Tie Rods - Both Sides

This procedure covers the removal and replacement of both inner and outer tie rod ends on the 2023 Chevrolet Bolt EUV, requiring a front-end alignment upon completion.

Warnings

Tools required

Parts

• Outer tie rod end - left × 1 — Use OEM specification
• Outer tie rod end - right × 1 — Use OEM specification
• Inner tie rod end - left × 1 — Use OEM specification
• Inner tie rod end - right × 1 — Use OEM specification
• Cotter pins × 4 — Appropriate size for tie rod end castle nut
• Thread locking compound × 1 — Medium strength

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect the 12V battery negative terminal to prevent inadvertent system activation
3. Loosen front wheel lug nuts while vehicle is on the ground
4. Raise vehicle and support securely on jack stands at manufacturer-approved lift points
5. Remove both front wheels completely
6. Spray all tie rod connections with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark and measure outer tie rod position
   Before loosening anything, mark the position of the outer tie rod end relative to the inner tie rod with a paint pen. Count and record the number of threads visible between the tie rod lock nut and the outer tie rod end. Measure the overall length from the center of the inner tie rod to the center of the outer tie rod end ball joint. This measurement is critical for maintaining approximate alignment during reassembly.
2. 2

   Remove outer tie rod end from knuckle - driver side
   Remove the cotter pin from the tie rod end castle nut using pliers or a cotter pin removal tool. Loosen but do not remove the tie rod end castle nut. Use a tie rod end separator or pickle fork to break the taper connection between the tie rod end and the steering knuckle. Once the taper is broken, remove the castle nut completely and separate the tie rod end from the knuckle.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Remove outer tie rod end from inner tie rod - driver side
   Hold the inner tie rod with locking pliers or a tie rod adjustment tool to prevent it from rotating. Loosen the tie rod lock nut. Unthread the outer tie rod end from the inner tie rod by turning counterclockwise. Count the turns as you remove it to assist with installation of the new part.
   Torque spec

   Tie Rod Lock Nut68 Nm (50 lb-ft)
4. 4

   Remove inner tie rod - driver side
   If replacing inner tie rods, the steering rack boot must be pulled back to access the inner tie rod connection. Use a wrench to loosen and remove the inner tie rod from the steering rack. The inner tie rod typically uses a hex flats section or may require a specialized inner tie rod tool. Remove the inner tie rod completely and inspect the rack boot for damage.
5. 5

   Install new inner tie rod - driver side
   Clean the threads on the steering rack with a wire brush. Apply a thin coat of thread locking compound to the threads of the new inner tie rod. Thread the inner tie rod into the steering rack by hand, then tighten to specification using the appropriate tool. Ensure the rack boot is properly seated after installation.
6. 6

   Install new outer tie rod - driver side
   Thread the new outer tie rod end onto the inner tie rod using the same number of turns or thread count as recorded during removal. This provides an approximate starting point for alignment. Do not tighten the lock nut yet. Insert the outer tie rod end ball stud into the steering knuckle.
7. 7

   Secure outer tie rod to knuckle - driver side
   Install the castle nut onto the tie rod end ball stud and tighten to specification. Ensure the cotter pin hole in the stud aligns with a castle nut slot. If necessary, tighten the nut slightly (never loosen) to align the holes. Install a new cotter pin and bend the ends to secure.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
8. 8

   Repeat for passenger side
   Perform steps 1 through 7 for the passenger side tie rods. Mark positions, remove outer tie rod end from knuckle, remove outer tie rod from inner tie rod, remove and replace inner tie rod if necessary, install new outer tie rod, and secure to knuckle with new cotter pin. Maintain consistent measurements and thread counts on both sides.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
9. 9

   Verify installation and prepare for alignment
   Check that both outer tie rod ends are securely fastened to the steering knuckles with cotter pins installed. Ensure both tie rods move freely without binding. Do not tighten the tie rod lock nuts yet as adjustments will be made during alignment. Verify all connections are secure and no parts or tools remain in the wheel wells.
10. 10

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground. 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)
11. 11

    Reconnect battery and perform alignment
    Reconnect the 12V battery negative terminal. Transport the vehicle to an alignment facility immediately. After alignment is completed and tie rod adjustments are finalized, the tie rod lock nuts must be torqued to specification. Inform the alignment technician of the required torque specification for the lock nuts.
    Torque spec

    Tie Rod Lock Nut68 Nm (50 lb-ft)

Reassembly

1. Ensure all cotter pins are properly installed and bent to prevent tie rod end separation
2. The tie rod lock nuts should only be tightened to final specification after alignment is complete
3. Verify steering wheel is centered after alignment
4. Test drive vehicle to verify proper steering response and no abnormal noises

Verification

• Confirm all tie rod end castle nuts are torqued properly with new cotter pins installed
• Verify wheel lug nuts are torqued to 136 Nm (100 lb-ft)
• Confirm vehicle has been professionally aligned and tie rod lock nuts torqued to 68 Nm (50 lb-ft)
• Check for any play in tie rod ends by attempting to move wheels side-to-side with vehicle on ground
• Test drive vehicle at various speeds to ensure straight-line stability and proper steering return
• Inspect for any leaks around steering rack boots after test drive

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