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Home >> Chevrolet >> 2004 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement (AWD) >> Installation Procedure
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Installation Procedure

  1. Install the pitman arm to the power steering gear. Refer to Pitman Arm Replacement (RWD) or Pitman Arm Replacement (AWD) 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 Cautions 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: Locating Steering Gear Mounting Bolts
    GM361693Courtesy of GENERAL MOTORS CORP.
  5. Connect the power brake booster outlet hose to the power steering gear.

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

    Fig 2: View Of Hydraulic Brake Booster Outlet Hose To Power Steering Gear
    GM701187Courtesy of GENERAL MOTORS CORP.
  6. Connect the power steering cooler hose to the power steering gear.

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

    Fig 3: Locating Power Steering Cooler Hose
    GM361686Courtesy of GENERAL MOTORS CORP.
  7. Connect the intermediate shaft to the power steering gear.
  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).

    Fig 4: Identifying Intermediate Shaft To Power Steering Gear Pinch Bolt
    GM361689Courtesy of GENERAL MOTORS CORP.
  9. Install the lower fan shroud. Refer to Fan Shroud Replacement - Lower in Engine Cooling.
  10. Remove the J 42640  from the steering column.
    11. Fig 5: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
  11. Install the pitman arm (3) to connecting rod (4) retaining nut (1).

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

    Fig 6: Identifying Pitman Arm
    GM375568Courtesy of GENERAL MOTORS CORP.
  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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