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Home >> Chevrolet >> 2003 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement (AWD) >> Installation Procedure

Installation Procedure

  1. Install the pitman arm to the power steering gear. Refer to STEERING LINKAGE (NON-RACK & PINION) or STEERING LINKAGE (NON-RACK & PINION) in Steering Linkage.
  2. Install the power steering gear to the vehicle.
  3. Connect the pitman arm to the connecting rod.
    NOTE: Refer to FASTENER NOTICE in Caution and Notices.
  4. Using the aid of an assistant, position the power steering gear to the frame and install the power steering mounting bolts.

    Tighten 

    Tighten the power steering mounting bolts to 143 N.m (106 lb ft).

    Fig 1: Power Steering Mounting Bolts
    G01645914Courtesy of GENERAL MOTORS CORP.
  5. Connect the power brake booster outlet hose to the power steering gear.
    Fig 2: Connecting Power Brake Booster Outlet Hose To Power Steering Gear
    G01645915Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the power brake booster outlet hose to the power steering gear to 27 N.m (20 lb ft).

  6. Connect the power steering cooler hose to the power steering gear.
    Fig 3: Connecting Power Steering Cooler Hose To Power Steering Gear
    G01645916Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the power steering cooler hose to the power steering gear to 27 N.m (20 lb ft).

  7. Connect the intermediate shaft to the power steering gear.
    Fig 4: Connecting Intermediate Shaft To Power Steering Gear
    G01645917Courtesy of GENERAL MOTORS CORP.
  8. Install the intermediate shaft to power steering gear pinch bolt.

    Tighten 

    Tighten the intermediate shaft to power steering gear pinch bolt to 41 N.m (30 lb ft).

  9. Install the lower fan shroud. Refer to FAN SHROUD REPLACEMENT - LOWER in Engine Cooling.
  10. Remove the J 42640  from the steering column.
    Fig 5: Removing J 42640 From Steering Column
    G01645918Courtesy of GENERAL MOTORS CORP.
  11. Install the pitman arm (3) to connecting rod (4) retaining nut (1).
    Fig 6: Installing Pitman Arm To Connecting Rod Retaining Nut
    G01645919Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the pitman arm to connecting rod retaining nut to 62 N.m (48 lb ft).

  12. Rotate the stabilizer shaft to the correct position.
  13. Install the stabilizer links. Refer to STABILIZER SHAFT LINK REPLACEMENT (RWD) or STABILIZER SHAFT LINK REPLACEMENT (AWD) in Front Suspension.
  14. Install the tire and the wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  15. Lower the vehicle.
  16. Bleed the power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM .
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