Catera 2000-2001

Removal & Installation

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Idler Arm




NOTE
This procedure requires the use of a linkage installer, special tool J42089 and a relay rod removal tool, special tool J42400 or the equivalents.


NOTE
Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.


CAUTION
To help avoid personal injury when a vehicle is raised, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

  1. Raise and support the vehicle.
  2.  
  3. Remove the idler arm bolts.
  4.  
  5. Remove the relay rod-to-idler arm ball stud nut.
  6.  
  7. Remove the idler arm using the J42400 or equivalent.

    Click image to see an enlarged view

    Fig. Idler arm assembly

  8.  

To install:

  1. Install the idler arm and bolts and tighten to 44 ft. lbs. (60 Nm).
  2.  
  3. Install the relay rod to the idler arm.
  4.  
  5. Install the J42089 to the relay rod ball stud and tighten the J42089 to 22 ft. lbs. (30 Nm).
  6.  
  7. Remove the J42089 from the relay rod ball stud.
    NOTE
    Use a new self-locking idler arm ball stud nut.

  8.  
  9. Install the relay rod-to-idler arm ball stud nut and tighten to 44 ft. lbs. (60 Nm).
  10.  
  11. Lower the vehicle.
  12.  

Inner Tie Rod




NOTE
This procedure requires the use of a tie rod remover, special tool J6627A and a linkage installer, special tool J42089 or equivalents.


NOTE
Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. Important: The tie rod adjuster parts often become rusted in service. Discard the rusted nuts and bolts if the torque to remove the tie rod clamp nut from the bolt after the breakaway exceeds 80 ft. lbs. (9 Nm). Apply penetrating oil between the tie rod clamp and the adjuster. Rotate the clamps until they move freely. Install the new bolts and nuts that are the same part number to ensure proper clamp at the specified torque.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel.
  6.  
  7. Loosen the tie rod clamp bolt at the end of the tie rod adjuster.

    Click image to see an enlarged view

    Fig. Tie rod assembly

  8.  
  9. Remove the tie rod ball stud nut.
  10.  
  11. Use the J6627A or equivalent to remove the tie rod ball stud from the relay rod.
  12.  
  13. Remove the tie rod from the tie rod adjuster.
    NOTE
    Count the number of turns required to remove the tie rod from the tie rod adjuster.

  14.  
  15. Inspect the threads on the ball stud. The ball stud may turn inside the inner tie rod when attempting to tighten the nut during the installation procedure if the threads are not clean if the threads are not smooth.
  16.  
  17. Inspect the ball stud taper for nicks.
  18.  

To install:

  1. Use EP Chassis Lubricant, GM P/N 1052356 or equivalent, to lubricate the tie rod adjuster threads.
  2.  
  3. Use the same number of turns counted in the removal procedure to thread the end of the inner tie rod into the tie rod adjuster.
  4.  
  5. Install the tie rod ball stud into the relay rod.
  6.  
  7. Install the J42089 to tie rod ball stud and tighten the J42089 to 22 ft. lbs. (30 Nm) to allow the tie rod ball stud taper to seat.
  8.  
  9. Remove the J42089 from the tie rod ball stud.
  10.  
  11. Install a new self-locking tie rod ball stud nut and tighten to 44 ft. lbs. (60 Nm).
    NOTE
    Ensure that the adjuster and the clamp are properly positioned before tightening the tie rod adjuster clamp bolt.

  12.  
  13. Tighten the tie rod adjuster clamp bolt to 11 ft. lbs. (15 Nm).
  14.  
  15. Install the tire and wheel.
  16.  
  17. Lower the vehicle.
  18.  
  19. Adjust the toe to the proper specification.
  20.  

Outer Tie Rod




NOTE
This procedure requires the use of a tie rod remover, special tool J6627A and a linkage installer, special tool J42089 or equivalents.


NOTE
Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. Important: The tie rod adjuster parts often become rusted in service. Discard the rusted nuts and bolts if the torque to remove the tie rod clamp nut from the bolt after the breakaway exceeds 80 ft. lbs. (9 Nm). Apply penetrating oil between the tie rod clamp and the adjuster. Rotate the clamps until they move freely. Install the new bolts and nuts that are the same part number to ensure proper clamp at the specified torque.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove or disconnect the following:
  6.  
  7. Remove the tire and wheel.
  8.  
  9. Loosen the tie rod clamp bolt at the end of the tie rod adjuster.
  10.  
  11. Remove the outer tie rod ball stud nut.

    Click image to see an enlarged view

    Fig. Tie rod assembly

  12.  
  13. Use the J6627A to remove the tie rod ball stud from the steering knuckle.

    Click image to see an enlarged view

    Fig. Removing tie rod end with J6627A or equivalent

  14.  
  15. Remove the outer tie rod from the tie rod adjuster.
  16.  
  17. Inspect the threads on the ball stud. The ball stud may turn inside the outer tie rod when attempting to tighten the nut during the installation procedure if the threads are not clean if the threads are not smooth.
    NOTE
    Count the number of turns required to remove the outer tie rod from the tie rod adjuster.

  18.  
  19. Inspect the outer tie rod ball stud taper for nicks.
  20.  

To install:

  1. Use EP Chassis Lubricant, GM P/N 1052356 or equivalent, to lubricate the tie rod adjuster threads.
  2.  
  3. Use the same number of turns counted in the removal procedure to thread the end of the outer tie rod into the tie rod adjuster.
  4.  
  5. Install the outer tie rod ball stud into the steering knuckle.
  6.  
  7. Install the J42089 or equivalent to the outer tie rod ball stud and tighten the J42089 to 22 ft. lbs. (30 Nm) to allow the outer tie rod ball stud taper to seat.
  8.  
  9. Remove the J42089 from the tie rod ball stud.
    NOTE
    Use a new self-locking outer tie rod ball stud nut.

  10.  
  11. Ensure that the adjuster and the clamp are properly positioned before tightening the tie rod adjuster clamp bolt.
  12.  
  13. Install the outer tie rod ball stud nut and tighten to 44 ft. lbs (60 Nm).
  14.  
  15. Tighten the tie rod adjuster clamp bolt to 11 ft. lbs. (15 Nm).
  16.  
  17. Install the tire and wheel.
  18.  
  19. Lower the vehicle.
  20.  
  21. Adjust the toe to the proper specification.
  22.  

Pitman Arm




NOTE
This procedure requires the use of a tie rod puller, special tool J6627A and a linkage installer, special tool J42089 and a relay rod removal tool, special tool J42400 or the equivalents.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the relay rod to pitman arm ball stud nut.
  6.  
  7. Remove the relay from the pitman arm using the J42400.
    WARNING
    Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.



    Click image to see an enlarged view

    Fig. Pitman arm assembly

  8.  
  9. Matchmark the alignment of the pitman arm in relation to the splines on the steering gear.
  10.  
  11. Remove the pitman arm nut.
  12.  
  13. Remove the pitman arm washer.
    NOTE
    Note the rubber steering gear shaft protector.

  14.  
  15. Remove the pitman arm using a universal pitman arm puller.

    Click image to see an enlarged view

    Fig. Universal pitman arm puller

  16.  

To install:

  1. Ensure the front wheels are in the straight ahead position.
  2.  
  3. Ensure the rubber steering gear shaft protector is in place.
  4.  
  5. Align the pitman arm with the marks previously scribed during the removal procedure on the steering gear.

    Click image to see an enlarged view

    Fig. Pitman arm assembly

  6.  
  7. Install the pitman arm to the pitman arm shaft.
    NOTE
    To assist in proper installation the pitman arm and the steering gear are blind-splined.

  8.  
  9. Install a new pitman arm washer.
  10.  
  11. Install a new pitman arm nut and tighten to 118 ft. lbs (160 Nm).
  12.  
  13. Install the relay rod to the pitman arm.
  14.  
  15. Install the J42089 to the relay rod ball stud and tighten to 22 ft. lbs. (30 Nm).
    NOTE
    Use a new self-locking pitman arm ball stud nut.

  16.  
  17. Remove the J42089 from the relay rod ball stud.
  18.  
  19. Install the relay rod to pitman arm ball stud nut and tighten to 44 ft. lbs. (60 Nm).
  20.  
  21. Lower the vehicle.
  22.  
  23. Adjust the toe to the proper specification if the steering wheel is not straight.
  24.  

Relay Rod (Center Link)




NOTE
This procedure requires the use of a tie rod puller, special tool J6627A and a linkage installer, special tool J42089 and a relay rod removal tool, special tool J42400 or the equivalents.


NOTE
Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.


CAUTION
To help avoid personal injury when a vehicle is raised, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the inner tie rod ball stud nuts.
  6.  
  7. Remove the inner tie rods from the relay rod using the J6627A
  8.  
  9. Remove the relay rod ball stud nut from the pitman arm.
  10.  
  11. Remove the relay rod ball stud from the pitman arm using the J42400.
  12.  
  13. Remove the relay rod ball stud nut from the idler arm.
  14.  
  15. Remove the relay rod ball stud from the idler arm using the J42400.

    Click image to see an enlarged view

    Fig. Relay rod assembly

  16.  

To install:

  1. Install the relay rod to the idler arm.
  2.  
  3. Install the J42089 to the relay rod ball stud and tighten the J42089 to 22 ft. lbs. (30 Nm) to allow the ball stud taper to seat.
  4.  
  5. Remove the J42089 from the relay rod ball stud.
    NOTE
    Use a new self-locking relay rod ball stud nut.

  6.  
  7. Install the relay rod ball stud-to-idler arm nut and tighten to 44 ft. lbs. (60 Nm).
  8.  
  9. Install the relay rod to the pitman arm.
  10.  
  11. Install the J42089 to the relay rod ball stud and tighten the J42089 to 22 ft. lbs. (30 Nm) to allow the ball stud taper to seat.
  12.  
  13. Remove the J42089 from the relay rod ball stud.
    NOTE
    Use a new self-locking relay rod ball stud nut.

  14.  
  15. Install the relay ball stud-to-pitman arm nut and tighten to 44 ft. lbs. (60 Nm).
  16.  
  17. Install the inner tie rods into the relay rod.
  18.  
  19. Install the J42089 to tie rod ball stud and tighten the J42089 to 22 ft. lbs. (30 Nm) to allow the tie rod ball stud taper to seat.
  20.  
  21. Remove the J42089 from the tie rod ball stud.
  22.  
  23. Install a new self-locking tie rod ball stud nut and tighten to 44 ft. lbs. (60 Nm).
  24.  
  25. Lower the vehicle.
  26.  
  27. Adjust the toe to the proper specification.
  28.  

Tie Rod Adjuster




NOTE
This procedure requires the use of a tie rod remover, special tool J6627A or equivalent.


NOTE
The tie rod adjuster parts often become rusted in service. Discard the rusted nuts and bolts if the torque to remove the tie rod clamp nut from the tie rod clamp bolt after the breakaway exceeds 80 ft. lbs. (9 Nm). Apply penetrating oil between the tie rod clamp and the adjuster. Rotate the steering linkage clamps until they move freely. Install the new bolts and nuts that are the same part number to ensure proper clamp at the specified torque.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel.
  6.  
  7. Remove the outer tie rod.
  8.  
  9. Loosen the tie rod adjuster clamp bolt at the inner tie rod end of the tie rod adjuster. Important: Count the number of turns required to remove the tie rod adjuster from the inner tie rod.
  10.  
  11. Remove the tie rod adjuster from the inner tie rod.

    Click image to see an enlarged view

    Fig. Tie rod adjuster assembly

  12.  

To install:

  1. Use EP Chassis Lubricant, GM P/N 1052356 or equivalent, to lubricate the tie rod threads.
  2.  
  3. Use the same number of turns as counted in the removal procedure to thread the tie rod adjuster to the inner tie rod.
  4.  
  5. Install the outer tie rod.
    NOTE
    Ensure that both ends of the tie rod adjuster are threaded equally onto the inner and the outer tie rods.

  6.  
  7. Ensure the clamps are positioned over the adjuster slots.
  8.  
  9. Install the tie rod adjuster clamp bolts and tighten to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the tire and wheel.
  12.  
  13. Lower the vehicle.
  14.  
  15. Adjust the toe to the proper specification.
  16.  

 
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