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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 219 (POWER STEERING SYSTEM)REPAIR INSTRUCTIONSRACK AND PINION BOOT REPLACEMENT - ON VEHICLEINSTALLATION 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 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Prior to the rack and pinion boot installation, apply grease to the inner tie rod (2) and the power steering gear (1).
  2. Install the rack and pinion boot (3) onto the inner tie rod (2).
  3. Install the breather tube while aligning the breather tube with the mark made during removal and the molded nipple of the rack and pinion boot.

    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 power steering gear (1) until the rack and pinion boot (3) is seated in the power steering gear groove.
    Fig 1: Installing Rack & Pinion Boot Onto Inner Tie Rod
    G01217129Courtesy of GENERAL MOTORS CORP.
  5. Install the boot clamp (1) on the rack and pinion boot (2).
  6. Crimp the boot clamp (1) using the J-22610  .
    Fig 2: Installing Boot Clamp Onto Rack & Pinion Boot
    G01217130Courtesy of GENERAL MOTORS CORP.
  7. Install the new boot clamp (2) onto the rack and pinion boot (1).
    Fig 3: Installing New Boot Clamp Onto Rack & Pinion Boot
    G01217131Courtesy of GENERAL MOTORS CORP.
  8. Install the hexagon jam nut (2) to the inner tie rod (1).
  9. Install the outer tie rod. Refer to Tie Rod End Replacement - Outer .
  10. Check the wheel alignment. Refer to Measuring Wheel Alignment in SPECIFICATIONS .
    Fig 4: Installing Hexagon Jam Nut To Inner Tie Rod
    G01217132Courtesy 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.