Rack and Pinion Boots

Replace the rack and pinion boots on a 2023 Chevrolet Bolt EUV to prevent contamination and maintain steering performance.

Warnings

Tools required

Parts

• Rack and pinion boot kit (left) × 1 — Use OEM specification
• Rack and pinion boot kit (right) × 1 — Use OEM specification
• Boot clamps × 4 — Included in boot kit
• Cotter pins × 2 — Use OEM specification
• Multi-purpose grease × 1 — Use OEM specification

Preparation

1. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge.
2. Raise vehicle on level surface and support securely on jack stands at manufacturer-specified lift points.
3. Remove both front wheels.
4. Mark the position of tie rod ends on the tie rod threads with paint or tape for approximate reassembly reference.
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes if vehicle has accumulated road salt exposure.

Procedure

1. 1

   Remove tie rod end castle nuts
   Remove the cotter pins from both tie rod end castle nuts using pliers or wire cutters. Loosen and remove the tie rod end castle nuts. Do not reuse the cotter pins.
   Torque spec

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

   Separate tie rod ends from knuckles
   Using a tie rod separator or pickle fork, carefully separate the tie rod ends from the steering knuckles on both sides. Avoid damaging the tie rod end boots. Once separated, support the tie rod ends to prevent strain on the steering rack.
   ⚠Use care when using a pickle fork as it may damage tie rod end boots if replacement is not planned. A tie rod separator is preferred.
3. 3

   Access the steering rack
   From underneath the vehicle, locate the steering rack assembly behind the subframe. Remove any protective covers or shields that obstruct access to the rack boots by removing the cover screws. Note the routing of any wiring or brake lines near the work area.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove old boot clamps
   On the side being serviced, locate the boot clamps at both ends of the rack boot (inner and outer). Cut or release the clamps using wire cutters or boot clamp pliers. Remove and discard the old clamps. Note the orientation and position of the boot for reference.
   ℹ️Some boots may use crimp-style clamps that must be cut, while others use screw-type clamps that can be loosened.
5. 5

   Remove old rack boot
   Slide the old boot off the steering rack and tie rod. Inspect the exposed rack for damage, corrosion, or excessive wear. Clean the rack surface and tie rod with brake cleaner and a shop rag. Remove all old grease and debris from the mounting surfaces.
   ⚠Do not extend the rack fully. Keep tie rods positioned near their normal operating range to prevent internal damage.
6. 6

   Install new rack boot
   Apply a thin layer of multi-purpose grease to the inside of the new boot and the rack surface. Slide the new boot onto the tie rod first, then position it over the rack housing. Ensure the boot is not twisted and sits properly in both grooves (inner on rack housing, outer on tie rod).
   ℹ️Ensure the boot is fully seated in both mounting grooves before installing clamps. An improperly seated boot will fail prematurely.
7. 7

   Install new boot clamps
   Install the new boot clamps from the kit at both ends of the boot. Position the inner clamp on the rack housing groove and the outer clamp on the tie rod groove. Tighten the clamps securely using boot clamp pliers or appropriate tool. Ensure the boot is not twisted or pinched.
   ℹ️Crimp-style clamps require special pliers for proper installation. Screw-type clamps should be tightened firmly but not over-tightened to avoid cutting the boot.
8. 8

   Repeat for opposite side
   Repeat steps 4 through 7 for the opposite side rack boot. Ensure both boots are properly installed, seated correctly, and securely clamped at all four attachment points (two per boot).
9. 9

   Reinstall protective covers
   Reinstall any protective covers or shields that were removed in step 3. Ensure all cover screws are torqued to specification and that no wiring or brake lines are pinched or interfered with.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
10. 10

    Reconnect tie rod ends
    Align the tie rod ends with the steering knuckle tapers on both sides. Install the tie rod ends into the knuckles and thread on the new castle nuts. Torque the castle nuts to specification. Install new cotter pins through the castle nut slots and tie rod end holes, then bend the pins to secure.
    ⚠If the cotter pin hole does not align after torquing, tighten the castle nut slightly more (up to 1/6 turn) until the next slot aligns. Never loosen the nut to align the cotter pin hole.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
11. 11

    Reinstall wheels
    Install both front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect the 12V battery negative terminal.
2. Start the vehicle and turn the steering wheel lock-to-lock several times to verify proper boot installation and check for any unusual noises.
3. Verify that the electric power steering system initializes properly with no warning lights on the instrument cluster.

Verification

• Visually inspect both rack boots to ensure they are properly seated and not twisted or torn.
• Check that all boot clamps are secure and properly positioned in their grooves.
• Verify that new cotter pins are properly installed and bent in the tie rod end castle nuts.
• Test drive the vehicle at low speed in a safe area and verify steering operates smoothly without binding or unusual noises.
• Schedule a professional wheel alignment to ensure proper toe settings after tie rod disturbance.

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