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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 158 (POWER STEERING SYSTEM)REPAIR INSTRUCTIONSRACK AND PINION BOOT REPLACEMENT - OFF VEHICLEASSEMBLY PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Assembly Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Assembly Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the new boot clamp (2) onto the rack and pinion boot (1).
    Fig 1: Installing Boot Clamp
    G01419087Courtesy of GENERAL MOTORS CORP.
  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).
    Fig 2: Installing Rack And Pinion Boot
    G01419088Courtesy of GENERAL MOTORS CORP.

    Important:  The rack and pinion boot (3) must not be twisted, puckered or out of shape in any way. If the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion boot (3) by hand before installing the boot clamp.

  4. 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.
  5. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610  .
  6. Crimp the boot clamp (1).
  7. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end clamp.
    Fig 3: Installing Boot Clamp On Rack And Pinion Boot
    G01419089Courtesy of GENERAL MOTORS CORP.
  8. Install the hex jam nut (2) to the inner tie rod assembly (1).
    Fig 4: Installing Hex Jam Nut To Inner Tie Rod Assembly
    G01419090Courtesy of GENERAL MOTORS CORP.
  9. To assemble the outer tie rod assembly; refer to TIE ROD END REPLACEMENT - OUTER  .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.