S10 Pickup, Sonoma 2000-2004

Removal & Installation

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Idler Arm



  1. Raise and safely support the front of the vehicle securely on jackstands.
  2.  
  3. On 4-wheel-drive vehicles, remove the following:
    1. Remove steering linkage shield.
    2.  
    3. Remove differential carrier shield mounting bolts.
    4.  
    5. Remove differential carrier shield.
    6.  

  4.  
  5. Remove the idler arm mounting bolts and nuts from the frame.
  6.  
  7. Remove the relay rod stud nut.
  8.  
  9. Disconnect the relay rod from the idler arm using Steering Linkage and Tie Rod Puller tool J 24319-B.
  10.  
  11. Remove the idler arm.
  12.  
  13. Inspect the ball stud threads for damage.
  14.  
  15. Inspect the ball stud seal for cuts or other damage.
  16.  
  17. Clean the threads on the ball stud.
  18.  
  19. Clean the threads on the ball stud nut.

    Click image to see an enlarged view

    Fig. Idler arm assembly

  20.  

To install:

  1. Position the idler arm on the frame.
  2.  
  3. Install the idler arm mounting bolts and nuts to the frame and tighten to 79 ft. lbs. (108 Nm).
  4.  
  5. Install the relay rod to the idler arm ball stud. Ensure that the seal is on the stud. Seat the taper using J 29193 or J 29194 and tighten to 40 ft. lbs. (54 Nm).
  6.  
  7. Remove J 29193 or J 29194 from the idler arm ball stud. Install the new nut to the idler arm ball stud and tighten to 60 ft. lbs. (82 Nm).
  8.  
  9. On 4-wheel-drive vehicles, install the following:
    1. Install differential carrier shield.
    2.  
    3. Install differential carrier shield mounting bolts and tighten to 19 ft. lbs. (25 Nm).
    4.  
    5. Install steering linkage shield.
    6.  

  10.  
  11. Lower the vehicle.
  12.  
  13. Adjust the front toe.
  14.  

Pitman Arm



  1. Remove the power steering gear.
  2.  
  3. Install power steering gear into vise.
  4.  
  5. Remove the pitman arm nut and washer from the pitman arm shaft. Do not hammer on the pitman arm, pitman arm shaft or puller. Damage to the pitman arm or steering gear may result.
  6.  
  7. Disconnect the pitman arm from the pitman shaft using Pitman Arm puller tool J 6632-01 or J 29107-A.
  8.  
  9. Inspect the following items:

    The ball stud threads for damage
     
    The ball stud seals for excessive wear
     

  10.  
  11. Clean the threads on the ball stud.

    Click image to see an enlarged view

    Fig. Pitman arm to power steering gear assembly

  12.  

To install:

  1. Install the pitman arm to the pitman arm shaft.
  2.  
  3. Install the pitman arm washer and nut to the pitman arm shaft and tighten to 185 ft. lbs. (250 Nm).
  4.  
  5. Remove power steering gear from the vise.
  6.  
  7. Install the power steering gear.
  8.  

Relay Rod (Center Link)



  1. Raise and safely support the front of the vehicle securely on jackstands.
  2.  
  3. Remove the steering linkage shield.
  4.  
  5. Remove the differential carrier shield mounting bolts.
  6.  
  7. Remove the differential carrier shield.
  8.  
  9. Remove inner tie rods ball stud nuts.
  10.  
  11. Remove the inner tie rods ball studs from the relay rod using Tie Rod Puller tool J 6627-A.
  12.  
  13. Remove the steering shock absorber ball stud nut at the relay rod.
  14.  
  15. Disconnect the steering shock absorber from the relay rod using Steering Linkage and Tie Rod Puller tool J 24319-B .
  16.  
  17. Remove the pitman arm ball stud nut at the relay rod.
  18.  
  19. Disconnect the pitman arm ball stud from the relay rod using J 24319-B .
  20.  
  21. Remove the idler arm ball stud nut at the relay rod.
  22.  
  23. Disconnect the idler arm ball stud from the relay rod using J 24319-B .
  24.  
  25. Remove the relay rod.
  26.  
  27. Inspect the following components:

    The threads on the tie rod for damage
     
    The threads on the tie rod end for damage
     
    The ball stud threads for damage
     
    The ball stud seals for excessive wear
     

  28.  
  29. Clean the threads on the ball stud and ball stud nut.
  30.  

To install:

  1. Install the idler arm ball stud to the relay rod. Ensure that the seal is on the stud.
  2.  
  3. Seat the tapers using J 29193 or J 29194 and tighten to 40 ft. lbs. (54 Nm).
  4.  
  5. Remove J 29193 or J 29194 from the idler arm ball stud.
  6.  
  7. Install the new nut to the idler arm ball stud at the relay rod and tighten to 60 ft. lbs. (82 Nm).
  8.  
  9. Install the relay rod ball stud to the pitman arm. Ensure that the seal is on the stud.
  10.  
  11. Seat the tapers using J 29193 or J 29194 and tighten to 40 ft. lbs. (54 Nm).
  12.  
  13. Remove J 29193 or J 29194 from the pitman arm ball stud.
  14.  
  15. Install the new nut to the pitman arm ball stud at the relay rod and tighten to 61 ft. lbs. (83 Nm).
  16.  
  17. Connect the steering shock absorber to the relay rod.
  18.  
  19. Install the steering shock absorber ball stud nut at the relay rod and tighten the steering shock absorber ball stud nut to 46 ft. lbs. (63 Nm).
  20.  
  21. Install the inner tie rod ball studs to the relay rod. Ensure the seal is on the stud.
  22.  
  23. Seat the tapers using J 29193 or J 29194 and tighten to 40 ft. lbs. (54 Nm).
  24.  
  25. Remove J 29193 or J 29194 from inner tie rod ball stud.
  26.  
  27. Repeat steps 12 and 13 for the opposite side.
  28.  
  29. Install the new nuts to the inner tie rod ball studs at the relay rod and tighten to 35 ft. lbs. (47 Nm).
  30.  
  31. Install the differential carrier shield and install the differential carrier shield mounting bolts and tighten to 19 ft. lbs. (25 Nm).
  32.  
  33. Install the steering linkage shield.
  34.  
  35. Lower the vehicle.
  36.  
  37. Adjust the front toe.
  38.  

Steering Damper



Steering Damper is only present on 4-wheel-drive models only.

  1. Raise and safely support the front of the vehicle securely on jackstands.
  2.  
  3. Remove the steering linkage shield.
  4.  
  5. Remove the differential carrier shield mounting bolts.
  6.  
  7. Remove the differential carrier shield.
  8.  
  9. Remove the cotter pin from the steering shock absorber ball stud nut.
  10.  
  11. Remove the steering shock absorber ball stud nut.
  12.  
  13. Remove the steering shock absorber from the relay rod using Steering Linkage and Tie Rod Puller tool J 24319-B.
  14.  
  15. Remove the steering shock absorber mounting bolt at the front crossmember bracket nut.
  16.  
  17. Remove the steering shock absorber mounting bolt from the front crossmember bracket.
  18.  
  19. Remove the steering shock absorber.
  20.  
  21. Inspect the ball stud threads for damage.
  22.  
  23. Inspect the ball stud seals for excessive wear.
  24.  
  25. Clean the threads in the ball stud and the ball stud nut.

    Click image to see an enlarged view

    Fig. Steering damper assembly-4-wheel-drive

  26.  

To install:

  1. Install the steering shock absorber mounting bolt to the front crossmember bracket.
  2.  
  3. Install the steering shock absorber mounting bolt to the front crossmember bracket nut and tighten to 44 ft. lbs. (60 Nm).
  4.  
  5. Install the new cotter pin to the steering shock absorber mounting bolt to the frame bracket nut. Bend out the ends of the cotter pin.
  6.  
  7. Install the steering shock absorber ball stud to the relay rod. Ensure that the seal is on the stud.
  8.  
  9. Seat the taper using J 29193 or J 29194 and tighten to 40 ft. lbs. (54 Nm).
  10.  
  11. Remove J 29193 or J 29194 from the steering shock absorber ball stud.
  12.  
  13. Install the steering shock absorber ball stud nut and tighten to 46 ft. lbs. (63 Nm).
  14.  
  15. Install the new cotter pin to the steering shock absorber ball stud nut. Bend out the ends of the cotter pin.
  16.  
  17. Install the differential carrier shield.
  18.  
  19. Install the differential carrier shield mounting bolts and tighten to 19 ft. lbs. (25 Nm).
  20.  
  21. Install the steering linkage shield.
  22.  
  23. Lower the vehicle.
  24.  

Tie Rods



  1. Raise and safely support the front of the vehicle securely on jackstands.
  2.  
  3. Remove the cotter pin from outer tie rod ball stud nut.
  4.  
  5. Remove the outer tie rod ball stud nut.
  6.  
  7. Remove the inner tie rod ball stud nut.
    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.

  8.  
  9. Remove the outer tie rod ball stud from the steering knuckle using J 24319-B.
  10.  
  11. Remove the inner tie rod ball stud from the relay rod using J 6627-A.
  12.  
  13. Perform the following steps in order to remove the tie rod ends from the adjuster tube:
    1. Loosen the clamp bolts.
    2.  
    3. Unscrew the assemblies.
    4.  

  14.  
  15. Inspect for the following possible conditions:

    The tie rod ends for damage
     
    The tie rod end seals for excessive wear
     
    The tie rod threads for damage
     
    The tie rod ends for damage
     
    The ball stud threads for damage
     
    The adjuster tube for bending
     
    The adjuster tube for damaged threads
     

  16.  
  17. Clean the following components:

    The ball stud threads
     
    The ball stud nut
     
    The tapered surfaces
     

  18.  

To install:

  1. Connect the tie rod ends to the adjuster tube. Ensure that the number of threads on both the inner and the outer tie rod ends are equal within three threads.
  2.  
  3. Install the inner tie rod ball stud to the relay rod. Ensure that the seal is on the stud.
  4.  
  5. Seat the taper using J 29193 or J 29194. Tighten to 40 ft. lbs. (54 Nm).
  6.  
  7. Remove J 29193 or J 29194 from inner tie rod ball stud.
  8.  
  9. Install the new nut to the inner tie rod ball stud. Tighten the inner tie rod ball stud nut to the relay rod to 35 ft. lbs. (47 Nm).
  10.  
  11. Connect the outer tie rod ball stud to the steering knuckle. Ensure that the seal is on the stud.
  12.  
  13. Seat the taper using J 29193 or J 29194. Tighten to 40 ft. lbs. (54 Nm).
  14.  
  15. Remove J 29193 or J 29194 from outer tie rod ball stud. Install the nut to the outer tie rod ball stud and tighten to 39 ft. lbs. (53 Nm).
  16.  
  17. Install the new cotter pin to the outer tie rod stud nut. Do not back the nut off in order to align the cotter pin hole. Advance the nut in order to align the nut slot with the cotter pin hole.
  18.  
  19. Spread the cotter pin ends.
  20.  
  21. Lower the vehicle.
  22.  
  23. Adjust the front toe.
  24.  
  25. Position the two clamps between the locating dimples at either end of the adjuster tube.
  26.  
  27. The clamps must be positioned within the correct angular travel, as shown.

    Click image to see an enlarged view

    Fig. Position the clamps within the correct angular travel

  28.  
  29. Ensure that the clamp slot is not aligned with the adjuster tube slot.
  30.  
  31. Maintain the position of each tie rod end as the clamps are tightened in order to ensure free movement of each joint.
  32.  
  33. When clamps are tightened to specifications, the ends may touch.
  34.  
  35. Install the adjuster tube clamp bolts and tighten to 16 ft. lbs. (21 Nm).
  36.  

 
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