GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 Steering 🢒 Manual Steering Gear 🢒 Rack and Pinion Replacement

Tools Required

KM-507-C Ball Joint Remover

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1248342 Size: SH
  1. Disconnect the negative battery cable.
  2. Position the tires straight ahead by turning the steering wheel.
  3. Remove the intermediate shaft.
  4. Remove the front tires.

    5. Object Number: 1248344 Size: SH
  5. Remove the outer tie rod hex nuts. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.

    6. Object Number: 1241963 Size: SH
  6. Remove the ball joint hex nuts and disconnect the stabilizer shaft from the knuckle by removing the stabilizer shaft link assembly. Refer to Stabilizer Shaft Replacement in Front Suspension.

    7. Object Number: 1248345 Size: SH
  7. Remove the cross member by removing the nuts and bolts to the underbody.

    8. Object Number: 1248346 Size: SH
  8. Remove the rack and pinion assembly by disconnecting the steering gear retaining bracket nuts.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1248346 Size: SH
  1. Install the rack and pinion assembly by connecting the steering gear retaining bracket nuts.

    2. Tighten
    Tighten the steering gear retaining bracket nuts to 50 N·m (37 lb ft).


    Object Number: 1248345 Size: SH
  2. Install the cross member by tightening the nuts and bolts to the underbody.

    3. Tighten
    Tighten the cross member by tightening the nuts and bolts to the underbody to 150 N·m (111 lb ft).


    Object Number: 1241963 Size: SH
  3. Install the ball joint hex nuts and connect the stabilizer shaft to the knuckle by tightening the bolt with stabilizer shaft link assembly. Refer to Stabilizer Shaft Replacement in Front Suspension.

    4. Tighten

        • Tighten the ball joint hex nuts to knuckle to 45 N·m (33 lb ft).
        • Tighten the bolts of stabilizer shaft to the knuckle to 45 N·m (33 lb ft).

    Object Number: 1248344 Size: SH
  4. Install the outer tie rod hex nuts.

    5. Tighten
    Tighten the outer tie rod hex nuts to 45 N·m (33 lb ft).

  5. Install the front tires. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

    6. Object Number: 1248342 Size: SH
  6. Install the intermediate shaft.
  7. Install the steering wheel and column.
  8. Connect the negative battery cable.
  9. Inspect the straight-ahead position of the steering system. Refer to Straight Ahead Diagnosis .
  10. Inspect the vehicle. Refer to Preliminary Alignment Inspection .
  11. Measure the wheel alignment.
  12. If necessary, adjust the front toe. Refer to Front Toe Adjustment .