Express, Savana, G1500, G2500, G3500, 1998-2005

Removal & Installation

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  1. Raise and support the vehicle.
  2.  
  3. Place a drain pan under the vehicle.
  4.  
  5. Remove the front tires and wheels.
  6.  
  7. Remove the engine protection shield.
  8.  
  9. Remove the outer tie rods retaining nuts.
  10.  
  11. Disconnect the outer tie rods from the steering knuckles.
  12.  
  13. Disconnect the lower intermediate shaft from the power steering gear.
  14.  
  15. Disconnect the power brake booster outlet hose and power steering gear outlet hose or the power steering cooler hose from the power steering gear.
  16.  
  17. Cap the ends of the hoses and the power steering gear fittings in order to prevent the entrance of dirt.
  18.  
  19. Remove the power steering gear from the vehicle.

    Click image to see an enlarged view

    Fig. Rack and pinion steering gear mounting-Express/Savana

  20.  

To install:

  1. Install the power steering gear to the vehicle.
  2.  
  3. Install the power steering gear to the frame mounting bolts and tighten to 110 ft. lbs. (150 Nm).
  4.  
  5. Remove the caps from the steering gear and hoses.
  6.  
  7. Connect the power brake booster outlet hose and power steering gear outlet hose or the power steering cooler hose to the power steering gear.
  8.  
  9. Connect the lower intermediate shaft to the power steering gear and tighten the bolt to 45 ft. lbs. (60 Nm).
  10.  
  11. Install the outer tie rods retaining nuts and tighten to 47 ft. lbs. (63 Nm).
  12.  
  13. Install the engine protection shield.
  14.  
  15. Install the front tires and wheels.
  16.  
  17. Lower the vehicle.
  18.  
  19. Bleed the power steering system.
  20.  
  21. Remove the drain pan from under the vehicle.
  22.  
  23. Check the wheel alignment.
  24.  

  1. Remove or disconnect the following:

    Wheel assemblies
     
    Engine shield, if equipped
     
    Stabilizer shaft
     
    Power steering high and low pressure lines
     
    Coupler clamp bolt from the intermediate shaft
     
    Outer tie rod ends from steering knuckle
     
    Intermediate shaft from the rack and pinion assembly
     
    Rack and pinion assembly mounting nuts, washers and bolts
     
    Rack and pinion assembly from the vehicle

    Click image to see an enlarged view

    Fig. Rack and pinion steering gear

     

  2.  

To install:

  1. Install or connect the following:

    Rack and pinion assembly into the vehicle
     
    Rack and pinion assembly mounting bolts, washers and nuts. Tighten the nuts to 111 ft. lbs. (150 Nm).
     
    Intermediate shaft to the rack and pinion assembly
     
    Coupler clamp bolt to the intermediate shaft. Tighten the bolt to 33 ft. lbs. (45 Nm).
     
    Low pressure hose
     
    High pressure hose. Tighten the hoses to 20 ft. lbs. (27 Nm).
     
    Outer tie rod ends
     
    Engine protection shield, if equipped
     
    Stabilizer shaft
     
    Wheels
     

  2.  
  3. Lower the vehicle.
  4.  
  5. Fill and bleed the power steering system.
  6.  

 
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