Malibu, Malibu MAXX 2006-2008

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn the steering wheel to the straight forward position and remove the key from the ignition.
  4.  
  5. Disable the Supplemental Inflatable Restraint (SIR) system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the front tires and wheels.
  10.  
  11. Remove the tie rod end castle nuts.
  12.  
  13. Using the J 24319-B, separate the tie rod ends from the steering knuckles.
  14.  
  15. Remove the intermediate shaft to steering gear pinch bolt. Discard the bolt.
    WARNING
    Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.

  16.  
  17. Separate the intermediate shaft from the steering gear.

    Click image to see an enlarged view

    Fig. Bolt (1), intermediate shaft (2), steering gear (3)

  18.  
  19. Loosen the transaxle mount through bolt.
  20.  
  21. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  22.  
  23. Disconnect the HO2S sensor harness from the transmission mount bracket.
  24.  
  25. Remove the 3 transaxle mount to transaxle bolts.
  26.  
  27. Remove the 3 transaxle bracket to frame nuts.
  28.  
  29. Position the transaxle bracket and rear mount aside.

    Click image to see an enlarged view

    Fig. Transaxle bracket frame nuts

  30.  
  31. Remove the bolt and disconnect the power steering gear inlet and outlet pipe/hoses from the power steering gear. Cap off the pipe/hoses and position aside.

    Click image to see an enlarged view

    Fig. Power steering gear inlet and outlet pipe/hoses

  32.  
  33. Remove the power steering gear outlet pipe routing pin style retainer from the right rear side of the frame.
  34.  
  35. Remove the power steering gear mounting bolts, nuts, and washers from the gear.
    NOTE
    The power steering gear will need to be rotated while it is removed through the left wheel opening.

  36.  
  37. Remove the power steering gear through the left wheel opening.
  38.  
  39. If the power steering gear is to be replaced, transfer the outer tie rod ends to the new steering gear.
  40.  

To install:


NOTE
The power steering gear will need to be rotated while it is installed through the left wheel opening.

  1. Position the power steering gear into the vehicle.
  2.  
  3. Connect the intermediate steering shaft to the steering gear.
  4.  
  5. Install the power steering gear mounting bolts, nuts and washers to the power steering gear. Tighten the mounting bolts, nuts to 81 ft. lbs. (110 Nm).
  6.  
  7. Install the power steering gear outlet pipe routing pin style retainer to the right rear side of the frame.
  8.  
  9. Connect the power steering gear inlet and outlet pipe/hoses to the power steering gear and install the bolt. Prior to tightening the retaining bolt, rotate the outlet pipe clockwise/down so it touches the inlet pipe. Verify the hoses are still touching after the retaining bolt is tight.
  10.  
  11. Tighten the pipe/hose to power steering gear bolt to 20 ft. lbs. (27 Nm).
  12.  
  13. Install the new intermediate steering shaft to steering gear pinch bolt and tighten to 36 ft. lbs. (49 Nm).
  14.  
  15. Position the transaxle bracket and rear mount back to their original position.
  16.  
  17. Install the 3 transaxle bracket to frame nuts and tighten to 37 ft. lbs. (50 Nm).
  18.  
  19. Install the 3 transaxle mount to transaxle bolts.
  20.  
  21. For 3.5L engines tighten the transaxle mount bolts to 66 ft. lbs. (90 Nm).
  22.  
  23. For 3.9L engines tighten the transaxle mount bolts to 37 ft. lbs. (50 Nm).
  24.  
  25. Connect the HO2S sensor harness to the transmission mount bracket.
  26.  
  27. Connect the HO2S electrical connector.
  28.  
  29. Install the transaxle mount through bolt.
  30.  
  31. For 3.5L engines tighten the transaxle mount through bolt to 66 ft. lbs. (90 Nm).
  32.  
  33. For 3.9L engines tighten the transaxle mount through bolt to 37 ft. lbs. (50 Nm).
  34.  
  35. Install new torque castle nuts to the tie rod end ball studs.
  36.  
  37. Tighten the castle nuts to 18 ft. lbs. (25 Nm) plus 90° rotation.
  38.  
  39. Install the front tires and wheels.
  40.  
  41. Lower the vehicle.
  42.  
  43. Fill and bleed the power steering system.
  44.  
  45. Measure the wheel alignment and adjust as necessary.
  46.  

 
label.common.footer.alt.autozoneLogo