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Steering and Suspension

sperry

Silent Avalanche RIP
SM 2007
SM 2006
SM 2005
Full Member
Joined
Oct 22, 2003
Messages
13,160
Location
Seligman, AZ
Note: Tools are referenced to the supplier #.

Available @ SPX-Kent Moore
SPX Corporation - Service Solutions
655 Eisenhower Dr.
Owatonna, MN 55060
Refer to Catalog # GM01-319 and/or A7000:
SPX Kent-Moore
800-GM-TOOLS
(800-468-6657)
(507)455-7000
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Links in this topic:

Stabilizer Shaft Link Replacement: Scroll down - this posting.

Steering Relay Rod Replacement

Idler Arm Replacement

Pitman Arm Replacement

Power Steering GearBox Replacement

Intermediate Steering Shaft R&R - Lower

Idler Arm Inspection

Front Shock Absorber Replacement (02 Referenced)

Rear Shock Absorber Replacement (15 Series) - 02 Referenced.

Rear Shock Absorber Replacement (2500 Series) - 02 Referenced.

Power Steering Pulley Replacement

Power Steering Pump R&R (02: 5.3 L and 6.0 L Engines)

Power Steering Pump Flow Control Valve Replacement - Off Vehicle (2005 Referenced)

Power Steering Pump Replacement (03+: 5.3L and 6.0L)

Power Steering Pump Replacement (02 8.1L)

Bleeding the Power Steering System

Lower Ball Joint Replacement (Torsion Bar Suspension)

Upper Control Arm Replacement - 4WD (04 Referenced)

Lower Control Arm Replacement

Rear Position Sensor Replacement - Electronic Suspension - Left (1500 Series)

Rear Position Sensor Replacement - Electronic Suspension - Right (1500 & 2500 Series)

Rear Position Sensor Replacement - Electronic Suspension - Left (2500 Series)

Front Position Sensor Link Assembly Replacement - Electronic Suspension (EXT)


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Stabilizer Shaft Link Replacement

Removal Procedure

  1. Raise and support the vehicle.

normal_348361.gif


  2. Remove the stabilizer shaft nut (1) from the link bolt.
  3. Remove the stabilizer shaft link bolt (3).
  4. Remove the stabilizer shaft link insulators and spacers (2).
  5. Inspect all of the parts for wear and damage.

Installation Procedure

normal_348361.gif


  1. Install the stabilizer shaft link insulators and spacers (2).
  2. Perform the following procedure before installing the stabilizer link bolts.
        - Remove all traces of the original adhesive patch.
        - Apply Threadlocker GM P/N 12345382 (Canadian P/N 10953489) BLUE LOCTITE # 242 on the threads of the bolts.
  3. Install the stabilizer shaft link bolts (3).

     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.

     Notice: To avoid stabilizer shaft damage due to loss of clamp load, the threads of the link bolt must protrude 2 to 4 threads above the link nut after the specified torque is achieved.

  4. Install the stabilizer shaft nut (1) to the link bolt.

    Tighten

     Tighten the nut to 10 N?m (89 lb in). Continue to tighten the nut until 2-4 threads protrude above the nut.
  5. Remove the safety stands
  6. Lower the vehicle.
 
Steering Relay Rod Replacement

Tools Required

  ? J 24319-B Universal Steering Linkage Puller
  ? J 29193 Steering Linkage Installer (12 mm)
  ? J 29194 Steering Linkage Installer (14 mm)

Tools available from SPX Kent-moore

Removal Procedure

normal_340481.gif


  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  3. Remove the steering damper from the relay rod, if equipped. Refer to Steering Damper Replacement .

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

  4. Remove the tie rod ends (6). Refer to Tie Rod Replacement .
  5. Remove the idler arm ball stud nut (10).
  6. Do not reuse the nut. Remove the pitman arm nut (:cool:.
     Do not reuse the nut.

normal_643351.gif


  7. Remove the relay rod from the idler arm ball stud using the J 24319-B .
  8. Remove the relay rod from the pitman arm ball stud using the J 24319-B .
  9. Remove the relay rod from the vehicle.
 10. Inspect the threads on the tie rod ends for damage.
 11. Inspect the ball stud threads for damage.
 12. Inspect the ball stud seals for excessive damage.
 13. Clean the threads on the ball studs.

Installation Procedure

normal_340481.gif


  1. Install the relay rod (9) to the vehicle.
  2. Install the relay rod (9) to the pitman arm ball stud (2).
  3. Install the relay rod (9) to the idler arm ball stud (1).
  4. Ensure the seal is on the stud.

normal_689037.gif


  5. Install the J 29193 or the J 29194 .

     Notice: Refer to Fastener Cautions.

  6. Tighten the steering linkage installer in order to seat the tapers.

     Tighten

     Tighten the steering linkage installer to 54 N?m (40 lb ft).
  7. Remove the J 29193 or the J 29194 .
  8. Install the new pitman arm prevailing torque nut.
  9. Install the new idler arm prevailing torque nut .

     Tighten

     Tighten the nuts to 62 N?m (46 lb ft).
 10. Install the tie rod ends. Refer to Tie Rod Replacement .
 11. Install the steering damper to the relay rod, if equipped. Refer to Steering Damper Replacement .
 12. Install the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement in Frame and Underbody.
 13. Lower the vehicle.
 14. Check the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment.
 
Idler Arm Replacement

NOTE: Images expand slightly, if clicked on. It's best to have your browser set to "Open a new window" for this.

Tools Required

  ? J 24319-B Universal Steering Linkage Puller
  ? J 29193 Steering Linkage Installer (12 mm)
  ? J 29194 Steering Linkage Installer (14 mm)

Removal Procedure

Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints.

  1. Safely raise the vehicle.



  2. Remove the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  3. Remove the idler arm ball stud nut (10).
     Do not reuse the idler arm ball stud nut.



  4. Remove the idler arm from the relay rod using the J 24319-B.



  5. Remove the idler arm frame bolts (3) and the nuts (1).
  6. Remove the idler arm (2) from the vehicle.

Installation Procedure



  1. Position the idler arm (2) on the frame.

     Notice: Refer to Fastener Notice.

  2. Install the frame bolts (3) and the nuts (1) to the idler arm.

     Tighten

     Tighten the frame bolts or nuts to 99 N?m (73 lb ft).



  3. Install the relay rod (9) to the idler arm ball stud (1).
     Ensure the seal is on the stud.


 
  4. Use the J 29193 in order to seat the tapers.

     Tighten

     Tighten the J 29193 or the J 29194 to 54 N?m (40 lb ft) in order to seat the tapers.

  5. Install the new idler arm ball stud prevailing torque nut to the idler arm ball stud.

     Tighten

  6. Install the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  7. Lower the vehicle.
  8. Check the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment.
 
Pitman Arm Replacement

Tools Required


  ? J 6632-01 Pitman Arm Puller
  ? J 29107-A Pitman Arm Puller

Removal Procedure



  1. Safely raise and suitable support the vehicle.  
  2. Remove the power steering gear. Refer to Power Steering GearBox Replacement.
  3. Install the power steering gear into a vise.
  4. Remove the pitman arm nut and washer.



  5. Remove the pitman arm from the pitman shaft using J 6632-01 or J 29107-A .

Installation Procedure



  1. Install the pitman arm to the power steering gear.

    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.

  2. Install a new pitman arm washer and nut.

     Tighten

     Tighten the nut to 250 N?m (184 lb ft).

  3. Remove the power steering gear from the vise.
  4. Install the power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
  5. Lower the vehicle.
  6. Check the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment.
 
Power Steering GearBox Replacement

NOTE: These images expand moderately by clicking on them.

Removal Procedure

Tools Required

  ? J 6632-01 Pitman Arm Puller
  ? J 24319-B Universal Steering Linkage Puller
  ? J 29107-A Pitman Arm Puller

  1. Place a drain pan under the vehicle.
  2. Remove the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement.

     Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system.

  3. Remove the power steering hoses from the steering gear.
  4. Cap the ends of the hoses and the power steering gear in order to prevent any entrance of dirt.
  5. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement - Lower.



  6. Remove the pitman arm to relay rod nut.



  7. Disconnect the pitman arm from the relay rod using J 24319-B .



  8. Remove the bolts retaining the steering gear to the frame.
  9. Remove the steering gear from the vehicle.



 10. Remove the pitman arm to the power steering gear retaining nut.



 11. Remove the pitman arm from the power steering gear using J 6632-01 or J 29107-A .

Installation Procedure



  1. Install the pitman arm to the power steering gear.

    Notice: Refer to Fastener Notice.

  2. Install the pitman arm to power steering gear retaining nut and washer.

     Tighten

     Tighten the nut to 250 N?m (184 lb ft).



  3. Install the steering gear to the frame and install the retaining bolts.

     Tighten

     Tighten the bolts to 150 N?m (110 lb ft).



  4. Install the pitman arm to the relay rod.
  5. Install the pitman arm to the relay rod nut.

     Tighten

     Tighten the nut to 62 N?m (46 lb ft).

  6. Install the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement - Lower in Steering Wheel and Column.
  7. Remove the caps or plugs from the steering gear and hoses.
  8. Install the hoses to the steering gear.

     Tighten

     Tighten the hoses fittings to 28 N?m (20 lb ft).

  9. Install the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement in Frame and Underbody.
 10. Remove the safety stands.
 11. Lower the vehicle.
 12. Bleed the power steering system. Refer to Bleeding the Power Steering System .
 
Intermediate Steering Shaft R&R - Lower

Tools Required

J 42640 Steering Column Anti-Rotation Pin.

Removal Procedure

Caution: Refer to SIR Caution!

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.

  1. Set the front wheels in the straight-ahead position.



  2. Install the J 42640 in the steering column lower access hole.
  3. Mark the relationship of the intermediate shaft components in order to assure proper installation.
        1. Mark the relationship of the upper intermediate shaft to the lower intermediate shaft.
        2. Mark the relationship of the lower shaft coupler to the steering gear input shaft.



  4. Remove the bolt from the upper to lower shaft connection.
  5. Remove the bolt from the lower shaft coupler.
  6. Remove the intermediate shaft assembly.
  7. Slide the shaft towards the dash in order to get the lower shaft coupler clear of the steering gear input shaft. Slide the intermediate shaft down out of the upper shaft.

Installation Procedure


  1. Install the upper end of the intermediate shaft into the upper shaft.
  2. Install the lower end of the intermediate shaft coupler.
        1. If you are reinstalling the same shaft, align the marks made during the removal procedure.
        2. Install the lower end of the intermediate shaft coupler onto the steering gear worm shaft.
  3. Install the bolt to the lower shaft coupler.

    Notice: Refer to Fastener Notice.

  4. Install the bolt to the upper end of the shaft.

     Tighten

        ? Tighten the upper bolt to 47 N?m (35 lb ft).
        ? Tighten the coupler pinch bolt to 50 N?m (37 lb ft).



  5. Remove the J 42640 from the steering column lower access hole.
 
Refer to GM Document #1637288

Idler Arm Inspection

Click on images to expand them.

Tools Required

  ? J 35999 Spring Scale
  ? J 42640 Steering Column Anti-Rotation Pin
  ? J 45101 Hub and Wheel Runout Gage

  1. Raise the vehicle on a hoist. Support the vehicle with jackstands. Refer to Lifting and Jacking the Vehicle .



     Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.

  2. Position the wheels in a straight-ahead position and install the J 42640.
  3. Install the dial indicator J 45101 between the idler arm and vehicle frame.
     Ensure the gage is at zero before taking a measurement.

 
  4. Place a J 35999 near the relay rod end of the idler arm.



  5. Exert a 110 N?m (25 lb) force upward, and then downward while measuring the total distance the arm moves.



  6. If movement exceeds 2 mm (0.078 in) replace the idler arm.



  7. Install the dial indicator at the idler arm.
  8. Push the tire inward slowly with one hand to remove any lash.
     Zero out the dial indicator and pull outward in order to take a reading.



  9. Allow only 1 mm (0.039 in) of movement at the idler arm ball stud.
 10. If more than 1 mm exists, replace the idler arm. Lower the vehicle.
 
Front Position Sensor Link Assembly Replacement - Electronic Suspension (EXT)

Tools Required:

J 38185 Spring Hose Clamp Pliers

Removal Procedure

      Important:
      Do not attempt to pry the link rod from the real time damping (RTD) ball stud. If the link rod needs to be replaced or disconnected you must use the following procedure
.

  1. Remove the RTD sensor from the vehicle. Refer to Front Position Sensor Replacement - Electronic Suspension .
  2. While supporting the sensor lever by hand, twist the link rod to remove it from the ball stud.
  3. Remove the link rod from the mounting bracket ball stud.

Installation Procedure



  1. Using the J 38185 install to link rod to the ball stud on the sensor lever and the mounting bracket.
  2. Install the RTD sensor to the vehicle. Refer to Front Position Sensor Replacement - Electronic Suspension .
 
Front Shock Absorber Replacement (02 Referenced)

Removal Procedure

Notice: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



  2. Support the lower control arm with a jack stand.
  3. Disconnect the front position sensor link rod from the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension.



  4. Grasp the connector lock tabs (1, 2). Rotate the connector tabs counterclockwise until the connector is unlocked.
  5. Disengage the connector from the tennon by firmly pulling the connector up.
  6. Hold the tennon end with a wrench while removing the nut.
  7. Remove the nut.



  8. Remove the upper insulator (1). Do not discard the plastic pilot ring (2).



  9. Remove the shock absorber mounting bolt at the lower control arm, 15 Series.



  10. Remove the shock absorber mounting bolt (2) at the lower control arm, 25/35 Series.
  11. Remove the shock absorber.

Installation Procedure

  1. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame.



  2. Align the shock absorber with the mounting holes in the lower control arm, 15 Series.



  3. Align the shock absorber with the mounting holes in the lower control arm, 25/35 Series.
  4. Install the shock absorber bolt (2) to the lower control arm.

      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.

  5. Install the shock absorber nut (3) to the bolt.

      Tighten

      Tighten the nut to 80 N?m (59 lb ft).




      Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators.

  6. Install the upper insulator to the shock absorber.
  7. Install the nut to the tennon end. Do not tighten the nut.
  8. Connect the front position sensor link rod to the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension.
  9. Remove the safety stands.
  10. Lower the vehicle.
  11. Hold the tennon end with a wrench while torquing the nut.

      Tighten

      Tighten the nut to 20 N?m (15 lb ft).

  12. Properly dispose of the old shock absorber(s).

Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury.
 
Rear Shock Absorber Replacement (15 Series Utility) - 02 Referenced.

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



  2. Disconnect the electrical connector and air line if equipped with Real Time Damping (RTD).
  3. Support the rear axle.
  4. Disconnect the RTD sensor (if equipped). Refer to Rear Position Sensor Replacement - Electronic Suspension - Left or Rear Position Sensor Replacement - Electronic Suspension - Right.



  5. Remove the upper shock absorber nut and the bolt.
  6. Remove the lower shock absorber nut and the bolt.
  7. Remove the shock absorber.

Installation Procedure



  1. Install the shock absorber.

     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.

  2. Install the upper shock absorber nut and bolt.
  3. Install the lower shock absorber nut and bolt.

     Tighten

     Tighten the nuts to 95 N?m (70 lb ft).



  4. Connect the electrical connector and air line if equipped with RTD.
  5. Connect the RTD sensor, if equipped. Refer to Rear Position Sensor Replacement - Electronic Suspension - Left or Rear Position Sensor Replacement - Electronic Suspension - Right.

  6. Remove the support from the rear axle.
  7. Remove the safety stands.
  8. Lower the vehicle.
 
Rear Shock Absorber Replacement (2500 Series Utility) - 02 Referenced.

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Support the rear axle.



  3. Disconnect the Real Time Damping (RTD) electrical connector at the pigtail connector left side only, if equipped.
  4. Disconnect the RTD electrical connector at the top of the right side shock, if equipped.
  5. Disconnect the RTD sensor (if equipped). Refer to Rear Position Sensor Replacement - Electronic Suspension - Left or Rear Position Sensor Replacement - Electronic Suspension - Right.



  6. Remove the upper shock absorber nut and the bolt.
  7. Remove the lower shock absorber nut and the bolt.
  8. Remove the shock absorber.

Installation Procedure



  1. Install the shock absorber.

     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.

  2. Install the upper shock absorber nut and bolt.
  3. Install the lower shock absorber nut and bolt.

     Tighten

     Tighten the nuts to 95 N?m (70 lb ft).

  4. Remove the rear axle support.
  5. Connect the RTD sensor (if equipped). Refer to Rear Position Sensor Replacement - Electronic Suspension - Left or Rear Position Sensor Replacement - Electronic Suspension - Right.
  6. Connect the RTD electrical connector at the top of the right side shock, if equipped.



  7. Connect the RTD electrical connector at the pigtail connector left side only (if equipped).
  8. Remove the safety stands.
  9. Lower the vehicle.
 
Rear Position Sensor Replacement - Electronic Suspension - Left (1500 Series)

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the wheel and tire assembly from the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



  3. Disconnect the sensor harness connector from the vehicle harness connector.
  4. Remove the bolt from the real time damping (RTD) sensor link bracket.
  5. Spread the bracket open until the bracket can be removed from the upper control arm.
  6. Remove the bolts from the frame.
  7. Remove the position sensor from the vehicle.

Installation Procedure



  1. Install the position sensor on the vehicle.

     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.

  2. Install the bolts to the frame.

     Tighten

     Tighten the bolts to 12 N?m (106 lb in).



  3. Close the bracket around the upper control arm making sure the bracket rests between the locating stops.
  4. Install the bolt.

     Tighten

     Tighten the bolt to 25 N?m (18 lb ft).

  5. Connect the sensor harness connector to the vehicle harness connector.
  6. Install the wheel and tire assembly to the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  7. Lower the vehicle.
 
Rear Position Sensor Replacement - Electronic Suspension - Left (2500 Series)

Removal Procedure

  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the wheel from the vehicle. Refer to Tire and Wheel Removal and Installation.



  3. Disconnect the sensor harness connector from the vehicle harness connector.



  4. Remove the bolts.
  5. Remove the position sensor from the vehicle.
  6. Disconnect the sensor link from the ball stud.

Installation Procedure



  1. Install the position sensor on the vehicle.

     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.

  2. Install the bolts.

     Tighten

     Tighten the bolts to 12 N?m (106 lb in).

  3. Connect the sensor link to the ball stud.



  4. Connect the sensor harness connector to the vehicle harness connector.
  5. Install the wheel onto the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  6. Lower the vehicle.
 
Rear Position Sensor Replacement - Electronic Suspension - Right (1500 & 2500 Series)

Removal Procedure

  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the wheel from the vehicle. Refer to Tire and Wheel Removal and Installation.



  3. Disconnect the sensor harness connector from the vehicle harness connector.
  4. Disconnect the sensor link from the ball stud.



  5. Remove the bolts.
  6. Remove the position sensor from the vehicle.

Installation Procedure



  1. Install the position sensor on the vehicle.

     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.

  2. Install the bolts.

     Tighten

     Tighten the bolts to 12 N?m (106 lb in).

  3. Connect the sensor link to the ball stud.



  4. Connect the sensor harness connector to the vehicle harness connector.
  5. Install the wheel onto the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  6. Lower the vehicle.
 
Upper Control Arm Replacement - 4WD (04 Referenced)

Tools Required

Source: SPX-Kent-Moore

  ? J 43631 Ball Joint Separator
  ? J 45851 Ball Joint Seperator Protector Adapters

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation.
  3. Disconnect the electronic suspension control (ESC) link rod from the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension.



  4. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets.
  5. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.



  6. Remove the upper ball joint retaining nut.



  7. Disconnect the upper control arm from the steering knuckle using the J 43631 and J 45851 .



  8. Remove the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD.
  9. Remove the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD.



 10. Remove the upper control arm nuts and the adjustment cams (2) for the 25/35 Series 4WD.
 11. Remove the upper control arm bolts (4) for the 25/35 Series 4WD.
 12. Remove the upper control arm.

Installation Procedure

  1. Install the upper control arm.



  2. Install the upper control arm bolts (4) for the 25/35 Series 4WD.

     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 upper control arm nuts and the adjustment cams (2) 25/35 Series 4WD.

     Tighten
     Tighten the nuts to 190 N?m (140 lb ft).



  4. Install the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD.
  5. Install the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD.

     Tighten
     Tighten the nuts to 190 N?m (140 lb ft).

  6. Connect the upper control arm to the steering knuckle .
  7. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.



  8. Install the new nut to the upper ball joint stud.

     Tighten
     Tighten the nut to 50 N?m (37 lb ft).


     
  9. Install the retaining bolts for the brake hose and wheel speed sensor brackets.

     Tighten
     Tighten the bolts to 9 N?m (80 lb in).

 10. Connect the ESC link rod to the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension.
 11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation.
 12. Remove the safety stands.
 13. Lower the vehicle.
 14. Verify the wheel alignment. Refer to Measuring Wheel Alignment.
 
Power Steering Pulley Replacement

    * Tools Required J 25034-C Power Steering Pump Pulley Remover
    * J 25033-C Power Steering Pump Pulley Installer

Removal Procedure

  1. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper.
  2. Remove the drive belt. Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Accessory.



  3. Remove the power steering pump pulley using the J 25034-C .

Installation Procedure



  1. Place the power steering pump pulley on the end of the power steering pump shaft.
  2. Install the power steering pump pulley using J 25033-C .



  3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft, with an allowable variance of 0.25 mm (0.010 in).
  4. Install the drive belt. Refer to Drive Belt Replacement - Accessory or Drive Belt Replacement - Accessory.
  5. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper.
 
Power Steering Pump R&R (02: 5.3 L and 6.0 L Engines)

Removal Procedure

  1. Remove the power steering pulley. Refer to Power Steering Pulley Replacement .
  2. Place a drain pan under the pump.
  3. Remove the hose guide bracket from the front of the pump.
  4. For vehicles with variable effort steering, disconnect the electrical connector.
  5. Remove the hoses from the pump.
  6. Remove the lower intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement - Lower in Steering Wheel and Column.
  7. Remove the bolt retaining the rear bracket to the engine.



  8. Remove the bolts from the front of the pump.
  9. Remove the pump from the vehicle.



  10. Remove the bracket (3) from the rear of the pump (1).

Installation Procedure

      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.



  1. Install the bracket (3) to the rear of the pump (1).

      Tighten
      Tighten the rear bracket retaining nuts to 50 N?m (37 lb ft).


     
  2. Install the pump.
  3. Install the hose guide bracket bolt to the pump.
  4. Install the bolt retaining the rear bracket to the engine.
  5. Install the bolts to the front of the pump.

      Tighten
      Tighten the bolts to 50 N?m (37 lb ft).

  6. For vehicles with variable effort steering, connect the electrical connector.
  7. Install the hoses to the pump.

      Tighten
      Tighten the nut to 28 N?m (20 lb ft).

  8. Install the intermediate shaft. Refer to Intermediate Steering Shaft Replacement - Lower.
  9. Install the power steering pulley. Refer to Power Steering Pulley Replacement .
  10. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System.

PSP Part: #15078157 2002 5.3
 
Power Steering Pump Replacement (03+: 5.3L and 6.0L)

Removal Procedure

  1. Remove the power steering pulley. Refer to Power Steering Pulley Replacement .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.



  3. Remove the oil pan skid plate bolts.
  4. Remove the oil pan skid plate from the vehicle, if equipped.
  5. Place a drain pan under the vehicle.



  6. Remove the power steering pressure hose (2) from the power steering pump from underneath the vehicle.
  7. Lower the vehicle.



  8. Remove the clamps (3,5) retaining the power steering return hoses to the power steering pump and remove the hoses.
  9. Remove the lower intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement - Lower.



  10. Remove the bolt retaining the rear bracket to the engine.
  11. Remove the bolts from the front of the pump.
  12. Remove the pump from the vehicle.



  13. Remove the bracket (3) from the rear of the pump (1).

Installation Procedure

      Notice: Refer to Fastener Notice.



  1. Install the bracket (3) to the rear of the pump (1).

      Tighten
      Tighten the rear bracket retaining nuts to 50 N?m (37 lb ft).



  2. Install the power steering pump.
  3. Install the bolt retaining the rear bracket to the engine.

      Tighten
      Tighten the rear power steering bracket bolt to engine bracket to 50 N?m (37 lb ft).
  4. Install the bolts to the front of the pump.

      Tighten
      Tighten the bolts to 50 N?m (37 lb ft).



  5. Install the power steering pump return hoses (2,4) to the power steering pump and install the retaining clamps.
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.



  7. Install the power steering pressure hose (2) to the power steering pump.

      Tighten
      Tighten the fitting to 28 N?m (20 lb ft).



  8. Install the oil pan skid plate, if equipped.
  9. Install the oil pan skid plate bolts.

      Tighten
      Tighten the retaining bolts to 20 N?m (15 lb ft).

  10. Lower the vehicle.
  11. Install the intermediate shaft. Refer to Intermediate Steering Shaft Replacement - Lower .
  12. Install the power steering pulley. Refer to Refer to Power Steering Pulley Replacement .
  13. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System .
 
Power Steering Pump Replacement (02 8.1L)

Removal Procedure

  1. Place a drain pan under the vehicle.
  2. Remove the power steering pulley. Refer to Power Steering Pulley Replacement.



  3. Remove the nut (1) and clamp (3) retaining the filler neck (1) to the power steering pump, if equipped.



  4. Remove the bolts (2) from the front of the pump.
  5. Remove the bolts retaining the power steering mounting bracket.



  6. Remove the bolts from the rear of the pump.
  7. Remove the hoses from the pump.
  8. For vehicles with variable effort steering, disconnect the electrical connector.
  9. Remove the pump from the vehicle.
 10. Remove the rear bracket from the power steering pump.

Installation Procedure

     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.

  1. Install the rear bracket to the power steering pump.

    Tighten
     Tighten the rear bracket retaining bolts to 50 N?m (37 lb ft).

  2. Install the power steering pump to the vehicle.
  3. Install the hoses to the pump.

     Tighten
     Tighten the hose fitting to 28 N?m (20 lb ft).

  4. For vehicles with variable effort steering, connect the electrical connector.


     
  5. Install the bolts (1) to the rear of the power steering pump.

     Tighten
     Tighten the rear bolts to 50 N?m (37 lb ft).

  6. Install the power steering pump mounting bracket.

     Tighten
     Tighten the mounting bracket bolts to 46 N?m (34 lb ft).


     
  7. Install the power steering pump (1) to the bracket.
  8. Install the bolts (2) to the front of the pump.

     Tighten
     Tighten the power steering pump retaining bolts to 50 N?m (37 lb ft).



  9. Install the filler neck to the power steering pump.
 10. Install the nut (1) and clamp (3) retaining the filler neck to the power steering pump.

     Tighten
     Tighten the filler neck retaining nut to 25 N?m (18 lb ft).

 11. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System.
 
Bleeding the Power Steering System

Tools Required:

  ? J 35555 Metal Mityvac
  ? J 43485 Power Steering Bleeder Adapter

     Important: Hoses touching the frame, body, or engine may cause system noise.

  1. Verify that the hoses do not touch any other part of the vehicle.


     Important: Loose connections may not leak, but could allow air into the steering system.

  2. Verify that all hose connections are tight.



     Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time.

    Important: Maintain the fluid level throughout the bleed procedure.

  3. Remove the pump reservoir cap.

     Important: Use clean, new power steering fluid only.

  4. Fill the pump reservoir with fluid to the FULL COLD level.



  5. Attach the J 43485 to the J 35555 or equivalent.
  6. Place the J 43485 on or in the pump reservoir filler neck.
  7. Apply a vacuum of 68 kPa (20 in Hg) maximum.
  8. Wait 5 minutes.
  9. Typical vacuum drop is 7-10 kPa (2-3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis at the end of this procedure. Remove the J 43485 and the J 35555 .
 10. Reinstall the pump reservoir cap.
 11. Start the engine. Allow the engine to idle.
 12. Turn off the engine.
 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes.

     Important: Do not turn steering wheel to lock.

 14. Start the engine. Allow the engine to idle.
 15. Turn the steering wheel 180-360 degrees in both directions 5 times.
 16. Switch the ignition off.

     Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.

 17. Verify the fluid level.



 18. Remove the pump reservoir cap.



 19. Attach the J 43485 to the J 35555 or equivalent.
 20. Place the J 43485 on or in the pump reservoir filler neck.
 21. Apply a vacuum of 68 kPa (20 in Hg) maximum.
 22. Wait 5 minutes.
 23. Remove the J 43485 and the J 35555 .
 24. Verify the fluid level.



 25. Reinstall the pump reservoir cap.

Excessive Vacuum Drop Diagnosis:



  1. If the vacuum continues to drop, remove the pressure and return hose from the pump.
  2. Install the plugs (1,2) supplied with the J 43485 into the pressure and return port.



  3. Attach the J 43485 to the J 35555 or equivalent.
  4. Place the J 43485 on or in the pump reservoir filler neck.
  5. Apply a vacuum of 68 kPa (20 in Hg) maximum.
  6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system.

     Important: Fluid must be free from bubbles and foam. Be aware of periodic bubbles that indicate a loose connection or leaking O-ring seal in the return hose or the pressure hose.

     Fluid must be free from discoloration.

  7. Observe the fluid.
  8. If condition persists, replace the following parts:
        - The return hose clamps
        - The return hose O-rings
        - The pressure hose O-rings
        - The gear cylinder line O-rings
        - The reservoir to pump O-ring
  9. Repeat the bleed procedure from the beginning.
 10. Drive the vehicle approximately 16 km (10 mi) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface.
 11. Verify the following conditions:
        - There is smooth power assist.
        - The vehicle operates quietly.
        - The pump maintains the proper fluid level.
        - There is not any leaking in the steering system.
        - The fluid is free of foam or discoloration.
 
Lower Control Arm Replacement

2003 2WD referenced.

    * Tools Required J 43631 Ball Joint Separator
    * J 45851 Ball Joint Separator Protector Adapters

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.


 
  2. Support the lower control arm with a safety stand.
  3. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installationhttp://www.chevyavalanchefanclub.com/cafcna/index.php/topic,45517.msg722450.html#msg722450http://www.chevyavalanchefanclub.com/cafcna/index.php/topic,45517.msg722450.html#msg722450.
  4. Remove the stabilizer shaft links from the lower control arm. Refer to Stabilizer Shaft Link Replacement .
  5. Remove the shock absorber lower nut and the bolt. Refer to Front Shock Absorber Replacement.
  6. Remove the torsion bars. Refer to Torsion Bar Replacement .
  7. (4WD) Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.

 
830506.jpg


  8. Remove the lower ball joint retaining nut.

853943_002.jpg

 
  9. Disconnect the lower ball joint stud from the steering knuckle using J 43631 and J 45851.

 
348376_003.jpg

     
  10. Remove the lower control arm nuts and the 15-series washers.
  11. Remove the lower control arm bolts.

 
348377_005.jpg

   
  12. Remove the lower control arm nuts and the 25/35-series washers.
  13. Remove the lower control arm bolts.
  14. Remove the lower control arm.

Installation Procedure

  1. Install the lower control arm.

348376_003.jpg

     
  2. Install the lower control arm 15-series bolts.

348377_005.jpg

   
  3. Install the lower control arm 25/35-series bolts.

      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.


  4. Install the lower control arm retaining nuts.

      Tighten

      Tighten the nuts to 150 N?m (110 lb ft).

  5. Connect lower ball joint stud to the steering knuckle.
  6. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.


 
830506.jpg


  7. Install the nut to the lower ball joint stud.

      Tighten

      Tighten the nut to 100 N?m (74 lb ft).

  8. Install the torsion bars. Refer to Torsion Bar Replacement .
  9. Install the shock absorber lower nut and bolt. Refer to Shock Absorber Replacement .
  10. Install the stabilizer shaft links to the lower control arm. Refer to Stabilizer Shaft Replacement .
  11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  12. Remove the safety stands.
  13. Lower the vehicle.
  14. Align the vehicle. Refer to Measuring Wheel Alignment in Wheel Alignment.
 
Lower Ball Joint Replacement (Torsion Bar Suspension)

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
  3. Remove the lower control arm. Refer to Lower Control Arm Replacement .
  4. Place the lower control arm in a bench vice.
  5. Using a chisel, remove the securing crimps from the ball joint body, if equipped.
  6. Using a press, remove the ball joint from the lower control arm.

Installation Procedure

      Important

      Use the outer flange of the ball joint in order to press the ball joint into place.


  1. Install the new ball joint using a press.
  2. Place the lower control arm in a bench vice.
  3. Using a punch, install crimps to the ball joint, if necessary. Use the replaced ball joint as a reference.
  4. Install the lower control arm. Refer to Lower Control Arm Replacement .
  5. Install the tire and wheel assembly. Refer to Refer to Tire and Wheel Removal and Installation.
  6. Remove the safety stands.
  7. Lower the vehicle.
  8. Verify the wheel alignment.
 
----------------------

Document ID# 431143
2005 Chevrolet Avalanche - 2WD​

Power Steering Pump Flow Control Valve Replacement - Off Vehicle

Disassembly Procedure



  1. Drain the oil from the reservoir (1).
  2. Remove the control valve assembly (3) from the pump housing (1). Make sure the flow control spring (4) does not fall out of the pump housing (1).
  3. Remove the rectangular section seal (2) from the control valve assembly (3).

Assembly Procedure



  1. Install the flow control spring (4) if removed from the pump housing (1).
  2. Lubricate the new rectangular section seal (2) with power steering fluid.
  3. Install the rectangular section seal (2) onto the control valve assembly (3).
  4. Install the control valve assembly (3).
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