Rack and Pinion Boots

Remove and replace the inner and outer rack and pinion steering boots on both sides of the steering rack to prevent contamination and ensure proper steering operation.

Warnings

Tools required

Parts

• Steering rack boot kit (inner and outer, left) × 1 — Use OEM specification
• Steering rack boot kit (inner and outer, right) × 1 — Use OEM specification
• Boot clamps (various sizes) × 8 — Typically included with boot kits
• Cotter pin for tie rod end × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn steering wheel to center position and lock steering column if possible
3. Raise front of vehicle and support securely on jack stands at manufacturer-approved lift points
4. Remove both front wheels
5. Clean tie rod ends and steering rack area with parts cleaner to expose fasteners and prevent contamination during boot replacement

Procedure

1. 1

   Remove front wheel and access steering components
   With the wheel already removed during preparation, inspect the tie rod end connection at the steering knuckle. Spray penetrating oil on the tie rod end castle nut and allow to soak for several minutes. This is a critical fastener and corrosion can make removal difficult.
2. 2

   Mark tie rod position and remove cotter pin
   Use a paint marker or scribe to mark the threaded position of the tie rod end on the tie rod shaft. Count and record the number of visible threads. If the tie rod end uses a castle nut with cotter pin (verify against Aston Martin service data), remove and discard the cotter pin using diagonal cutters or needle-nose pliers.
3. 3

   Disconnect tie rod end from steering knuckle
   Using the correct size socket (verify against Aston Martin service data), loosen but do not fully remove the tie rod end castle nut by several turns. This protects the threads during separation. Insert a tie rod end separator or pickle fork between the tie rod end taper and the steering knuckle arm. Strike the separator firmly with a hammer to break the taper free. Once separated, remove the castle nut completely and remove the tie rod end from the knuckle. Note: Using the correct size socket (verify against OEM specification), loosen but do not fully remove the tie rod end castle nut by several turns. Note: The DB9 may use a self-locking nut or a castle nut with cotter pin (verify fastener type against Aston Martin service data). If a cotter pin is present, remove and discard it using diagonal cutters or needle-nose pliers.
   Torque spec

   Tie Rod End Castle Nut48 Nm (35 lb-ft)
4. 4

   Loosen tie rod jam nut
   Locate the jam nut (lock nut) between the outer tie rod end and the inner tie rod/rack boot. This nut secures the tie rod end adjustment. Using the correct size wrench (verify against OEM specification), loosen but do not remove the jam nut. This will allow the outer tie rod to unthread from the inner tie rod assembly. Note: Using the correct size wrench (verify against Aston Martin service data), loosen but do not remove the jam nut.
5. 5

   Remove outer tie rod end
   Counting the turns for reference, unthread the outer tie rod end from the inner tie rod by hand. Record the exact number of turns observed during removal for this specific vehicle, as the count varies and is not published for the DB9. Record the exact number of turns to aid reassembly. Set the outer tie rod end and jam nut aside. Note: The number of turns varies; the critical step is to count and record the exact turns during removal so the position can be matched on reassembly. Note: The exact number of turns varies; rely on the count you recorded during removal rather than a generic value. Note: Not published — count and record the actual number of turns during removal on this specific vehicle
6. 6

   Remove outer boot clamps
   Locate the two clamps securing the outer steering rack boot: one at the tie rod end of the boot and one at the rack housing end. These are typically crimp-style or worm-drive clamps. Using boot clamp pliers or side cutters, cut or release both clamps and discard them. Note the orientation and position of the clamps for reinstallation.
7. 7

   Remove outer steering rack boot
   Slide the outer boot off the inner tie rod and over the rack housing. If the boot is stuck due to dried grease or corrosion, carefully twist and pull it free. Inspect the inner tie rod threads and ball joint for wear or damage. Wipe away old grease with shop rags to expose the connection between inner and outer boot sections.
8. 8

   Access and remove inner boot clamps
   The inner boot connects directly to the steering rack housing and is secured with clamps at both the rack housing end and the breather tube connection (if equipped). Cut or release the inner boot clamps using boot clamp pliers or side cutters. On the DB9, access to the rack-side clamp may require turning the steering wheel to expose the boot attachment point. Discard old clamps.
9. 9

   Remove inner steering rack boot
   Slide the inner boot off the steering rack housing. Only grease should be present; power steering fluid leaking from the rack housing is NOT normal and indicates a failed internal rack seal requiring further diagnosis. Inspect the rack housing seal and inner tie rod connection point for damage, excessive wear, or fluid leakage beyond normal residue. Clean the rack housing mounting surface with parts cleaner and allow to dry.
10. 10

    Install new inner steering rack boot
    Slide the new inner boot onto the steering rack housing, ensuring it seats fully into the groove on the rack body. The boot should sit flush without gaps. Install new clamps at both ends of the inner boot: one at the rack housing and one at the breather tube connection (if applicable). Position clamps according to manufacturer specifications and tighten securely using boot clamp pliers or a clamp installation tool. Ensure clamps do not cut or pinch the boot material.
11. 11

    Install new outer steering rack boot
    Apply a small amount of the OEM-specified steering boot/joint grease to the inner tie rod threads and ball joint if not pre-greased. Slide the new outer boot over the rack housing and onto the inner tie rod, ensuring it overlaps correctly with the inner boot section. Install new clamps at both ends of the outer boot and tighten securely. Verify the boot is not twisted and has freedom to flex during steering movement. Note: Apply a small amount of appropriate steering rack grease (per OEM specification) to the inner tie rod threads and ball joint if not pre-greased. Note: Apply a small amount of appropriate steering/suspension grease to the inner tie rod threads and ball joint if not pre-greased.
12. 12

    Reinstall outer tie rod end
    Thread the outer tie rod end back onto the inner tie rod, counting turns to match the number recorded during removal. When the tie rod end is positioned approximately at the original mark, hand-tighten the jam nut against the tie rod end body but do not torque yet (final alignment adjustment may be needed). Verify the tie rod end ball stud is clean and free of debris.
13. 13

    Reconnect tie rod end to steering knuckle
    Insert the tie rod end ball stud into the steering knuckle taper. Install the castle nut and tighten to specification using a torque wrench. The castle nut slots must align with the ball stud cotter pin hole. If necessary, tighten the nut slightly beyond torque spec (never loosen) to align the slots. Install a new cotter pin and bend the ends to secure.
    Torque spec

    Tie Rod End Castle Nut48 Nm (35 lb-ft)
14. 14

    Complete opposite side
    Repeat steps 1 through 13 for the opposite side of the vehicle, replacing both inner and outer boots on the second side of the steering rack. Ensure all clamps are tight and boots are properly seated on both sides before proceeding.
15. 15

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, ensuring the mounting surfaces are clean. Install lug nuts and tighten in a star pattern to specification using a torque wrench. Lower the vehicle from jack stands and perform a final torque check on all lug nuts with the vehicle weight on the ground.
    Torque spec

    Wheel Lug Nuts89 Nm (66 lb-ft)

Reassembly

1. Verify all boot clamps are tight and boots are not twisted or damaged
2. Check power steering fluid reservoir level and top off with CHF 11S if necessary
3. Inspect for any fluid leaks around the steering rack boots after starting the engine
4. Turn steering wheel lock-to-lock several times to verify boots flex properly without binding

Verification

• Start engine and turn steering wheel fully left and right to check for binding or unusual noises
• Inspect all boot clamps and connections for leaks with engine running and steering at full lock
• Verify no power steering fluid is leaking from boot connections
• Check that boots flex smoothly during steering operation without twisting or pulling loose
• Schedule professional wheel alignment as tie rod ends have been disconnected and adjusted

More procedures for this vehicle