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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 219 (POWER STEERING SYSTEM)REPAIR INSTRUCTIONSPOWER STEERING GEAR REPLACEMENT (NON-RACK AND PINION)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION 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. Install the pitman arm to the power steering gear.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  2. Install the pitman arm to power steering gear retaining nut and washer.

    Tighten 

    Tighten the nut to 250 N.m (184 lb ft).

    Fig 1: Installing Pitman Arm To Power Steering Gear
    G01217162Courtesy of GENERAL MOTORS CORP.
  3. Install the power steering gear to the vehicle.
  4. Install the power steering gear to the frame mounting bolts.

    Tighten 

    Tighten the bolts to 150 N.m (111 lb ft).

    Fig 2: Installing Power Steering Gear
    G01217163Courtesy of GENERAL MOTORS CORP.
  5. Install the pitman arm to relay rod.
  6. Install the pitman arm to relay rod retaining nut.

    Tighten 

    Tighten the nut to 63 N.m (47 lb ft).

    Fig 3: Installing Pitman Arm To Relay Rod
    G01217164Courtesy of GENERAL MOTORS CORP.
  7. Remove the caps from the steering gear and hoses.
  8. Connect the power brake booster outlet hose (4) and power steering gear outlet hose or the power steering cooler hose (1) to the power steering gear (2).

    Tighten 

    Tighten the hose fittings to 33 N.m (24 lb ft).

    Fig 4: Connecting Power Brake Booster Outlet Hose & Power Steering Gear Outlet Hose Or Power Steering Cooler Hose
    G01217165Courtesy of GENERAL MOTORS CORP.
  9. Align marks on lower intermediate shaft and power steering gear.
  10. Connect the lower intermediate shaft to the power steering gear.
  11. Install the lower intermediate shaft to power steering gear retaining bolt.

    Tighten 

    Tighten the bolt to 61 N.m (45 lb ft).

  12. Lower the vehicle.
  13. Bleed the power steering system. Refer to Bleeding the Power Steering System .
  14. Remove the drain pan from under the vehicle.
    Fig 5: Connecting Lower Intermediate Shaft To Power Steering Gear
    G01217166Courtesy 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.