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Power Steering System: Removal & Installation Chevrolet Silverado 1500

Manual & Power Steering 54 illustrations ~6778 words

Power Steering Pulley Replacement

Tools Required

  1. J 25034-C Power Steering Pump Pulley Remover. See «Special Tools»(ref-238245-S22550396302006072400000) .
  2. J 25033-C Power Steering Pump Pulley Installer. See «Special Tools»(ref-238245-S22550396302006072400000) .

Removal Procedure

  1. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (w/RPO HP2)»(ref-238207-S37433842052006072400000) , «Fan Shroud Replacement - Upper (Automatic Transmission - Diesel)»(ref-238207-S40483265232006072400000) , «Fan Shroud Replacement - Upper (Manual Transmission - Diesel)»(ref-238207-S15352724182006072400000) , «Fan Shroud Replacement - Upper (Automatic Transmission - Gasoline)»(ref-238207-S21117948602006072400000) or «Fan Shroud Replacement - Upper (Manual Transmission - Gasoline)»(ref-238207-S32669583992006072400000) in Engine Cooling.
  2. Remove the drive belt. Refer to one of the following: «Drive Belt Replacement»(ref-238222-S32770416892006072400000) in Engine Mechanical - 4.3L. «Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines)»(ref-238223-S23117335532006072400000) or «Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2)»(ref-238223-S05989847012006072400000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L. «Drive Belt Replacement»(ref-238224-S14033949082006072400000) in Engine Mechanical - 6.6L (LLY). «Drive Belt Replacement - Accessory»(ref-238225-S30832365212006072400000) in Engine Mechanical - 8.1L.
  3. Remove the power steering pump pulley using the J 25034-C . See «Special Tools»(ref-238245-S22550396302006072400000) .

Scheme 22

Scheme 22: Installation Procedure
Scheme 22: Installation Procedure

Scheme 23

Scheme 23
Scheme 23
  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»(ref-238245-S22550396302006072400000) .
  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 drive belt. Refer to one of the following: «Drive Belt Replacement»(ref-238222-S32770416892006072400000) in Engine Mechanical - 4.3L. «Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines)»(ref-238223-S23117335532006072400000) or «Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2)»(ref-238223-S05989847012006072400000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L. «Drive Belt Replacement»(ref-238224-S14033949082006072400000) in Engine Mechanical - 6.6L (LLY). «Drive Belt Replacement - Accessory»(ref-238225-S30832365212006072400000) in Engine Mechanical - 8.1L.
  5. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (w/RPO HP2)»(ref-238207-S37433842052006072400000) , «Fan Shroud Replacement - Upper (Automatic Transmission - Diesel)»(ref-238207-S40483265232006072400000) , «Fan Shroud Replacement - Upper (Manual Transmission - Diesel)»(ref-238207-S15352724182006072400000) , «Fan Shroud Replacement - Upper (Automatic Transmission - Gasoline)»(ref-238207-S21117948602006072400000) or «Fan Shroud Replacement - Upper (Manual Transmission - Gasoline)»(ref-238207-S32669583992006072400000) in Engine Cooling.
  1. Place a drain pan under the pump.
  2. Remove the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  3. Remove the power steering return hoses (2,4) from the power steering pump.
  4. Remove the power steering rear mounting bracket nut from the engine stud.
  5. Remove the power steering pump mounting bolts.
  6. Remove the accessory mounting bracket mounting bolts and nut.
  7. Pull the accessory mounting bracket forward.
  8. Remove the power steering pump from the vehicle.
  9. Remove the power steering pressure hose (2) from the power steering pump.
  10. Remove the nuts retaining the power steering pump rear bracket from the power steering pump.

Scheme 24

Scheme 24: Installation Procedure
Scheme 24: Installation Procedure

Scheme 25

Scheme 25
Scheme 25
  1. Install the power steering pump rear bracket to the pump.
  2. Install the nuts retaining the bracket to the power steering pump. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  3. Install the power steering pressure hose (2) to the power steering pump. Tighten: Tighten the fitting to 28 N.m (20 lb ft).
  4. Install the power steering pump mounting bolts. Tighten: Tighten the power steering mounting bolts and nut to 50 N.m (37 lb ft).
  5. Install the power steering rear mounting bracket nut to the engine stud. Tighten: Tighten the power steering rear bracket nut to 50 N.m (37 lb ft).
  6. Install the power steering return hoses and retaining clamps (3,5) to the power steering pump.
  7. Reposition the accessory mounting bracket and install the bolts and nut. Tighten: Tighten the accessory mounting bracket bolts to 50 N.m (37 lb ft). Tighten the accessory mounting bracket nut to 41 N.m (30 lb ft).
  8. Install the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  9. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 26

Scheme 26: Removal Procedure
Scheme 26: Removal Procedure

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Remove the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
  3. Remove the oil pan skid plate bolts.
  4. Remove the oil pan skid plate from the vehicle, if equipped.
  5. Place a drain pan under the vehicle.
  6. Remove the power steering pressure hose (2) from the power steering pump from underneath the vehicle.
  7. Lower the vehicle.
  8. Remove the clamps (3,5) retaining the power steering return hoses to the power steering pump and remove the hoses.
  9. Remove the lower intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(ref-238184-S04023553392006072400000) in Steering Wheel and Column.
  10. Remove the bolt retaining the rear bracket to the engine.
  11. Remove the bolts from the front of the pump.
  12. Remove the pump from the vehicle.
  13. Remove the bracket (3) from the rear of the pump (1).

Scheme 29

Scheme 29: Installation Procedure
Scheme 29: Installation Procedure
  1. Install the bracket (3) to the rear of the pump (1). Tighten: Tighten the rear bracket retaining nuts to 50 N.m (37 lb ft).
  2. Install the power steering pump.
  3. Install the bolt retaining the rear bracket to the engine. Tighten: Tighten the rear power steering bracket bolt to engine bracket to 50 N.m (37 lb ft).
  4. Install the bolts to the front of the pump. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  5. Install the power steering pump return hoses (2,4) to the power steering pump and install the retaining clamps.
  6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
  7. Install the power steering pressure hose (2) to the power steering pump. Tighten: Tighten the fitting to 28 N.m (20 lb ft).
  8. Install the oil pan skid plate, if equipped.
  9. Install the oil pan skid plate bolts. Tighten: Tighten the retaining bolts to 20 N.m (15 lb ft).
  10. Lower the vehicle.
  11. Install the intermediate shaft. Refer to «Intermediate Steering Shaft Replacement - Lower»(ref-238184-S04023553392006072400000) .
  12. Install the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  13. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  1. Place a drain pan under the vehicle.
  2. Remove the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  3. Remove the nut (1) and clamp (3) retaining the filler neck (1) to the power steering pump, if equipped.
  4. Remove the bolts (2) from the front of the pump.
  5. Remove the bolts retaining the power steering mounting bracket.
  6. Remove the bolts (1) from the rear of the pump.
  7. Remove the power steering return hoses (2,4) from the power steering pump.
  8. Remove the power steering pressure hoses (2) from the power steering pump.
  9. Remove the pump from the vehicle.
  10. Remove the rear bracket from the power steering pump.

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32
  1. Install the rear bracket to the power steering pump. Tighten: Tighten the rear bracket retaining nuts to 50 N.m (37 lb ft).
  2. Install the power steering pump to the vehicle.
  3. Install the pressure hose (2) to the power steering pump. Tighten: Tighten the hose fitting to 28 N.m (20 lb ft).
  4. Install the power steering return hoses (2,4) and retaining clamps to the power steering pump.
  5. Install the bolts (1) to the rear of the power steering pump. Tighten: Tighten the rear bolts to 50 N.m (37 lb ft).
  6. Install the power steering pump mounting bracket bolts. Tighten: Tighten the mounting bracket bolts to 50 N.m (37 lb ft).
  7. Install the bolts (2) to the front of the pump. Tighten: Tighten the power steering pump retaining bolts to 50 N.m (37 lb ft).
  8. Install the filler neck to the power steering pump.
  9. Install the nut (1) and clamp (3) retaining the filler neck to the power steering pump. Tighten: Tighten the filler neck retaining nut to 25 N.m (18 lb ft).
  10. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 33

Scheme 33: Removal Procedure
Scheme 33: Removal Procedure
  1. Place a drain pan under the vehicle.
  2. Remove the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  3. Remove the bolt retaining the battery junction block from the power steering bracket.
  4. Remove the bolts (1) from the rear of the pump.
  5. Remove the bolts (2) from the front of the pump.
  6. Remove the power steering pump mounting bracket retaining bolts to gain access to the power steering hoses.
  7. Remove the power steering return hoses (2,4) from the power steering pump.
  8. Remove the power steering pressure hose (2) from the power steering pump.
  9. Remove the power steering pump from the vehicle.
  10. Remove the rear bracket from the power steering pump.

Installation Procedure

  1. Install the rear bracket to the power steering pump. Tighten: Tighten the rear bracket retaining nuts to 50 N.m (37 lb ft).
  2. Install the power steering return hoses and retaining clamps (3,5) to the power steering pump.
  3. Install the power steering pressure hose (2) to the power steering pump. Tighten: Tighten the fitting to 28 N.m (20 lb ft).
  4. Install the bolts (1) to the rear of the power steering pump. Tighten: Tighten the rear bolts to 50 N.m (37 lb ft).
  5. Install the power steering pump mounting bracket and bolts. Tighten: Tighten the mounting bracket bolts to 46 N.m (34 lb ft).
  6. Install the bolts (2) to the front of the pump. Tighten: Tighten the power steering pump retaining bolts to 50 N.m (37 lb ft).
  7. Install the bolt retaining the battery junction block from the power steering bracket. Tighten: Tighten the battery junction block retaining bolt to 9 N.m (80 lb in).
  8. Install the power steering pulley. Refer to «Power Steering Pulley Replacement»(ref-238245-S25058667052006072400000) .
  9. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 34

Scheme 34: Removal Procedure
Scheme 34: Removal Procedure
  1. Disconnect the energy storage box before servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.
  2. Place a drain pan under the vehicle.
  3. Disconnect the power steering pump pressure hose from the power steering pump.
  4. Remove the clamps (2, 4) retaining the power steering return hoses (1, 5) to the power steering pump and remove the hoses.
  5. Disconnect the upper electrical connector (3) from the power steering pump by pressing down on the rear of the locking tab and pulling the connector outward.
  6. Disconnect the lower electrical connector (4) from the power steering pump by moving the locking lever over center and pulling the connector outward.
  7. Remove the bolts (2) retaining the power steering pump to the bracket.
  8. Remove the power steering pump from the vehicle.
  1. Install the power steering pump (1) to the vehicle.
  2. Install the bolts retaining the power steering pump to the power steering pump bracket. Tighten: Tighten the power steering pump mounting bolts to 25 N.m (18 lb ft).
  3. Connect the lower electrical connector (4) to the power steering pump.
  4. Connect the upper electrical connector (3) to the power steering pump.
  5. Install the power steering pump return hoses (1, 5) to the power steering pump.
  6. Install the clamps retaining the power steering return hoses to the power steering pump.
  7. Install the power steering pump pressure hose to the power steering pump. Tighten: Tighten the power steering pump pressure hose to 32 N.m (24 lb ft).
  8. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  9. Clean up any spilled power steering fluid from the hoses, connectors or pump.
  10. Connect the energy storage box after servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.
  11. Calibrate the brake pedal position sensor. Refer to «Brake Pedal Position Sensor Calibration Description and Operation»(ref-238245-S08553498542006072400000)

Scheme 35

Scheme 35: Removal Procedure
Scheme 35: Removal Procedure
  1. Remove the power steering pump from the bracket (3). Refer to «Power Steering Pump Replacement (4.3L)»(ref-238245-S27869478672006072400000) , «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-238245-S13268514532006072400000) , «Power Steering Pump Replacement (8.1L)»(ref-238245-S20383065892006072400000) , «Power Steering Pump Replacement (6.6L Diesel)»(ref-238245-S33311737962006072400000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-238245-S01243377872006072400000) .
  2. Remove the positive battery junction block bracket retaining bolts (2) from the power steering pump bracket.
  3. Remove the bolts retaining the power steering pump bracket (3) to the engine.
  4. Remove the power steering pump bracket from the vehicle.

Scheme 36

Scheme 36
Scheme 36
  1. Install the power steering pump (3) bracket to the engine. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
  2. Install the power steering pump bracket retaining bolts. Tighten: Tighten the power steering pump bracket retaining bolts to 25 N.m (18 lb ft).
  3. Install the power steering pump to the bracket. Refer to «Power Steering Pump Replacement (4.3L)»(ref-238245-S27869478672006072400000) , «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-238245-S13268514532006072400000) , «Power Steering Pump Replacement (8.1L)»(ref-238245-S20383065892006072400000) , «Power Steering Pump Replacement (6.6L Diesel)»(ref-238245-S33311737962006072400000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-238245-S01243377872006072400000) .
  4. Install the positive battery junction block bracket retaining bolts (2) to the power steering pump bracket. Tighten: Tighten the battery junction block retaining bolts to 9 N.m (80 lb in).

Scheme 37

Scheme 37: Removal Procedure
Scheme 37: Removal Procedure
  1. Disconnect the energy storage box before servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.
  2. Remove the coolant surge tank to gain access to the electrical connectors. Refer to «Surge Tank Replacement»(ref-238207-S06344072432006072400000) in Engine Cooling.
  3. Disconnect the electrical connectors (2) from the harness.
  4. Remove the bolt retaining the wiring harness bracket (3) from the engine block.
  5. Remove the electrical wiring harness clip (4) from the bracket.
  6. Disconnect the electrical connector (3) from the power steering pump (4) by pressing downward on the rear of the locking tab and pulling the connector outward.
  7. Remove the power steering pump wiring harness from the vehicle.

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39
  1. Install the power steering wiring harness to the vehicle.
  2. Connect the power steering pump wiring harness electrical connector (3) to the power steering pump (4).
  3. Install the electrical wiring harness clip (4) to the bracket.
  4. Install the bolt retaining the wiring harness bracket (3) to the engine block. Tighten: Tighten the bolt retaining the ground to the engine block to 9 N.m (80 lb in).
  5. Connect the electrical connectors (2) to the wiring harness.
  6. Install the coolant surge tank to the vehicle. Refer to «Surge Tank Replacement»(ref-238207-S06344072432006072400000) in Engine Cooling.
  7. Connect the energy storage box after servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.

Scheme 40

Scheme 40: Disassembly Procedure
Scheme 40: Disassembly Procedure

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42
  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 (5). To remove the variable assist steering actuator (3) and retaining ring (4); refer to «Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle»(ref-238245-S06819182802006072400000) .
  4. Remove the O-ring seal (6) 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 (Regular)»(ref-238245-S36093592802006072400000) .
  6. Remove the reservoir assembly (1) from the pump housing assembly (2).
  7. Remove the O-ring seals (1) (4).
  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 housing (2).
  1. Remove the power steering pump from the vehicle. Refer to «Power Steering Pump Replacement (4.3L)»(ref-238245-S27869478672006072400000) , «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-238245-S13268514532006072400000) , «Power Steering Pump Replacement (8.1L)»(ref-238245-S20383065892006072400000) , «Power Steering Pump Replacement (6.6L Diesel)»(ref-238245-S33311737962006072400000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-238245-S01243377872006072400000) .
  2. Use a chisel in order to cut and remove the seal.
  1. Lubricate the seal using power steering fluid.
  2. Use a deep 1 inch tall socket in order to install the seal.
  3. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(ref-238245-S27869478672006072400000) , «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-238245-S13268514532006072400000) , «Power Steering Pump Replacement (8.1L)»(ref-238245-S20383065892006072400000) , «Power Steering Pump Replacement (6.6L Diesel)»(ref-238245-S33311737962006072400000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-238245-S01243377872006072400000) .

Scheme 43

Scheme 43: Disassembly Procedure
Scheme 43: Disassembly Procedure
  1. Remove the electrical connector from the variable assist steering actuator (1).
  2. Remove pump assembly from the vehicle, if the variable assist steering actuator (1) is not accessible. Refer to «Power Steering Pump Replacement (4.3L)»(ref-238245-S27869478672006072400000) , «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-238245-S13268514532006072400000) , «Power Steering Pump Replacement (8.1L)»(ref-238245-S20383065892006072400000) , «Power Steering Pump Replacement (6.6L Diesel)»(ref-238245-S33311737962006072400000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-238245-S01243377872006072400000) .
  3. Remove the retaining ring (2) from the variable assist steering actuator (1).
  4. Remove the variable assist steering actuator (1).
  5. Remove the O-ring seal from the variable assist steering actuator.
  1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
  2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-238261-S35716783552006072400000) in Tires and Wheels.
  3. Remove the torque prevailing nut from outer tie rod stud.
  4. Loosen the jam nut (2) on the inner tie rod assembly (1).
  5. Remove the outer tie rod assembly (2) from the steering knuckle (1) using J 24319-01 . See «Special Tools»(ref-238245-S22550396302006072400000) .
  6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1).
  1. Connect the outer tie rod assembly (3) to the inner tie rod (1). Do not tighten the jam nut (2).
  2. Install the tie rod seal (2) to the outer tie rod assembly (1).
  3. Connect the outer tie rod assembly (1) to the steering knuckle (2). NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
  4. Install the torque prevailing nut (3) to the outer tie rod stud (1). Tighten: Tighten the torque prevailing nut (3) to 50 N.m (37 lb ft).
  5. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(ref-238306-S31266173742006072400000) in Wheel Alignment.
  1. Install the power steering cooler (1) to the radiator support. Tighten: Tighten the bolts retaining the power steering cooler to 5 N.m (44 lb in).
  2. Install the power steering cooler outlet hose (3) to the power steering pump (2).
  3. Install the retaining clamp.
  4. Install the power steering inlet hose (5) to the power steering gear (1).
  5. Install the retaining clamp.
  6. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  7. Inspect all the hose connections for leaks.
  8. Install the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.
  1. Remove the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.
  2. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4).
  3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5).
  4. Remove the bolts (2) retaining the power steering cooler from the radiator support.
  5. Remove the power steering cooler from the vehicle.
  1. Install the power steering cooler (1) to the vehicle. Tighten: Tighten the power steering cooler retaining bolts to 5 N.m (44 lb in).
  2. Connect the power steering outlet hose (3) to the power steering gear (4).
  3. Install the retaining clamp.
  4. Connect the power steering inlet hose to the power steering pump.
  5. Install the retaining clamp.
  6. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  7. Inspect all the hose connections for leaks.
  8. Install the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.
  1. Remove the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.
  2. Remove the power steering outlet hose (4) from the power steering gear (3).
  3. Remove the power steering inlet hose from the power steering pump (1).
  4. Remove the bolts (2) retaining the cooler to the radiator support.
  5. Remove the power steering cooler from the vehicle.
  1. Install the power steering cooler (1) to the vehicle. Tighten: Tighten the power steering cooler retaining bolts to 5 N.m (44 lb in).
  2. Connect the power steering inlet hose to the power steering pump (5). Install the retaining clamp.
  3. Connect the power steering outlet hose (4) to the power steering gear (3). Install the retaining clamp.
  4. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  5. Inspect all the hose connections for leaks.
  6. Install the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.

Scheme 44

Scheme 44: Removal Procedure
Scheme 44: Removal Procedure
  1. Disconnect the energy storage box before servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.
  2. Remove the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.
  3. Place a drain pan under the vehicle.
  4. Siphon the fluid from the reservoir to prevent excess spillage.
  5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear.
  6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1).
  7. Remove the bolts (2) retaining the power steering cooler from the radiator support.
  8. Remove the power steering cooler from the vehicle.
  1. Install the power steering cooler (1) to the radiator support. Tighten: Tighten the bolts retaining the power steering cooler to 5 N.m (44 lb in).
  2. Install the power steering cooler outlet hose (2) to the power steering pump (1).
  3. Install the retaining clamp.
  4. Install the power steering inlet hose (3) to the power steering gear (1).
  5. Install the retaining clamp.
  6. Fill and bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  7. Inspect all the hose connections for leaks.
  8. Install the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) in Exterior Trim.
  9. Connect the energy storage box after servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.

Scheme 45

Scheme 45: Removal Procedure
Scheme 45: Removal Procedure
  1. Disconnect the energy storage box before serving the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.
  2. Install a drain pan under the vehicle.
  3. Remove the power steering gear inlet hose (4) from the brake booster.
  4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster.
  5. Remove the power brake booster inlet hose (1) from the brake booster.
  6. Remove the power steering gear inlet hose (4) from the power steering gear.
  7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump.
  8. Remove the power brake booster inlet hose from the power steering pump.
  9. Remove the power steering hose assembly from the vehicle.
  1. Install the gear inlet hose to the gear (4).
  2. Install the booster inlet hose to the pump.
  3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp.
  4. Install the booster inlet hose (1) to the booster.
  5. Install the gear inlet hose to the booster. Tighten: Tighten both power steering inlet hose fittings to 32 N.m (24 lb ft).
  6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2).
  7. Remove the drain pan from under the vehicle.
  8. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  9. Connect the energy storage box after servicing the vehicle. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-238198-S14706325592006072400000) in Engine Electrical.

Scheme 46

Scheme 46: Removal Procedure
Scheme 46: Removal Procedure
  1. Install a drain pan under the vehicle.
  2. Remove the power steering gear inlet hose (1) from the brake booster.
  3. Remove the power steering gear inlet hose from the power steering gear.
  4. Remove the power steering gear inlet hose from the vehicle.
  1. Route the hose in the same position the hose occupied prior to removal.
  2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only.
  3. Install the power steering gear inlet hose to the power steering gear. Tighten: Tighten both power steering gear inlet hose fittings to 28 N.m (20 lb ft).
  4. Remove the drain pan from under the vehicle.
  5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 47

Scheme 47: Removal Procedure
Scheme 47: Removal Procedure
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
  2. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
  3. Install a drain pan under the vehicle.
  4. Remove the power steering gear inlet hose (3) from the power steering pump (1).
  5. Remove the power steering gear inlet hose from the power steering gear.
  6. Remove the power steering gear inlet hose from the vehicle.
  1. Route the hose in the same position the hose occupied prior to removal.
  2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only.
  3. Install the power steering gear inlet hose to the power steering gear. Tighten: Tighten both power steering gear inlet hose fittings to 28 N.m (20 lb ft).
  4. Remove the drain pan from under the vehicle.
  5. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
  6. Lower the vehicle.
  7. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Note. Refer to POWER STEERING HOSE DISCONNECTED NOTICE in Cautions and Notices.

Scheme 48

Scheme 48: Removal Procedure
Scheme 48: Removal Procedure
  1. Remove the power steering inlet hose (2) from the power steering pump (1).
  2. Remove the power steering inlet hose (2) from the power steering gear (3).
  1. Connect the power steering inlet hose (2) to the power steering gear (3).
  2. Connect the power steering inlet hose (2) to the power steering pump (1). Tighten: Tighten the hose connections to 28 N.m (20 lb ft.)
  3. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  4. Inspect all the hose connections for leaks.

Scheme 49

Scheme 49: Removal Procedure
Scheme 49: Removal Procedure
  1. Install a drain pan under the vehicle.
  2. Remove the power steering gear outlet hose (3) from the steering gear (2).
  3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1). Remove the power steering gear outlet hose from the power steering pump.
  4. 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 power steering gear outlet hose (3) to the power steering pump (1). Position the clamp at the end of the hose.
  3. Install the power steering gear outlet hose to the power steering gear. Tighten: Tighten the outlet hose fitting to 28 N.m (20 lb ft).
  4. Remove the drain pan from under the vehicle.
  5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Note. Refer to POWER STEERING HOSE DISCONNECTED NOTICE in Cautions and Notices.

  1. Remove the power steering outlet hose (4) from the power steering gear (3).
  2. Remove the power steering outlet hose (4) from the power steering cooler (5).
  1. Connect the power steering outlet hose (4) to the power steering cooler (5).
  2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only.
  3. Connect the power steering outlet hose (2) to the power steering pump (1). Tighten: Tighten both hose connections to 28 N.m (20 lb ft).
  4. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .
  5. Inspect all the hose connections for leaks.

Scheme 50

Scheme 50: Removal Procedure
Scheme 50: Removal Procedure
  1. Install a drain pan under the vehicle.
  2. Remove the brake booster inlet hose (1) from the brake booster (2).
  3. Remove the brake booster inlet hose from the power steering pump.
  4. Remove the brake booster inlet hose from the vehicle.
  1. Route the hose in the same position the hose occupied prior to removal.
  2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only.
  3. Install the brake booster inlet hose to the power steering pump. Tighten: Tighten the brake booster inlet hose fittings to 28 N.m (20 lb ft).
  4. Remove the drain pan from under the vehicle.
  5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 51

Scheme 51: Removal Procedure
Scheme 51: Removal Procedure
  1. Install a drain pan under the vehicle.
  2. Remove the brake booster outlet hose (1) from the brake booster (2).
  3. Remove the clamp retaining the brake booster outlet hose to the power steering pump.
  4. Remove the brake booster outlet hose from the vehicle.
  1. Route the hose in the same position the hose occupied prior to removal.
  2. Install the brake booster outlet hose (1) to the brake booster (2). Position the clamp at the end of the hose.
  3. Install the brake booster outlet hose to the power steering pump (4). Position the clamp at the end of the hose.
  4. Remove the drain pan from under the vehicle.
  5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 52

Scheme 52: Removal Procedure
Scheme 52: Removal Procedure

Scheme 53

Scheme 53
Scheme 53
  1. Raise the vehicle on a hoist. Support the vehicle with suitable safety stands. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
  2. Remove both of the front tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-238261-S35716783552006072400000) in Tires and Wheels.
  3. Remove the engine shield, if equipped. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
  4. Remove the outer tie rod end from the steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-238245-S13280589462006072400000) .
  5. Remove the stabilizer bar mounting brackets from the frame and lower the stabilizer bar.
  6. Place a drain pan under the lines in order to catch the fluid.
  7. Remove the power steering high pressure line (2) from the rack and pinion assembly (3).
  8. Remove the power steering low pressure line (1) from the rack and pinion assembly (3).
  9. Disconnect the intermediate shaft from the rack and pinion assembly. Refer to «Intermediate Steering Shaft Replacement - Lower»(ref-238184-S04023553392006072400000) in Steering Wheel and Column.
  10. Remove the rack and pinion assembly mounting nuts (1), the washers (2) and the bolts (4).
  11. Remove the rack and pinion assembly (3) from the vehicle.
  1. Install the rack and pinion assembly (3) into the vehicle.
  2. Install the rack and pinion assembly mounting bolts (4), the washers (2) and the nuts (1). Tighten: Tighten the nuts to 185 N.m (136 lb ft).
  3. Connect the intermediate shaft to the rack and pinion assembly. Refer to «Intermediate Steering Shaft Replacement - Lower»(ref-238184-S04023553392006072400000) in Steering Wheel and Column.
  4. Install the power steering low pressure hose (1) to the rack and pinion assembly (3).
  5. Install the power steering high pressure hose (2) to the rack and pinion assembly (3). Tighten: Tighten both hoses to 28 N.m (20 lb ft).
  6. Install the engine protection shield, if equipped. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
  7. Install the outer tie rod end to the steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-238245-S13280589462006072400000) .
  8. Install the stabilizer bar mounting brackets to the frame. Tighten: Tighten the bolts to 33 N.m (24 lb ft).
  9. If the steering gear is equipped with a ground strap, install the ground strap to the crossmember bracket. Place the ground strap on the left side of the bracket and mark the location. Center punch the bolt hole location. Drill a hole using a 7 mm (9/32 in) drill bit. Install the bolt and washer retaining the ground strap to the crossmember. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  10. Install both of the front tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-238261-S35716783552006072400000) in Tires and Wheels.
  11. Remove the safety stands.
  12. Lower the vehicle.
  13. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Power Steering Gear Replacement (Non Rack and Pinion)

Tools Required

  1. J 6632-01 Pitman Arm Puller. See «Special Tools»(ref-238245-S22550396302006072400000) .
  2. J 24319-B Universal Steering Linkage Puller
  3. J 29107-A Pitman Arm Puller. See «Special Tools»(ref-238245-S22550396302006072400000) .

Scheme 54

Scheme 54: Removal Procedure
Scheme 54: Removal Procedure

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57

Scheme 58

Scheme 58
Scheme 58
  1. Place a drain pan under the vehicle.
  2. Remove the engine protection shield, if equipped. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
  3. For vehicles equipped with a 6.6L diesel, remove the left charge air cooler hose. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Left)»(ref-238224-S26744735612006072400000) or «Charged Air Cooler Hoses/Pipes Replacement (Right)»(ref-238224-S09843896152006072400000) in Engine Mechanical - 6.6L (LLY).
  4. Remove the power steering hoses from the steering gear.
  5. Cap the ends of the hoses and the power steering gear in order to prevent any entrance of dirt.
  6. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(ref-238184-S04023553392006072400000) in Steering Wheel and Column.
  7. Remove the pitman arm to relay rod nut.
  8. Disconnect the pitman arm from the relay rod using the J 24319-B .
  9. Remove the bolts retaining the steering gear to the frame.
  10. Remove the steering gear from the vehicle.
  11. Remove the pitman arm to the power steering gear retaining nut.
  12. Remove the pitman arm from the power steering gear using the J 6632-01 or the J 29107-A . See «Special Tools»(ref-238245-S22550396302006072400000) .
  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 steering gear to the frame and install the retaining bolts. Tighten: Tighten the bolts to 150 N.m (110 lb ft).
  4. Install the pitman arm to the relay rod.
  5. Install the pitman arm to the relay rod nut. Tighten: Tighten the nut to 62 N.m (46 lb ft).
  6. Install the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement - Lower»(ref-238184-S04023553392006072400000) in Steering Wheel and Column.
  7. Remove the caps or plugs from the steering gear and hoses.
  8. Install the hoses to the steering gear. Tighten: Tighten the hose fittings to 28 N.m (20 lb ft).
  9. For vehicles equipped with a 6.6L diesel, install the left charge air cooler hose. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Left)»(ref-238224-S26744735612006072400000) or «Charged Air Cooler Hoses/Pipes Replacement (Right)»(ref-238224-S09843896152006072400000) in Engine Mechanical - 6.6L (LLY).
  10. Install the engine protection shield, if equipped. Refer to «Engine Protection Shield Replacement»(ref-238217-S17740186002006072400000) in Frame and Underbody.
  11. Remove the safety stands.
  12. Lower the vehicle.
  13. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-238245-S37963845102006072400000) .

Scheme 59

Scheme 59: Rack and Pinion Gear Rack Bearing Preload Adjustment - Off Vehicle (Rack and Pinion)
Scheme 59: Rack and Pinion 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).

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

Tools Required

  1. J 21552 Rack Piston Arbor. See «Special Tools»(ref-238245-S22550396302006072400000) .
  2. J 8947 Rack Piston Teflon Ring Compressor. See «Special Tools»(ref-238245-S22550396302006072400000) .

Scheme 60

Scheme 60: Disassembly Procedure
Scheme 60: Disassembly Procedure

Scheme 61

Scheme 61
Scheme 61
  1. Remove the pitman shaft seals and bearing. Refer to «Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)»(ref-238245-S42640168052006072400000) .
  2. Remove the housing end plug. Refer to «Steering Gear Housing End Plug Replacement - Off Vehicle»(ref-238245-S16673142602006072400000) .
  3. Turn the stub shaft counterclockwise until the rack piston (2) begins to come out of the steering gear housing (3).
  4. Remove the rack piston plug (1).
  5. Insert J 21552 into the bore of the rack piston (2). See «Special Tools»(ref-238245-S22550396302006072400000) .
  6. Hold J 21552 tightly against the worm shaft while turning the stub shaft counterclockwise. See «Special Tools»(ref-238245-S22550396302006072400000) . Turning the stub shaft forces the rack piston (2) onto J 21552 . See «Special Tools»(ref-238245-S22550396302006072400000) . The rack piston balls remain in place.
  7. Remove the following items as an assembly from the steering gear housing (9): The rack piston (4) The rack piston screws (8), clamp (7), ball guide (6) and balls (5) J 21552 . See «Special Tools»(ref-238245-S22550396302006072400000) .
  8. Remove the spool valve assembly. Refer to «Steering Gear Valve Replacement - Off Vehicle (700 Gear)»(ref-238245-S28898052372006072400000) .
  9. Remove the worm shaft (14).
  10. Remove the thrust bearing (12) and the flat races (11, 13).
  11. Remove J 21552 from the rack piston (4). See «Special Tools»(ref-238245-S22550396302006072400000) .
  12. Remove the rack piston balls (5).
  13. Remove the following items from the rack piston (4): The screws (8) The clamp (7) The ball guide (6) The remaining rack piston balls (5) in the ball guide (6)
  14. Remove the teflon ring (2).
  15. Remove the O-ring seal (3).
  16. Clean all of the disassembled parts.
  17. Inspect all of the disassembled parts for wear.
  18. Replace the parts if necessary.

Scheme 62

Scheme 62: Assembly Procedure
Scheme 62: Assembly Procedure

Scheme 63

Scheme 63
Scheme 63

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65
Scheme 65

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67
  1. Install the O-ring seal (3) and the teflon ring (2).
  2. Lubricate both parts with power steering fluid.
  3. Install the worm shaft (14) to the rack piston (4) outside of the steering gear housing (9). Fully seat the worm shaft to the rack piston.
  4. Align the worm shaft spiral groove with the rack piston ball return guide hole (1).
  5. Lubricate the rack piston balls with power steering fluid.
  6. Insert the rack piston balls through the ball return guide hole (1) while turning worm shaft (2) counterclockwise in order to install the rack piston balls into the rack piston. Install the black and the silver rack piston balls alternately into the rack piston and the ball guide to maintain the rack piston to the worm shaft preload.
  7. Install the remaining rack piston balls (3) into the ball guide (1) using grease at each end (2) to retain the rack piston balls (3).
  8. Install the ball guide (3) to the rack piston (2).
  9. Install the ball guide clamp (4).
  10. Install the screws (5). Tighten: Tighten the screws (5) to 6 N.m (53 lb in).
  11. Insert J 21552 into the bore of the rack piston while turning the worm shaft counterclockwise. See «Special Tools»(ref-238245-S22550396302006072400000) . The turning of the worm shaft forces the rack piston onto J 21552 . See «Special Tools»(ref-238245-S22550396302006072400000) . The rack piston balls remain in place.
  12. Install the flat races (2, 4) and the thrust bearing (3) onto the worm shaft (1).
  13. Install the worm shaft (4) to the steering gear housing (3).
  14. Install the spool valve. Refer to «Steering Gear Valve Replacement - Off Vehicle (700 Gear)»(ref-238245-S28898052372006072400000) .
  15. Install the rack piston (2) to the worm (4) from J 21552 using J 8947 to compress the seals. See «Special Tools»(ref-238245-S22550396302006072400000) .
  16. Hold J 21552 tightly against the worm shaft (4). See «Special Tools»(ref-238245-S22550396302006072400000) .
  17. Turn the stub shaft clockwise until the rack piston (2) is seated on the worm shaft (4).
  18. Remove J 21552 from the rack piston (1). See «Special Tools»(ref-238245-S22550396302006072400000) .
  19. Install the rack piston plug (1). Tighten: Tighten the rack piston plug to 150 N.m (111 lb ft).
  20. Install the housing end plug. Refer to «Steering Gear Housing End Plug Replacement - Off Vehicle»(ref-238245-S16673142602006072400000) .
  21. Install the pitman shaft seals and bearing. Refer to «Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)»(ref-238245-S42640168052006072400000) .
  22. To adjust the steering gear; refer to one of the following procedures: «Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)»(ref-238245-S05506265442006072400000) «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(ref-238245-S35339312402006072400000)

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

Tools Required

  1. J 6278 Pitman Shaft Bearing Remover and Installer. See «Special Tools»(ref-238245-S22550396302006072400000) .
  2. J 4245 Internal Snap Ring Pliers. See «Special Tools»(ref-238245-S22550396302006072400000) .

Scheme 68

Scheme 68: Disassembly Procedure
Scheme 68: Disassembly Procedure

Scheme 69

Scheme 69
Scheme 69

Scheme 70

Scheme 70
Scheme 70
  1. Remove the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (670 Gear)»(ref-238245-S40447259652006072400000) .
  2. Remove the pitman arm (3) from the steering gear (1).
  3. Remove the pitman shaft boot (2).
  4. Remove the dust seal (1).
  5. Remove the retaining ring using the J 4245 . See «Special Tools»(ref-238245-S22550396302006072400000) .
  6. Use a screwdriver to pry the backup washer (3) and the double lip seal (2) from the steering gear housing (1).
  7. Inspect the steering gear housing (1) for burrs.
  8. Insert J 6278 through the hole in the top of the steering gear housing (1). See «Special Tools»(ref-238245-S22550396302006072400000) .
  9. Drive out the needle bearing (2).

Scheme 71

Scheme 71: Assembly Procedure
Scheme 71: Assembly Procedure

Scheme 72

Scheme 72
Scheme 72

Scheme 73

Scheme 73
Scheme 73
  1. Install the needle bearing (2) to the steering gear housing (1) using the J 6278 . See «Special Tools»(ref-238245-S22550396302006072400000) .
  2. Coat the double lip seal (2) and the washer (3) with grease.
  3. Install the double lip seal (2).
  4. Install the backup washer (3).
  5. Install the retaining ring using the J 4245 . See «Special Tools»(ref-238245-S22550396302006072400000) .
  6. Install the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (670 Gear)»(ref-238245-S40447259652006072400000) .
  7. Install the dust seal (1).
  8. Install the pitman shaft boot (2).
  9. Install the pitman arm (3) to the steering gear (1).
  10. Install the lock washer (4).
  11. Install the nut (5). Tighten: Tighten the pitman arm nut to 250 N.m (184 lb ft).
  12. Refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(ref-238245-S35339312402006072400000) to adjust the pitman shaft.

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

Tools Required

  1. J 42882 Adjuster Nut Socket. See «Special Tools»(ref-238245-S22550396302006072400000) .
  2. J 43435 Adjuster Lock Nut Wrench. See «Special Tools»(ref-238245-S22550396302006072400000) .

Scheme 74

Scheme 74
Scheme 74

Scheme 75

Scheme 75
Scheme 75
  1. Rotate the stub shaft back and forth in order to drain the power steering fluid.
  2. Remove the coupling shield retainer and the lock nut from the steering gear housing using J 43435 and a torque wrench. See «Special Tools»(ref-238245-S22550396302006072400000) .
  3. Remove the adjuster nut assembly (2) from the steering gear housing (1) using J 42882 . See «Special Tools»(ref-238245-S22550396302006072400000) .
  4. Remove the thrust support assembly (2) from the steering gear housing (1).
  5. Remove the O-ring seal (3) from the thrust support assembly (2).

More articles — Power Steering System