S10 Pickup, Sonoma 2000-2004

Removal & Installation

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2wd Models



  1. Position a fluid catch pan under the power steering gear.
    WARNING
    Do NOT rotate the steering shaft after the steering column has been removed.

  2.  
  3. Lock the steering column through the access hole in the steering column lower trim cover using steering column anti-rotation pin J 42640.

    Click image to see an enlarged view

    Fig. Use J 42640 to lock the steering column

  4.  
  5. Remove or disconnect the following:

    Air cleaner assembly
     
    Intermediate shaft from the steering gear
     
    Feed and return fluid hoses from the steering gear. Immediately cap or plug all openings to prevent system contamination or excessive fluid loss.
     
    Intermediate shaft lower coupling shield, if equipped
     
    Lower intermediate shaft coupling bolt
     
    Matchmark the lower intermediate shaft coupling and the steering shaft
     
    Lower intermediate shaft coupling from the steering shaft
     
    Pitman arm from the gear pitman shaft
     
    Power steering gear-to-frame bolts and washers, then carefully remove the steering gear from the vehicle

    Click image to see an enlarged view

    Fig. Power steering gear mounting

     

  6.  

To install:

  1. Install or connect the following:

    Steering gear to the vehicle and tighten the bolts to 55 ft. lbs. (75 Nm)
     
    Pitman arm
     
    Intermediate shaft to the power steering, making sure the matchmarks line up. Tighten the bolt to 26 ft. lbs. (35 Nm).
     
    Pressure and return hoses to the power steering gear. Tighten the pressure hose to 18 ft. lbs. (25 Nm) for 2.2L engines and 22 ft. lbs. (30 Nm) for 4.3L engines. Tighten the return hose to 18 ft. lbs. (25 Nm).
     
    Shield over the intermediate shaft lower coupling, if equipped
     
    Air cleaner assembly
     

  2.  
  3. Remove the steering column lock pin
  4.  
  5. Bleed the power steering system
  6.  

4wd Models



This procedure requires the use of the following special tools: J 24319-B Steering Linkage and Tie Rod Puller, J 42640 Steering Column Anti-Rotation Pin, J 29193 Steering Linkage Installer (12mm), J 29194 Steering Linkage Installer (14mm).

  1. Position a fluid catch pan under the power steering gear.
    WARNING
    DO NOT rotate the steering shaft after the steering column has been removed.

  2.  
  3. Lock the steering column through the access hole in the steering column lower trim cover using steering column anti-rotation pin J 42640.
  4.  
  5. Remove or disconnect the following:

    Air cleaner assembly
     
    Intermediate shaft lower coupling shield, if equipped
     
    Wiring harness clip from the power steering return hose at the power steering gear
     
    Feed and return fluid hoses from the steering gear. Immediately cap or plug all openings to prevent system contamination or excessive fluid loss.
     
    Lower intermediate shaft coupling bolt
     
    Matchmark the lower intermediate shaft coupling and the steering shaft
     
    Lower intermediate shaft coupling from the steering shaft
     

  6.  
  7. Raise the vehicle.

    Steering linkage shield
     
    Differential carrier shield mounting bolts
     
    Differential carrier shield
     
    Pitman arm ball stud cotter pin and nut at the relay rod
     
    Pitman arm from relay rod using a suitable puller
     
    Steering gear mounting bolts and the washers from the frame
     
    Steering gear
     
    Pitman arm
     

  8.  

To install:

  1. Install or connect the following:

    Pitman arm
     
    Steering gear
     
    Power steering gear to the frame washers and mounting bolts. Tighten the bolts to 55 ft. lbs. (75 Nm).
     
    Relay rod to the pitman arm ball stud. Ensure the seal is on the stud
     

  2.  
  3. On 2002-03 vehicles, seat the taper using tool J 29193 or J 29194 and tighten the tool to 48 ft. lbs. (62 Nm).
  4.  
  5. Remove the special tool from the pitman arm ball stud, if necessary.
  6.  
  7. Install or connect the following:

    New nut and cotter pin to the pitman arm ball stud at the relay rod and tighten the pitman arm ball stud nut at the relay rod to 61 ft. lbs. (83 Nm)
     
    Differential carrier shield
     
    Differential carrier shield mounting bolts
     
    Steering linkage shield
     

  8.  
  9. Lower the vehicle.

    Intermediate shaft to the power steering, making sure the matchmarks line up. Tighten the bolt to 26 ft. lbs. (35 Nm).
     
    Pressure and return hoses to the power steering gear. Tighten the pressure hose to 22 ft. lbs. (30 Nm) and the return hose to 18 ft. lbs. (25 Nm).
     
    Wiring harness clip to the power steering return hose at the power steering gear
     
    Shield over the intermediate shaft lower coupling, if equipped
     
    Air cleaner assembly
     

  10.  
  11. Remove the steering column lock pin
  12.  
  13. Bleed the power steering system
  14.  

 
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