Pitman Arm

This procedure covers the removal and replacement of the pitman arm on a 2023 Chevrolet Bolt EUV. Note that this electric vehicle uses electric power steering, but some steering linkage components may still be referred to by traditional names.

Warnings

Tools required

Parts

• Pitman arm × 1 — Use OEM specification
• Pitman arm nut × 1 — Replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off the vehicle completely and ensure it is in Park
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle and support securely on jack stands at manufacturer-recommended lift points
5. Remove front wheels
6. Spray pitman arm connection points with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark alignment reference
   Before removing the pitman arm, mark the relationship between the pitman arm and the steering gear sector shaft using a paint pen or marking tool. This will aid in proper alignment during reinstallation and help maintain steering wheel center position.
2. 2

   Remove pitman arm retaining nut
   Using a socket and breaker bar, loosen and remove the pitman arm retaining nut from the steering gear sector shaft. Note the position of any washers. The nut is torqued to 185 Nm and may require significant force to break free.
   Torque spec

   Pitman Arm Nut185 Nm (136 lb-ft)
3. 3

   Separate pitman arm from sector shaft
   Install a pitman arm puller tool onto the pitman arm. Tighten the puller forcing screw gradually while supporting the pitman arm. Do not strike the end of the sector shaft with a hammer as this can damage the steering gear. Continue tightening the puller until the pitman arm releases from the tapered shaft. Remove the puller and pitman arm.
   ⚠Never use a pickle fork on the sector shaft taper as this will damage the shaft and require steering gear replacement
4. 4

   Disconnect pitman arm from center link
   If the pitman arm is still connected to the center link or relay rod, separate this connection. This may require loosening the tie rod nut and using a tie rod separator or pickle fork. Use caution not to damage the rubber boot on the ball joint.
   Torque spec

   Tie Rod Nut54 Nm (40 lb-ft)
5. 5

   Remove pitman arm
   Once separated from both the sector shaft and steering linkage, remove the pitman arm from the vehicle. Inspect the tapered bore of the arm for wear, scoring, or elongation. Inspect the ball joint (if integral) for excessive play or torn boots.
6. 6

   Prepare sector shaft and new pitman arm
   Clean the steering gear sector shaft taper thoroughly with a wire brush to remove any dirt, rust, or debris. Clean the tapered bore of the new pitman arm. Ensure both surfaces are completely clean and dry for proper seating. Inspect the sector shaft splines for damage.
7. 7

   Install new pitman arm onto sector shaft
   Align the new pitman arm with the alignment marks made during disassembly. Slide the pitman arm onto the sector shaft, ensuring proper engagement with the splines and taper. The arm should slide on partially by hand. Install the retaining nut and washer (if applicable).
8. 8

   Torque pitman arm nut
   Using a torque wrench, tighten the pitman arm retaining nut to the specified torque of 185 Nm (136 lb-ft). This is a critical fastener - ensure the torque wrench is properly calibrated and the full specified torque is achieved. The taper should draw the arm fully onto the shaft.
   ⚠Proper torque is critical for steering safety - do not overtighten or undertighten this fastener
   Torque spec

   Pitman Arm Nut185 Nm (136 lb-ft)
9. 9

   Connect pitman arm to steering linkage
   If disconnected, reconnect the pitman arm ball stud to the center link or relay rod. Install the tie rod nut and torque to specification using a torque wrench. Ensure the connection is secure and the ball joint boot is properly seated.
   Torque spec

   Tie Rod Nut54 Nm (40 lb-ft)
10. 10

    Reinstall wheels
    Reinstall the front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the wheels just contact the ground but the suspension is not yet loaded.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
11. 11

    Final torque and lower vehicle
    With the wheels on the ground, torque the wheel lug nuts to 136 Nm (100 lb-ft) in a star pattern. Remove the jack stands and fully lower the vehicle. Remove wheel chocks.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification
2. Confirm steering wheel is centered when wheels are pointing straight ahead
3. Check that no tools or parts were left in the work area

Verification

• Start the vehicle and turn the steering wheel lock-to-lock while stationary to verify proper operation
• Test drive the vehicle at low speed in a safe area and verify steering responds correctly with no unusual noises or vibrations
• Check steering wheel returns to center properly after turns
• Verify steering wheel is centered when driving straight
• Schedule a professional wheel alignment as soon as possible, as steering geometry has been disturbed

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