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

Removal & Installation


These vehicles use a conventional power steering gear with a recirculating ball system. All tubes, hoses and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Be sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Inspect the hoses with the wheels in the straight-ahead position. Then, turn the wheels fully to the left and right while observing the movement of the hoses. Correct any hose contact with other parts of the vehicle that could cause chafing or wear. Power steering hoses and pipes should not be twisted, kinked or tightly bent. The hoses should have sufficient natural curvature in the routing to absorb movement and hose shortening during vehicle operation.

Click image to see an enlarged view

Fig. 3 long bolts attach the power steering gear to the driver-s side frame rail

  1. Before servicing the vehicle, refer to the Precautions section.
  3. Set the front wheels in the straight-ahead position.
  5. Place a drain pan under the steering gear and disconnect the fluid lines. Cap the openings to protect the system from contamination.
  7. Remove or disconnect the following:

    Negative battery cable
    Adapter and shield from the gear and flexible coupling
    Flexible coupling clamp and steering box input shaft, matchmark for reassemble
    Flexible coupling pinch bolt
    Pitman arm to the Pitman shaft, matchmark for reassemble
    Pitman shaft nut and lockwasher
    Pitman arm from the shaft using the proper puller
    Steering gear to frame bolts
    Gear assembly


To install:

  1. Install or connect the following:
    Check that the relationship of the flexible coupling to the flange is 1 / 4 - 3 / 4 in. (6-19mm) of flat.

    Steering gear in position, guiding the input shaft into the flexible coupling. Align the flat in the coupling with the flat on the input shaft.
    Steering gear-to-frame bolts. Torque the bolts to 100 ft. lbs. (135 Nm)
    Flexible coupling pinch bolt. Torque the pinch bolt to 22 ft. lbs. (30 Nm)

    Pitman arm onto the Pitman shaft, lining up the marks made at removal. Torque the nut to 215 ft. lbs. (285 Nm).
    Adapter and shield
    Fluid lines and refill the reservoir with the proper power steering fluid

  3. Properly bleed the system and verify no leaks.
  5. Road test the vehicle for proper steering system operation.

  1. Raise and support the front end on jack stands.
  3. Remove as much power steering fluid from the reservoir as possible.
  5. Remove the engine under cover.
  7. On diesel models, remove the wheelhouse liner.
  9. Disconnect the hoses from the steering gear. Plug the lines to prevent leakage and contamination.
  11. Disconnect the steering shaft coupling from the gear.
  13. Remove the pitman arm nut, then separate the arm from the relay rod using puller J24319-B or equivalent.
  15. Remove the steering gear bolts and remove the gear from the vehicle.

To install:

  1. Install the gear in the vehicle. Tighten the bolts to 110 ft. lbs. (150 Nm).
  3. Connect the pitman arm to the relay rod.
  5. Connect the power steering hoses. Tighten the fittings to 24 ft. lbs. (32 Nm).
  7. The remaining installation is the reverse of removal. Bleed the power steering system.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly