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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 414 (POWER STEERING SYSTEM)REPAIR INSTRUCTIONSTIE ROD REPLACEMENT - INNERASSEMBLY PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Assembly Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Assembly Procedure
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  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 

    Tighten the inner tie rod to 100 N.m (74 lb ft).

  6. Slide the shock dampener (2) forward onto the rack.
    Fig 1: Sliding Shock Dampener Forward Onto Rack
    G01499373Courtesy of GENERAL MOTORS CORP.

    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 

    Tighten the inner tie rod to 100 N.m (74 lb ft).

    Fig 2: Sliding Shock Dampener Forward Onto Rack
    G01499374Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 3: Staking Female Inner Tie Rod Assembly Housing To Male Rack
    G01499375Courtesy of GENERAL MOTORS CORP.
  13. Insert a 0.25 mm gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler gauge (1) must not pass between the rack and the housing stake.
    Fig 4: Checking Stakes
    G01499376Courtesy of GENERAL MOTORS CORP.
  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. Refer to RACK AND PINION BOOT AND BREATHER TUBE REPLACEMENT - OFF VEHICLE  .
    Fig 5: Sliding Shock Dampener Over Inner Tie Rod Housing
    G01499377Courtesy of GENERAL MOTORS CORP.
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.