Tie Rod Assembly

This procedure covers the removal and replacement of the outer tie rod end assembly on a 2023 Chevrolet Bolt EUV, including proper torque specifications and alignment preparation.

Warnings

Tools required

Parts

• Outer tie rod end assembly × 1 — Use OEM specification for 2023 Bolt EUV
• Cotter pin × 1 — Standard automotive cotter pin
• Tie rod lock nut (if reusing is not possible) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Power off the vehicle completely and remove key fob from vehicle interior
4. Disconnect the 12V battery negative terminal to disable electric power steering
5. Loosen wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle and secure on jack stands at manufacturer-specified lift points
7. Remove wheel and tire assembly completely
8. Spray penetrating oil on tie rod end castle nut and tie rod lock nut, allow to soak for 5-10 minutes

Procedure

1. 1

   Measure existing tie rod length
   Before disassembly, measure and record the exposed thread length from the inner tie rod jam nut to the end of the outer tie rod threads. This measurement will help maintain approximate toe setting during installation and minimize alignment deviation. Mark the position with a paint pen if possible.
2. 2

   Remove cotter pin and castle nut
   Straighten and remove the cotter pin from the tie rod end castle nut using pliers. Discard the old cotter pin. Using a 19mm socket, remove the castle nut from the tie rod end stud. Keep the nut if it is in good condition as a reference.
   ℹ️The cotter pin must be replaced with a new one during reassembly. Do not reuse the old cotter pin.
3. 3

   Separate tie rod end from knuckle
   Using a tie rod end separator tool or pickle fork, separate the tie rod end ball stud from the steering knuckle. Position the separator tool between the knuckle and tie rod end boot, then strike with a hammer or tighten the tool to apply separating force. Alternatively, use a pickle fork and hammer. Avoid damaging the ball joint boot if the tie rod is being reused for any reason.
   ⚠Use caution when striking the separator tool. The tie rod end may release suddenly. Keep hands clear of pinch points.
4. 4

   Loosen tie rod lock nut
   Using an adjustable wrench or 22mm wrench, loosen the tie rod lock nut (jam nut) that secures the outer tie rod end to the inner tie rod. Do not remove it completely yet. Note the position of the lock nut relative to your measurement marks.
5. 5

   Remove outer tie rod end
   Count and record the number of complete turns as you unthread the outer tie rod end from the inner tie rod shaft. This count will help achieve approximate reinstallation position. Once the outer tie rod end is free, remove the lock nut completely from the old tie rod end.
6. 6

   Prepare new tie rod end
   Clean the threads on the inner tie rod with a wire brush to remove dirt and corrosion. Thread the tie rod lock nut onto the new outer tie rod end threads first (it will slide down toward the inner tie rod during installation). Inspect the new tie rod end ball joint boot for damage.
7. 7

   Install new outer tie rod end
   Thread the new outer tie rod end onto the inner tie rod shaft by the same number of turns recorded during removal, using your measurement as a guide. The exposed thread length should match your initial measurement. This sets the approximate toe angle to minimize alignment deviation until professional alignment can be performed.
   ℹ️Do not tighten the lock nut at this time. Final tightening occurs after alignment.
8. 8

   Install tie rod end into steering knuckle
   Insert the tie rod end ball stud into the steering knuckle tapered hole. Ensure the stud is fully seated in the taper. Install the castle nut onto the ball stud and hand-tighten.
9. 9

   Torque castle nut and install cotter pin
   Using a torque wrench, tighten the tie rod end castle nut to specification. If the cotter pin hole does not align with a castle nut slot, tighten the nut further (not to exceed 1/6 turn additional) until the next slot aligns with the hole. Never loosen the nut to align the cotter pin hole. Insert a new cotter pin through the castle nut and ball stud, then bend the ends to secure.
   ⚠Never loosen a properly torqued castle nut to align the cotter pin hole. Only tighten further within acceptable limits.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
10. 10

    Temporarily snug lock nut
    Hand-tighten the tie rod lock nut against the outer tie rod end body to hold the adjustment in place. Do NOT torque to final specification at this time. The lock nut will be torqued to final specification only after the vehicle has received a professional wheel alignment.
    ℹ️The tie rod lock nut must only be torqued to 68 Nm (50 lb-ft) AFTER professional alignment is completed.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly. Hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground to prevent rotation. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Reconnect battery and test steering
    Reconnect the 12V battery negative terminal. Power on the vehicle and turn the steering wheel lock-to-lock while stationary to verify the tie rod end has full range of motion and no binding occurs. Check for any unusual noises or resistance in the steering system.

Reassembly

1. Ensure all fasteners have been properly installed and torqued except the tie rod lock nut, which awaits alignment
2. Verify the new cotter pin is properly installed and bent to prevent ejection
3. Confirm the tie rod end boot is not torn or damaged

Verification

• Test drive the vehicle at low speed in a safe area to verify steering response and that there are no unusual noises from the front suspension
• Visually inspect the tie rod end connection to the steering knuckle for proper seating and no gaps
• Check that the steering wheel returns to center after turning
• Schedule a professional wheel alignment immediately after completing this repair
• After alignment is complete, ensure the technician torques the tie rod lock nut to 68 Nm (50 lb-ft) specification
• Verify no pulling to left or right during straight-line driving after alignment is completed

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