Power Steering Rack

Complete replacement of the electric power steering rack assembly on the 2023 Chevrolet Bolt EUV, including removal of tie rod ends, steering coupling, and rack mounting hardware.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification for electric power steering
• Cotter pins for tie rod ends × 2 — Match OEM size
• Steering coupling bolt × 1 — Use OEM specification
• Rack mounting hardware kit × 1 — Check if reusable per service manual

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Turn ignition off and remove key/fob from vehicle.
3. Disconnect the negative terminal of the 12-volt battery and wait 5 minutes for high-voltage system to safely power down.
4. Center the steering wheel and install a steering wheel holder to prevent rotation during the procedure.
5. Loosen front wheel lug nuts while vehicle is on ground.
6. Raise vehicle on a lift or with floor jack and support securely on jack stands at manufacturer-specified lift points.
7. Remove both front wheels.
8. Mark the tie rod end position on the threaded tie rod shaft with paint or marker for rough alignment reference.
9. Spray tie rod end tapers and steering coupling bolts with penetrating oil if corrosion is present.

Procedure

1. 1

   Remove tie rod ends from steering knuckles
   Remove the cotter pins from both tie rod end castle nuts and discard. Using a wrench, remove the tie rod end castle nuts. Use a tie rod end separator or pickle fork to separate the tie rod ends from the steering knuckles. Avoid damaging the rubber boots on the tie rod ends.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
2. 2

   Disconnect intermediate steering shaft
   Working from under the vehicle or inside the cabin (access may vary), locate the intermediate steering shaft coupling at the base of the steering column where it connects to the rack input shaft. Remove the coupling bolt. Carefully separate the coupling from the steering rack pinion shaft. Mark the orientation if not already indexed with a master spline.
   ⚠Do not allow the steering shaft to rotate after disconnection to prevent clockspring damage.
   Torque spec

   Coupling Bolt34 Nm (25 lb-ft)
3. 3

   Disconnect electrical connectors
   Locate the power steering motor electrical connector on the steering rack assembly. Depress the locking tab and disconnect the connector. Secure the connector out of the way to prevent damage during rack removal.
4. 4

   Remove rack mounting hardware access covers
   Remove any shields, covers, or underbody panels that obstruct access to the steering rack mounting bolts. This typically includes the front subframe shields or belly pan sections. Set hardware aside in an organized manner for reinstallation.
5. 5

   Support the subframe (if required)
   Depending on clearance, it may be necessary to slightly lower the front subframe for rack removal. If required, place a transmission jack or adjustable jack stand under the subframe. Loosen but do not remove the subframe mounting bolts and lower the subframe approximately 25-50mm to create clearance. Consult service manual for subframe support requirements specific to this model year.
   ⚠If lowering the subframe, ensure all components connected to it (control arms, sway bar links, etc.) have sufficient slack to prevent damage.
6. 6

   Remove steering rack mounting bolts
   Locate the steering rack mounting bolts that secure the rack to the subframe or chassis. There are typically two mounting bolts. Remove these bolts completely while supporting the rack assembly to prevent it from falling.
   Torque spec

   Rack Mounting Bolts102 Nm (75 lb-ft)
7. 7

   Remove steering rack assembly
   Carefully maneuver the steering rack assembly out from its mounting position. This typically requires moving it toward one side of the vehicle while rotating to clear the tie rod ends through the chassis openings. The rack may need to be tilted and rotated to navigate around subframe components and chassis members. Take care not to damage brake lines, ABS wiring, or other nearby components.
   ⚠The steering rack assembly is heavy and awkward. Use a helper or supporting device to prevent injury or damage.
8. 8

   Transfer tie rod ends to new rack (if applicable)
   If the tie rod ends are being reused, count and record the number of exposed threads before removal from the old rack. Unscrew the tie rod ends from the old rack assembly. Thread the tie rod ends onto the new rack to the same thread depth as marked earlier. This provides a rough preliminary alignment.
9. 9

   Install new steering rack assembly
   Position the new steering rack assembly and carefully maneuver it into the mounting location, reversing the removal process. Route the tie rod ends through the chassis openings and align the rack mounting holes with the subframe or chassis mounting points. Ensure no wiring harnesses or brake lines are pinched.
10. 10

    Install and torque rack mounting bolts
    Insert the rack mounting bolts and hand-thread them to ensure proper alignment. Torque the mounting bolts to specification in the sequence recommended in the service manual (typically alternating side-to-side for even clamping).
    ⚠Verify torque sequence with service manual to ensure proper rack alignment and prevent binding.
    Torque spec

    Rack Mounting Bolts102 Nm (75 lb-ft)
11. 11

    Raise subframe (if lowered)
    If the subframe was lowered in Step 5, carefully raise it back to its original position. Torque the subframe mounting bolts to specification per the service manual. Remove the supporting jack.
12. 12

    Reconnect intermediate steering shaft
    Align the intermediate steering shaft coupling with the steering rack pinion shaft, ensuring proper spline engagement and orientation. Install the new coupling bolt and torque to specification. Verify the steering shaft coupling is fully seated.
    ⚠Ensure the coupling is properly aligned and the bolt passes through both the coupling and pinion shaft before tightening.
    Torque spec

    Coupling Bolt34 Nm (25 lb-ft)
13. 13

    Reconnect electrical connectors
    Reconnect the power steering motor electrical connector to the steering rack assembly. Ensure the connector clicks into place and the locking tab is fully engaged.
14. 14

    Connect tie rod ends to steering knuckles
    Insert the tie rod end tapered studs into the steering knuckle holes. Install the castle nuts and torque to specification. Install new cotter pins through the castle nut slots and tie rod stud holes. Bend the cotter pin ends to secure.
    ⚠If the castle nut slots do not align with the cotter pin hole at specified torque, tighten further up to 1/6 turn (60 degrees). Never loosen to align.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
15. 15

    Reinstall wheels and underbody panels
    Reinstall any underbody shields, covers, or panels removed during the procedure. Install both front wheels and hand-thread the lug nuts. Lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect the negative terminal of the 12-volt battery.
2. Start the vehicle and verify the power steering system operates normally with no warning lights.
3. Remove the steering wheel lock and verify the steering wheel is still centered.
4. Check for proper steering operation by turning lock-to-lock while stationary (engine running).
5. Schedule a professional wheel alignment immediately. The alignment reference marks are only approximate and not sufficient for safe operation.

Verification

• Power on the vehicle and verify no power steering warning lights are illuminated on the instrument cluster.
• Turn the steering wheel lock-to-lock while stationary and verify smooth operation with no binding, noise, or vibration.
• Test drive the vehicle in a safe area at low speed and verify proper steering response and returnability.
• Verify the steering wheel is centered when driving straight.
• Re-torque all fasteners after test drive and verify no leaks or loose connections.
• Have the vehicle professionally aligned and verify all steering angles are within specification.

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