GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Electrical 🢒 Steering Gear Replacement

Removal Procedure
  1. Turn the steering wheel to the straight forward position, support it from movement, and remove the key from the ignition.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation .

    4. Object Number: 851655 Size: SH
  4. Remove the intermediate shaft to steering gear pinch bolt. Discard the bolt.

    5. Important: Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.

  5. Separate the intermediate shaft from the steering gear.
  6. Remove the tie rod end castle nuts.

    7. Object Number: 643351 Size: SH

    Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.

  7. Using the J 24319-B , separate the tie rod ends from the steering knuckles.

    8. Object Number: 1770184 Size: SH
  8. Remove the rear transmission mount-to-transmission bolt.

    9. Object Number: 1229955 Size: SH
  9. Remove the steering gear to frame bolts.
  10. Remove the steering gear through the left side of the vehicle. Rotate the gear 90 degrees in order to clear the rear transmission mount.
  11. If replacing the steering gear, remove the outer tie rod ends. Refer to Rack and Pinion Outer Tie Rod End Replacement .

Installation Procedure
  1. Install the outer tie rod ends to the steering gear. Refer to Rack and Pinion Outer Tie Rod End Replacement .

    2. Object Number: 1229955 Size: SH
  2. Install the steering gear to the vehicle. Rotate the gear as necessary to clear the rear transmission mount.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the steering gear to frame bolts.

    4. Tighten
    Tighten the bolts to 70 N·m (52 lb ft) plus an additional 90 degrees.


    Object Number: 1770184 Size: SH
  4. Install the rear transmission mount-to-transmission bolt.

    5. Tighten
    Tighten the bolt to 90 N·m (66 lb ft).


    Object Number: 851655 Size: SH
  5. Connect the intermediate steering shaft to the steering gear as noted during removal.
  6. Install the new intermediate steering shaft to steering gear pinch bolt.

    7. Tighten
    Tighten the bolt to 49 N·m (36 lb ft).

  7. Position the outer tie rod ends into the steering knuckles.

    8. Important: Hold the ball stud from turning during installation of the castle nut.

  8. Install new torque castle nuts to the tie rod end ball studs.

    9. Tighten
    Tighten the castle nuts to 60 N·m (44 lb ft).

  9. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  10. Lower the vehicle.
  11. Measure the wheel alignment and adjust as necessary. Refer to Wheel Alignment Measurement .