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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1040 (POWER STEERING SYSTEM)REPAIR INSTRUCTIONSRACK AND PINION BOOT REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Rack And Pinion Boot & Boot Clamp
    GM1759493Courtesy of GENERAL MOTORS CORP.
  1. Install the new boot clamp (1) onto the rack and pinion boot (2).
    2. Fig 2: View Of Rack And Pinion Gear Assembly, Inner Tie Rod Assembly & Rack And Pinion Boot
    GM1759513Courtesy 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).
    4. 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. Fig 3: View Of Rack & Pinion Boot & Boot Clamp
    GM1759515Courtesy of GENERAL MOTORS CORP.
  5. Crimp the boot clamp (1) with J 22610  or equivalent. See Special Tools .
  6. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end clamp.
    7. Fig 4: View Of Rack & Pinion Boot & Clamp
    GM1759500Courtesy of GENERAL MOTORS CORP.
  7. Compress the clamp (2) and install it onto the rack and pinion boot (1).
    8. Fig 5: View Of Inner Tie Rod Assembly & Hex Jam Nut
    GM1759516Courtesy of GENERAL MOTORS CORP.
  8. Install the hex jam nut (2) to the inner tie rod assembly (1).
  9. Install the outer tie rod assembly. Refer to Rack and Pinion Outer Tie Rod End Replacement .
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.