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.

Slide the shock dampener (4) forward onto the rack (3).

Fig 1: Installing Left Inner Tie Rod End
Courtesy of GENERAL MOTORS CORP.

Important: Threads must be clean prior to LOCTITE° application. Check LOCTITE°, or equivalent, container for expiration date. Use only enough LOCTITE° to evenly coat threads.

If male rack (3) and female inner tie rod (2) do not apply LOCTITE°.
If female rack (3) and male inner tie rod (2), apply LOCTITE° 262, or equivalent, to the inner tie rod threads.
Attach the inner tie rod onto the rack (3).
NOTE: Refer to PIPE WRENCH POSITIONING NOTICE .
Place a pipe wrench on the rack (3) next to the inner tie rod housing (2).
NOTE: Refer to FASTENER NOTICE .
Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2). Tighten the inner tie rod to 100 N.m (74 lb ft).
Slide the shock dampener (2) forward onto the rack.

Fig 2: Installing Right Inner Tie Rod End
Courtesy of GENERAL MOTORS CORP.

Important: Threads must be clean prior to LOCTITE° application. Check LOCTITE°, or equivalent, container for expiration date. Use only enough LOCTITE° to evenly coat threads.

If male rack and female inner tie rod (1) do not apply LOCTITE°.
If female rack and male inner tie rod (1), apply LOCTITE° 262, or equivalent, to the inner tie rod threads.
Attach the inner tie rod (1) onto the rack.
NOTE: Refer to PIPE WRENCH POSITIONING NOTICE .
Place a pipe wrench on the rack next to the inner tie rod housing (4).
Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7). Tighten the inner tie rod to 100 N.m (74 lb ft).
Place the inner tie rod assembly (2) in a vise.
Important: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and female inner tie rod (2) you must stake.

Fig 3: Staking Female Inner Tie Rod

Courtesy of GENERAL MOTORS CORP.

Stake both sides of the female inner tie rod assembly housing to the male rack.
Insert a 0.010 inch gage (1) between the rack (2) and the inner tie rod housing in order to check both stakes. The feeler (1) must not pass between the rack and the housing stake.

Fig 4: Inspecting Tie Rod Housing Stake
Courtesy of GENERAL MOTORS CORP.
Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener (2) bottoms against the inner tie rod housing (3).

Fig 5: Sliding Dampener Over Inner Tie Rod Housing
Courtesy of GENERAL MOTORS CORP.
To assemble the rack and pinion boot and the breather tube. Refer to Rack and Pinion Boot and Breather Tube Replacement - Off Vehicle .