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Home >> Chevrolet >> 2004 >> Tracker 4WD >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement >> Installation Procedure
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Installation Procedure

    IMPORTANT: If you are replacing the steering gear, measure the location of the match mark made on the original inner tie rods. Use this measurement in order to make a corresponding mark on the replacement steering gear.
  1. Using paint, place match marks (2) on the inner tie rods in order to position the 2 lock nuts during assembly.
  2. Install the 2 tie rod lock nuts to the inner tie rods. Position the lock nuts at the match marks. Do NOT tighten the lock nuts.
  3. Install the 2 outer tie rod ends to the inner tie rods. Do NOT tighten the outer tie rod ends or the lock nuts.
    4. Fig 1: View Of Match Marks
    GM461933Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If you are replacing the steering gear, measure the location of the match mark made on the pinion shaft (3) and the steering gear housing (4). Make corresponding marks on the replacement steering gear in order to set the rack in the straight ahead position.
  4. Place match marks (2, 4) on the pinion shaft (3) and on the steering gear housing (1).
  5. Verify the steering wheel and the front wheels are in the straight ahead position.
    6. Fig 2: View Of Steering Gear Housing, Pinion Shaft & Match Marks
    GM461889Courtesy of GENERAL MOTORS CORP.
  6. Install the 2 insulators to the steering gear (3).
  7. Install the 2 brackets to the 2 insulators.
    8. IMPORTANT: Do NOT tighten the bracket bolts before tightening the lower steering shaft clamp bolt.
  8. Install the steering gear and the 4 bolts (1) to the vehicle.
    9. Fig 3: View Of Steering Gear & Mounting Bolts
    GM482771Courtesy of GENERAL MOTORS CORP.
  9. Align the match mark (2) on the pinion shaft with the match mark (4) on the steering gear housing.
    10. Fig 4: View Of Steering Gear Housing, Pinion Shaft & Match Marks
    GM461889Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Connect the lower steering shaft (1) to the steering gear. Install the clamp bolt (2) to the lower steering shaft.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    11. Fig 5: Identifying Power Steering Components
    GM461756Courtesy of GENERAL MOTORS CORP.
  11. Tighten the mounting bolts (1) on the steering gear.

    Tighten:  Tighten the bolts to 55 N.m (40 lb ft).

    12. Fig 6: View Of Steering Gear & Mounting Bolts
    GM482771Courtesy of GENERAL MOTORS CORP.
  12. Remove the plugs from the disconnected pipes and hoses (3, 6).
    13. NOTE: Refer to Installing Hoses without Twists or Bends Notice in Cautions and Notices.
  13. Install the power steering fluid reservoir hose (3) and the hose clamp to the steering gear.
    14. IMPORTANT: The first design banjo bolt style fitting uses 2 gaskets. The second design flare nut style fitting uses seals. The first design power steering components are not interchangeable with the second design power steering components.
  14. Install the following components to the steering gear:
    • The power steering gear inlet hose (6)
    • The 2 gaskets, if equipped
    • The power steering gear inlet hose fitting (5)
  15. Tighten the fitting.

    Tighten:  Tighten the fitting to 35 N.m (25.5 lb ft).

    16. Fig 7: Identifying Power Steering Components
    GM461756Courtesy of GENERAL MOTORS CORP.
  16. Install the left outer tie rod end (3) to the knuckle (2).
  17. Install a NEW nut (1) to the ball stud.

    Tighten:  Tighten the nut to 43 N.m (31.5 lb ft).

  18. Install the right outer tie rod end to the knuckle.
  19. Install a NEW nut to the ball stud.

    Tighten:  Tighten the nut to 43 N.m (31.5 lb ft).

  20. Install the skid plate, if equipped. Refer to Skid Plate Replacement - Steering Linkage in Frame and Underbody.
  21. Lower the vehicle.
    22. NOTE: Refer to Using Proper Power Steering Fluid Notice in Cautions and Notices.
  22. Add fluid to the reservoir. Refer to Checking and Adding Power Steering Fluid .
    23. NOTE: Refer to Air in the Power Steering System Notice in Cautions and Notices.
  23. Bleed the power steering system. Refer to Bleeding the Power Steering System .
  24. Enable the SIR. Refer to SIR Disabling and Enabling Zone 3 in SIR.
  25. Measure the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment.
  26. Adjust the front toe, if necessary. Refer to Front Toe Adjustment in Wheel Alignment.
  27. Tighten the tie rod lock nuts.

    Tighten:  Tighten the nuts to 65 N.m (47 lb ft).

    28. Fig 8: Rod Components Assembly View
    GM461507Courtesy of GENERAL MOTORS CORP.
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