrench and the J-34028 wrench on the flats of the left inner tie rod housing. Tighten the inner tie rod to 100 N.m (74 lb ft).
5. If the steering gear has a female rack (5) and a male inner tie rod (1), apply LOCTITE® 262, or equivalent, to the threads on the right inner tie rod.
6. Install the right inner tie rod to the rack.
7. Place a pipe wrench on the rack next to the left inner tie rod housing (4).
8. Place a torque wrench and the J-34028 wrench on the flats of the steering linkage inner tie rod housing (7). Tighten the inner tie rod to 100 N.m (74 lb ft).
9. Place each inner tie rod assembly (2) on a vise.
10. Stake both sides of the 2 female inner tie rod housings to the male rack.
11. Insert a 0.25 mm gauge (1) between the rack (2) and the inner tie rod housing in order to inspect the 4 stakes. The feeler gauge must not pass between the rack and the inner tie rod housing stake.
12. Slide the left shock dampener (2) over the left inner tie rod housing (3) until the front lip of the left shock dampener bottoms against the left inner tie rod housing.
13. Slide the right shock dampener over the right inner tie rod housing until the front lip of the right shock dampener bottoms against the right inner tie rod housing.
14. Install the 2 steering gear boots and breather tubes to the steering gear. Refer to «Steering Gear Boot and Breather Tube Replacement - Off Vehicle»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-boot-and-breather-tube) .
15. Install the steering gear to the vehicle. Refer to «Steering Gear Replacement (Rack and Pinion)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-rack-and-pinion) , «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .

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) and tighten. Valve end fittings to 17 N.m (13 lb ft) Cylinder end fittings to 27 N.m (20 lb ft)

Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle

1. Remove the steering gear. Refer to «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .
2. Loosen the steering gear pitman shaft lash adjuster nut (1).
3. Turn the steering gear pitman shaft lash adjuster screw (2) counterclockwise until fully extended.
4. Turn the steering gear pitman shaft lash adjuster screw (2) clockwise one full turn.
5. Rotate the steering gear stub shaft (3) from stop to stop, using an open-ended crow foot 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 (1) faces upward. The flat on the steering gear stub shaft is parallel with the steering gear side cover.
8. Place a torque wrench with an open-ended crow foot 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. Completely drain the steering gear housing by rotating the input shaft from stop to stop before recording any preload measurements.
11. Record the steering gear worm bearing preload measured on or near the center.
12. Recorded steering gear worm bearing preload must be 0.7-1.6 N.m (6.1-14.1 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.
13. To obtain the correct preload torque, adjust the over center preload by turning the steering gear pitman shaft lash adjuster screw clockwise.
14. Tighten the adjuster nut while holding the steering gear pitman shaft lash adjuster screw. Tighten the nut to 49 N.m (36 lb ft).
15. Install the steering gear. Refer to «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .

1. Remove the steering gear. Refer to «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .
2. Remove the pitman arm nut (1).
3. Remove the pitman arm washer (2).
4. Mark the pitman arm position to the steering gear housing for installation aid.
5. Remove the pitman arm (3).
6. Clean off the steering gear housing (4).
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 pitman shaft dust seal.
9. Remove the steering gear pitman shaft housing cover bolts (1).
10. Remove the steering gear pitman shaft and housing cover (3). Ensure the steering gear pitman shaft O-ring (4) is removed. If the O-ring is not present, remove the O-ring from the housing.
11. Remove the pitman shaft seal and discard. Refer to «Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-pitman-shaft-seal-and) .

1. Install a new pitman shaft seal. Refer to «Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-pitman-shaft-seal-and) .
2. Wipe the steering gear housing openings clean.
3. Install a new steering gear pitman shaft housing cover O-ring (4) to the pitman shaft.
4. Install the steering gear pitman shaft housing cover (3).
5. Install the steering gear pitman shaft housing cover bolts (1) and tighten to 62 N.m (46 lb ft).
6. Install the pitman shaft boot seal to the pitman shaft and steering gear housing (4).
7. Install the pitman arm (3) on the pitman shaft using the alignment marks made during removal.
8. Install the pitman arm washer (2).
9. Install the pitman arm nut (1) and tighten to 250 N.m (184 lb ft).
10. If necessary adjust the steering gear pitman shaft over-center preload. Refer to «Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-pitman-shaft-over-center-preload) .
11. Install the steering gear. Refer to «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .

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
3. J 4245 Internal Snap Ring Pliers

1. Remove the steering gear. Refer to «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .
2. Remove the steering gear pitman shaft and housing cover. Refer to «Steering Gear Pitman Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
3. Remove the pitman arm (4) from the steering gear (1). Refer to «Pitman Arm Replacement»(/chevrolet/express-g2500/2013-2013/remont/steering-linkage/#steering-linkage-system__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 J 4245 internal snap ring pliers.
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 J 6278 pitman shaft bearing remover and installer 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 J 6278 pitman shaft bearing remover and installer.
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 J 6219 pitman shaft oil seal installer.
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 J 4245 internal snap ring pliers.
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 Replacement»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
10. Install the pitman arm (4) to the steering gear (1). Refer to «Pitman Arm Replacement»(/chevrolet/express-g2500/2013-2013/remont/steering-linkage/#steering-linkage-system__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»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-pitman-shaft-over-center-preload) .
12. Install the steering gear. Refer to «Steering Gear Replacement (Recirculating Ball)»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system__steering-gear-replacement-recirculating-ball) .

Scheme 9

Stub Shaft Housing Replacement

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. Remove the left front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
5. From the left front wheel well, disconnect the power brake booster inlet hose (1) from the power steering pump (2).
6. Lower the vehicle.
7. Disconnect 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. Position the power brake booster inlet hose (1) in the vehicle.
2. Connect the power brake booster inlet hose to the power brake booster (2). Hand tighten the fitting.
3. Raise the vehicle.
4. From the left front wheel well, connect the power brake booster inlet hose (1) to the power steering pump (2). Tighten the hose fitting to 34 N.m (25 lb ft).
5. Install the left front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Lower the vehicle.
7. Tighten the power brake booster inlet hose fitting on the power brake booster to 34 N.m (25 lb ft).
8. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
9. Clean any excess power steering fluid from the vehicle.
10. Remove the drain pans from under the vehicle.

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. From the left front wheel well, disconnect the power brake booster inlet hose (2) from the power steering pump (1).
5. Lower the vehicle.
6. Disconnect 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. Position the power brake booster inlet hose (1) in the vehicle.
2. Connect the power brake booster inlet hose to the power brake booster (2). Hand tighten the fitting.
3. Raise the vehicle.
4. From the left front wheel well, connect the power brake booster inlet hose (2) to the power steering pump (1). Tighten the hose fitting to 34 N.m (25 lb ft).
5. Lower the vehicle.
6. Tighten the power brake booster inlet hose fitting on the power brake booster to 34 N.m (25 lb ft).
7. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
8. Clean any excess power steering fluid from the vehicle.
9. Remove the drain pans from under the vehicle.

1. Place drain pans under the vehicle.
2. Remove as much power steering fluid from the reservoir as possible.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
4. If necessary, remove the water deflector from the fender.
5. Through the wheel well, disconnect the power brake booster outlet hose (1) from the steering gear (2).
6. Disconnect the power brake booster outlet hose (1) from the power brake booster (2).
7. Remove the power brake booster outlet hose from the vehicle.

1. Position the power brake booster outlet hose in the vehicle.
2. Connect the power brake booster outlet hose (1) to the power brake booster (2). Hand tighten the fitting.
3. Through the wheel well, connect the power brake booster outlet hose (1) to the steering gear (2) and tighten to 34 N.m (25 lb ft).
4. Lower the vehicle.
5. Tighten the power brake booster outlet hose fitting at the power brake booster to 34 N.m (25 lb ft).
6. If you removed the water deflector, install the water deflector to the fender.
7. Fill and bleed the power steering system. Refer to «Power Steering System Bleeding»(/chevrolet/express-g2500/2013-2013/remont/manual-power-steering/#power-steering-system) .
8. Clean any excess power steering fluid from the vehicle.
9. Remove the drain pans 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

Illustration Tool Number/ Description GE-28431-6 J-28431-6 Fluorescent Dye 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-8001 Dial Indicator Set 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-42640 Steering Column Anti-rotation Pin J-44721 Power Steering System Analyzer

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

See also:
• Steering Wheel in the Full Turn Position Caution
• Hydraulic Brake Booster Leak Inspection
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Steering Linkage Inspection
• Noise Diagnosis - Front Suspension
• Drive Belt Replacement - Accessory
• Drive Belt Replacement
• Upper Intermediate Steering Shaft Replacement
• Lifting and Jacking the Vehicle
• Tire and Wheel Removal and Installation (6-Lug Wheel)
• Wheel Alignment Measurement
• Fluid and Lubricant Recommendations
• Fastener Caution
• Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)
• Power Steering Hose Disconnected Caution
• Installing Hoses without Twists or Bends Caution
• Wheelhouse Splash Shield Replacement
• Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment
• Stabilizer Shaft Insulator Replacement
• Pitman Arm Replacement
• 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
• Power Steering Pump Specifications
• Steering Gear Replacement (Rack and Pinion)
• Steering Gear Replacement (Recirculating Ball)
• Special Tools
• Power Steering Pump Pulley Replacement (6.6L)
• Power Steering Pump Pulley Replacement (4.3L)
• Power Steering Pump Pulley Replacement (4.8L, 5.3L, 6.0L, or 6.2L)
• Steering Linkage Inner Tie Rod Replacement
• Steering Linkage Outer Tie Rod Replacement
• Steering Gear Boot and Breather Tube Replacement - Off Vehicle
• Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle
• Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle