Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2002CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 6.5 FREPAIR AND DIAGNOSISSTEERINGSTEERING LINKAGE (NON-RACK & PINION)REPAIR INSTRUCTIONSRELAY ROD REPLACEMENTREMOVAL PROCEDURE

2002 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.5 F

Removal Procedure

2002 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.5 FSECTION Removal Procedure

WARNING: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.

Raise the vehicle. Support the vehicle with safety stands.
Important: Do not free the ball stud by using a pickle fork or a wedge- type tool. Damage to the seal or bushing may result.
Remove the inner tie rod from the relay rod (4).
Refer to Tie Rod Replacement .
Remove the nuts from the idler arm (1) and connecting rod arm ball studs at the relay rod.

Fig 1: Removing Nuts From Idler Arm
Courtesy of GENERAL MOTORS CORP.
Use the J 24319-B in order to remove the relay rod from the idler arm.
Use the J 24319-B in order to remove the relay rod from the connecting rod.
Remove the relay rod from the vehicle.
Clean the threads on the ball stud and the ball stud nut.
Inspect the threads on the tie rod and the tie rod end for damage.
Inspect the ball stud threads for damage.
Inspect the ball stud seals for excessive wear.

Fig 2: Removing Relay Rod
Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

NO RELATED

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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.