GM Service Manual Online
For 1990-2009 cars only

Relay Rod Replacement RWD

Tools Required

    • J 6627-A Tie Rod Puller
    • J 24319-B Steering Linkage and Tie Rod Puller

Removal Procedure


    Object Number: 291236  Size: SH
  1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the inner tie rods ball stud nuts.

  3. Object Number: 397350  Size: SH

    Important: Use the proper tool in order to separate all ball joints.

  4. Disconnect the inner tie rods ball studs from the relay rod using J 6627-A .
  5. Remove the relay rod ball stud nut at the pitman arm.

  6. Object Number: 397356  Size: SH
  7. Disconnect the relay rod ball stud from the pitman arm using J 24319-B .
  8. Remove the relay rod ball stud nut at the idler arm.

  9. Object Number: 397352  Size: SH
  10. Disconnect the relay rod from the idler arm usingJ 24319-B .
  11. Remove the relay rod.
  12. Inspect the following components:
  13. • The threads on the tie rod for damage
    • The threads on the tie rod end for damage
    • The ball stud threads for damage
    • The ball stud seals for excessive wear
  14. Clean the threads on the ball stud and ball stud nut.

Installation Procedure


    Object Number: 291252  Size: SH
  1. Install the relay rod ball stud to the idler arm.
  2. Ensure that the seal is on the stud.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the new nut to the relay rod ball stud at the idler arm.
  4. Tighten
    Tighten the relay rod ball stud nut at the idler arm to 47 N·m (35 lb in).


    Object Number: 291242  Size: SH
  5. Install the relay rod ball stud to the pitman arm.
  6. Ensure that the seal is on the stud.

  7. Install the new nut to the relay rod ball stud at the pitman arm.
  8. Tighten
    Tighten the relay rod ball stud nut at the pitman arm to 48 N·m (36 lb ft).


    Object Number: 291236  Size: SH
  9. Install the inner tie rod ball studs to the relay rod.
  10. Ensure that the seal is on the stud.

  11. Install the new nuts to the inner tie rod ball studs.
  12. Tighten
    Tighten the inner tie rod ball studs nuts to 47 N·m (35 lb ft).

  13. Lower the vehicle.
  14. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.

Relay Rod Replacement 4WD

Tools Required

    • J 6627-A Tie Rod Puller
    • J 24319-B Steering Linkage and Tie Rod Puller

Removal Procedure


    Object Number: 141840  Size: SH
  1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the steering linkage shield. Refer to Steering Linkage Shield Replacement .
  3. Remove the differential carrier shield mounting bolts.
  4. Remove the differential carrier shield.

  5. Object Number: 291250  Size: SH

    Important: Use the proper tool in order to separate all ball joints.

  6. Remove inner tie rods ball stud nuts.

  7. Object Number: 397360  Size: SH
  8. Remove the inner tie rods ball studs from the relay rod using J 6627-A .

  9. Object Number: 291256  Size: SH
  10. Remove the steering shock absorber ball stud nut at the relay rod.

  11. Object Number: 397364  Size: SH
  12. Disconnect the steering shock absorber from the relay rod usingJ 24319-B .

  13. Object Number: 291250  Size: SH
  14. Remove the pitman arm ball stud nut at the relay rod.

  15. Object Number: 397366  Size: SH
  16. Disconnect the pitman arm ball stud from the relay rod using J 24319-B .

  17. Object Number: 291252  Size: SH
  18. Remove the idler arm ball stud nut at the relay rod.

  19. Object Number: 397363  Size: SH
  20. Disconnect the idler arm ball stud from the relay rod using J 24319-B .
  21. Remove the relay rod.
  22. Inspect the following components:
  23. • The threads on the tie rod for damage
    • The threads on the tie rod end for damage
    • The ball stud threads for damage
    • The ball stud seals for excessive wear
  24. Clean the threads on the ball stud and ball stud nut.

Installation Procedure


    Object Number: 291252  Size: SH
  1. Install the idler arm ball stud to the relay rod.
  2. Ensure that the seal is on the stud.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the new nut to the idler arm ball stud at the relay rod.
  4. Tighten
    Tighten the idler arm ball stud nut to 82 N·m (60 lb ft).


    Object Number: 291254  Size: SH
  5. Install the relay rod ball stud to the pitman arm.
  6. Ensure that the seal is on the stud.

  7. Install the new nut to the pitman arm ball stud at the relay rod.
  8. Tighten
    Tighten the pitman arm ball stud nut to 83 N·m (61 lb ft).


    Object Number: 291256  Size: SH
  9. Connect the steering shock absorber to the relay rod.
  10. Install the steering shock absorber ball stud nut at the relay rod.
  11. Tighten
    Tighten the steering shock absorber ball stud nut to 63 N·m (46 lb ft).


    Object Number: 291250  Size: SH
  12. Install the inner tie rod ball studs to the relay rod.
  13. Ensure the seal is on the stud.

  14. Install the new nuts to the inner tie rod ball studs at the relay rod.
  15. Tighten
    Tighten the inner tie rod ball stud nuts to 47 N·m (35 lb ft).


    Object Number: 141840  Size: SH
  16. Install the differential carrier shield.
  17. Install the differential carrier shield mounting bolts.
  18. Tighten
    Tighten the differential carrier shield mounting bolts to 25 N·m (19 lb ft).

  19. Install the steering linkage shield. Refer to Steering Linkage Shield Replacement .
  20. Lower the vehicle.
  21. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.