Assembly Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

Install the new boot clamp (1) onto the rack and pinion boot (3).

Fig 1: Identifying Rack & Pinion Boot Clamp (Big End)

Courtesy of GENERAL MOTORS CORP.

Prior to rack and pinion boot installation, apply grease to the inner tie rod assembly (2) and the rack and pinion gear assembly (1).

Fig 2: Identifying Rack & Pinion Boot Grease Locations
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Install the rack and pinion boot (3) onto the inner tie rod assembly (2).
If present, install the breather tube while aligning the breather tube with the mark made during removal and the molded nipple of the rack and pinion boot.
Important: The rack and pinion boot (3) must not be twisted, puckered or out of shape in any way. If the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion boot (3) by hand before installing the boot clamp.
Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3) is seated in the gear assembly groove.
Install the boot clamp (1) on the rack and pinion boot (2) with J 22610.
Crimp the boot clamp (1).

Fig 3: Crimping Rack & Pinion Boot Clamp
Courtesy of GENERAL MOTORS CORP.
Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end clamp.
Install the tie rod end clamp (2) onto the rack and pinion boot (1).

Fig 4: Installing Rack & Pinion Boot Clamp (Small End)
Courtesy of GENERAL MOTORS CORP.
Install the hexagon jam nut (2) to the inner tie rod assembly (1).

Fig 5: Identifying Inner Tie Rod Assembly Hexagon Jam Nut
Courtesy of GENERAL MOTORS CORP.
To assemble the outer tie rod assembly. Refer to Tie Rod End Replacement - Outer .