Power Steering System: Other Chevrolet Silverado 2500

Tools Required

1. J 35555 Metal Mityvac™
2. J 43485 Power Steering Bleeder Adapter

Important: Hoses touching the frame, body, or engine may cause system noise.

Scheme 64

1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system.
2. Verify that all hose connections are tight. NOTE: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Important: Maintain the fluid level throughout the bleed procedure.
3. Remove the pump reservoir cap Important: Use clean, new power steering fluid only.
4. Fill the pump reservoir with fluid to the FULL COLD level.
5. Attach the J 43485 to the J 35555 or equivalent.
6. Place the J 43485 on or in the pump reservoir filler neck.
7. Apply a vacuum of 68 kPa (20 in Hg) maximum.
8. Wait 5 minutes. Typical vacuum drop is 7-10 kPa (2-3 in Hg). If the vacuum does not remain steady, refer to «Excessive Vacuum Drop Diagnosis»(ref-175031-S42361360312005041400000) .
9. Remove the J 43485 and J 35555 .
10. Reinstall the pump reservoir cap.
11. Start the engine. Allow the engine to idle.
12. Turn off the engine.
13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock.
14. Start the engine. Allow the engine to idle.
15. Turn the steering wheel 180-360 degrees in both directions 5 times.
16. Switch the ignition off. NOTE: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
17. Verify the fluid level.
18. Remove the pump reservoir cap.
19. Attach the J 43485 to the J 35555 or equivalent.
20. Place the J 43485 on or in the pump reservoir filler neck.
21. Apply a vacuum of 68 kPa (20 in Hg) maximum.
22. Wait 5 minutes.
23. Remove the J 43485 and the J 35555 .
24. Verify the fluid level.
25. Reinstall the pump reservoir cap.

Scheme 65

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

1. J 25034-C Power Steering Pump Pulley Remover
2. J 25033-C Power Steering Pump Pulley Installer

J 34028 Inner Tie Rod Wrench

Scheme 66

1. Raise the vehicle. Support the vehicle with suitable safety stands.
2. Remove the tire and wheel assembly from the vehicle.
3. Remove the rack and pinion boot. Refer to «Rack & Pinion Boot Replacement - On Vehicle»(ref-175031-S17536811742005041400000) . NOTE: Do not change the rack bearing preload adjustment before removing the inner tie rod from the steering rack. This could cause damage to the pinion or the steering rack or both.
4. Remove the shock dampener (2) from the inner tie rod (5).
5. Slide the shock dampener (2) back onto the rack (1). Important: Do not hold the steering rack while removing the inner tie rod if the preload adjustment has not been changed.
6. Remove the inner tie rod (5) from the rack assembly (1) as follows: Place a wrench on the flats of the inner tie rod housing (4) Rotate the inner tie rod housing (4) counterclockwise until the inner tie rod (5) separates from the rack.
7. Remove the old Loctite® from the threads (2) of the rack (1) and the inner tie rod (3).

J 24319-01 Universal Steering Linkage Puller

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1. Raise the vehicle. Support the vehicle with suitable safety stands.
2. Remove the tire and wheel assembly.
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 .
6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1).

J 22610 Service Boot Clamp Installer

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Scheme 73

1. Raise the vehicle. Support the vehicle with suitable safety stands.
2. Remove the outer tie rod. Refer to «Tie Rod End Replacement - Outer»(ref-175031-S18818581722005041400000) .
3. Remove the hexagon jam nut (2) from the inner tie rod assembly (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). Important: Prior to removing the breather tube or the rack and pinion boot, mark the location of the breather tube on the gear assembly.
7. Remove the rack and pinion boot (1) and the breather tube from the rack and pinion gear assembly.

J 22610 Service Boot Clamp Installer

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Scheme 75

1. To remove the outer tie rod. Refer to «Tie Rod End Replacement - Outer»(ref-175031-S18818581722005041400000) .
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). Important: If a breather tube is present, mark the location of the breather tube on the gear assembly before removal of the rack and pinion boot.
6. Remove the rack and pinion boot (1) and the breather tube, if present, from the rack and pinion gear assembly.

J 34028 Inner Tie Rod Wrench

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Scheme 77

1. To remove the rack and pinion boot and the breather tube. Refer to «Rack & Pinion Boot & Breather Tube Replacement - Off Vehicle»(ref-175031-S29154656872005041400000) .
2. Place the gear in a vise. NOTE: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear.
3. Remove the shock dampener (4) from the inner tie rod housing (6).
4. Slide the shock dampener (4) back on the rack (5).
5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (6).
6. Place a wrench on the flats of the inner tie rod housing (6).
7. Rotate the inner tie rod housing (6) counterclockwise, while holding the rack stationary, until the inner tie rod separates from the rack (5). NOTE: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear.
8. Remove the shock dampener (3) from the inner tie rod housing (2).
9. Slide the shock dampener (3) back on the rack (5).
10. Place a pipe wrench on the rack.
11. Place a wrench on the flats of the inner tie rod housing (2).
12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary, until the inner tie rod (1) separates from the rack (5).
13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE® from the threads (2) of the inner tie rod and the rack. If male rack (5) and female inner tie rod (4) LOCTITE® will not be present.

Scheme 78

Scheme 79

1. Slide the shock dampener (4) forward onto the rack (3). Important: Threads must be clean prior to LOCTITE® application. Check LOCTITE®, or equivalent, container for expiration date. Use only enough LOCTITE® to evenly coat threads. If male rack (3) and female inner tie rod (2) do not apply LOCTITE®.
2. If female rack (3) and male inner tie rod (2), apply LOCTITE® 262, or equivalent, to the inner tie rod threads.
3. Attach the inner tie rod onto the rack (3).
4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2).
5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). Tighten the inner tie rod to 100 N.m (74 ft lbs).
6. Slide the shock dampener (2) forward onto the rack. Important: Threads must be clean prior to LOCTITE® application. Check Loctite®, or equivalent, container for expiration date. Use only enough LOCTITE® to evenly coat threads. If male rack and female inner tie rod (1) do not apply LOCTITE®.
7. If female rack and male inner tie rod (1), apply LOCTITE® 262, or equivalent, to the inner tie rod threads.
8. Attach the inner tie rod (1) onto the rack.
9. Place a pipe wrench on the rack next to the inner tie rod housing (4).
10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). Tighten the inner tie rod to 100 N.m (74 ft lbs).
11. Place the inner tie rod assembly (2) in a vise. Important: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and female inner tie rod (2) you must stake.
12. Stake both sides of the female inner tie rod assembly housing to the male rack.
13. Insert a 0.010 inch gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler (1) must not pass between the rack and the housing stake.
14. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener (2) bottoms against the inner tie rod housing (3).
15. To assemble the rack and pinion boot and the breather tube.

Scheme 80

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).

J 29810 Stub Shaft Seal Protector

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Scheme 83

1. Remove the adjuster plug lock nut (5) from the adjuster plug (4).
2. Remove the adjuster plug (4) from the gear assembly (1).
3. Remove the adjuster spring (3) and the rack bearing (2).
4. Remove the spool shaft boot (1) from the rack and pinion gear assembly.
5. Remove the retaining ring (2) from the valve bore of the rack and pinion gear assembly.
6. Remove the dust cover (4) from the bottom of the rack and pinion gear assembly.
7. Remove the hex lock nut (3) from the lower end of the pinion and valve assembly while holding the stub shaft with a 14 mm crowfoot wrench. Important: When performing the following procedure, do not remove pinion and valve assembly from the rack and pinion gear assembly (5). Press the pinion and valve assembly only far enough to allow removal of the stub shaft bearing annulus (3) and the stub shaft seal (2).
8. Using an arbor press (1), press on the threaded end of the pinion until removal of the following items is possible: 8.1. The stub shaft (4) 8.2. The stub shaft seal (2) 8.3. The stub shaft bearing annulus assembly (3)

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Scheme 89

1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft. Tighten the nut to 30 N.m (22 ft lbs)
2. Install the dust cover (2) to the rack and pinion gear assembly.
3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2).
4. Install J 29810 onto the valve stub shaft.
5. Lubricate the stub shaft seal (3) with grease
6. Install the stub shaft seal (3) into the rack and pinion gear assembly.
7. Install the retaining ring (2) into the groove in the rack and pinion gear assembly.
8. Install the spool shaft boot (1) onto the rack and pinion gear assembly.
9. Lubricate the following items with lithium base grease: 9.1. The rack bearing (2) 9.2. The adjuster spring (3) 9.3. The adjuster plug (4)
10. Install the following items into the gear assembly: 10.1. The rack bearing (2) 10.2. The adjuster spring (3) 10.3. The adjuster plug (4)
11. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster plug (1) back 50 degrees to 70 degrees.
12. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 N.m (16 in lbs).
13. Install the adjuster plug lock nut (5) to the adjuster plug (4). Finger tighten the lock nut while holding the adjuster plug stationary.

1. J 42882 Adjuster Nut Socket
2. J 43435 Adjuster Lock Nut Wrench

Scheme 90

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Scheme 94

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.
3. Turn the adjuster nut assembly (1) clockwise using J 42882 until the adjuster nut assembly (1) and the thrust support assembly (2) are firmly bottomed in the steering gear housing (3). Tighten the adjuster nut assembly (1) to 28-31 N.m (20-23 ft lbs).
4. Place an index mark (1) on the steering gear housing (4) parallel with one of the holes (3) in the adjuster nut assembly (2).
5. Measure back counterclockwise 13 mm (1/2 in).
6. Place a second mark (2) on the steering gear housing (1).
7. Using J 42882 and a torque wrench, turn the adjuster nut assembly (1) counterclockwise 15-25 degrees to align the hole (2) in the adjuster nut assembly (1) with the second mark (4) on the steering gear housing (3).
8. Install the coupling shield retainer and the lock nut.
9. Hold the adjuster nut assembly in position to maintain alignment of the marks.
10. Tighten the coupling shield retainer and the lock nut using J 43435 and a torque wrench. Tighten the coupling shield retainer and the lock nut to 109 N.m (80 ft lbs).
11. To adjust the pitman shaft, refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(ref-175031-S37273800422005041400000) .

Scheme 95

Scheme 96

1. Adjust the worm shaft and valve. Refer to «Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)»(ref-175031-S38027584492005041400000) .
2. Rotate the stub shaft (3) back and forth to drain the power steering fluid.
3. Loosen the adjuster lock nut (4).
4. Turn the pitman shaft adjuster screw (1) counterclockwise until the screw is fully extended.
5. Turn the pitman shaft adjuster screw (1) clockwise 1 full turn.
6. Rotate the stub shaft (3) from stop to stop using a 12-point socket while counting the number of turns.
7. Starting at either stop, turn the stub shaft (3) back half of the total number of turns. This is the center of the gear.
8. Make sure that the gear is centered by checking the following items: The flat on the stub shaft (3) faces upward. The flat on the stub shaft (3) is parallel with the side cover (2).
9. Align the master spline (5) on the pitman shaft (4) with the adjuster screw (1).
10. Place a torque wrench on the stub shaft (2) with the handle in the vertical position.
11. Rotate the stub shaft (2) 45 degrees from each side of the center of the stub shaft. The stub shaft (2) must rotate smoothly.
12. Record the worm bearing preload measured on or near the center (1). The recorded bearing preload must be 0.7-1.7 N.m (6-15 in lbs) with the worm and the ball nut installed. If the torque is outside of this range, readjust or repair the steering gear assembly as required.
13. To obtain the correct preload torque, adjust the over-center torque by turning the pitman shaft adjuster screw clockwise.
14. Add 0.7-1.1 N.m (6-10 in lbs) torque to the previously measured worm bearing preload torque. Tighten the adjuster lock nut to 49 N.m (36 ft lbs). Prevent the adjuster screw from turning while tightening the adjuster lock nut.

Scheme 97

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

1. J 21552 Rack Piston Arbor
2. J 8947 Rack Piston Teflon Ring Compressor

1. J 6278 Pitman Shaft Bearing Remover and Installer
2. J 4245 Internal Snap Ring Pliers

Scheme 98

Scheme 99

1. Remove the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft & Housing Cover Replacement - Off Vehicle (700 Gear)»(ref-175031-S03861701352005041400000) or «Steering Gear Pitman Shaft & Housing Cover Replacement - Off Vehicle (670 Gear)»(ref-175031-S06170758992005041400000) .
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 . Important: Do care not to score the steering gear housing bore when prying out the seals and the washers.
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).
9. Drive out the needle bearing (2).

Scheme 100

1. Install the needle bearing (2) to the steering gear housing (1) using the J 6278 .
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 Important: Do not install the lock washer and nut until complete installation of the pitman arm and it's components have been installed. Do not adjust the pitman shaft until all components have been installed on the steering gear housing.
6. Install the pitman shaft and the side cover. Refer to «Steering Gear Pitman Shaft & Housing Cover Replacement - Off Vehicle (700 Gear)»(ref-175031-S03861701352005041400000) or «Steering Gear Pitman Shaft & Housing Cover Replacement - Off Vehicle (670 Gear)»(ref-175031-S06170758992005041400000) .
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).
12. Refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(ref-175031-S37273800422005041400000) to adjust the pitman shaft.

1. J 6278 Pitman Shaft Bearing Remover and Installer
2. J 6219 Pitman Shaft Oil Seal Installer
3. J 4245 Internal Snap Ring Pliers

Scheme 101

Scheme 102

1. Remove the steering gear pitman shaft and housing cover. Refer to «Steering Gear Pitman Shaft & Housing Cover Replacement - Off Vehicle (700 Gear)»(ref-175031-S03861701352005041400000) or «Steering Gear Pitman Shaft & Housing Cover Replacement - Off Vehicle (670 Gear)»(ref-175031-S06170758992005041400000) .
2. Remove the pitman arm (4) from the steering gear.
3. Remove the pitman shaft boot (3) from the steering gear housing (1). Important: Do not score the housing bore when prying out seals and washers.
4. Remove the pitman shaft dust seal (2) from the steering gear housing (1).
5. Remove the pitman shaft retaining ring (2) from the steering gear housing (1) using J 4245 .
6. Remove the backup washer (3) from the steering gear housing (1).
7. Pry the pitman shaft seal (2) from the steering gear housing (1) using a screwdriver.
8. Inspect the housing for burrs and replace if necessary.
9. Insert J 6278 through the hole in the top of the steering gear housing (1).
10. Drive out the needle bearing (2) from the steering gear housing (1).

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Scheme 105

1. Install the needle bearing into the steering gear housing (1) using J 6278
2. Drive the bearing into the housing until the needle bearing shoulder seats against the housing.
3. Coat the pitman shaft seal (2) and backup washer (3) with grease.
4. Install the pitman shaft seal (2) onto the steering gear housing (1) using J 6219 .
5. Install the backup washer (3) onto the steering gear housing (1). Important: The pitman shaft seal must not contact the bearing.
6. Install the pitman shaft retainer ring (2) onto the steering gearing housing (1) using J 4245 .
7. Coat the dust seal (2) with grease.
8. Install the dust seal (2) onto the steering gear housing (1).
9. Install the pitman shaft boot (3) onto the steering gear housing (1). Important: Do not install the lock washer and nut until all components have been installed onto the steering gear housing.
10. Install the pitman shaft and the side cover.
11. Install the pitman arm (4) to the steering gear.
12. Install the lock washer (2).
13. Install the nut (3).
14. To adjust the pitman shaft, refer to «Pitman Shaft Over-Center Preload Adjustment - Off Vehicle (700 Gear)»(ref-175031-S37273800422005041400000) .

1. J 42882 Adjuster Nut Socket
2. J 6222-A Shaft Seal Protector
3. J 43435 Adjuster Lock Nut Wrench

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Scheme 108

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.
3. Remove the adjuster nut assembly (2) from the steering gear housing (1) using J 42882 .
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).