Remove and replace the outer and inner tie rod assemblies on a 1966 Corvette to restore proper steering geometry and eliminate play in the steering linkage.

Warnings

Tools required

Parts

• Outer tie rod end (left) × 1 — Use OEM specification or quality aftermarket
• Outer tie rod end (right) × 1 — Use OEM specification or quality aftermarket
• Inner tie rod assembly (left) × 1 — Use OEM specification or quality aftermarket
• Inner tie rod assembly (right) × 1 — Use OEM specification or quality aftermarket
• Castellated nut for outer tie rod end × 2 — 3/4-20 thread, typically included with tie rod end
• Cotter pin (1/8 inch diameter) × 2 — Standard 1/8 inch x 1.5 inch

Preparation

1. Park vehicle on level, solid ground and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
4. Jack up front of vehicle at factory jacking points on frame
5. Place jack stands under frame rails behind front suspension crossmember
6. Lower vehicle onto jack stands and verify stability
7. Remove front wheels completely
8. Spray all tie rod fasteners and threads with penetrating oil and allow 10-15 minutes to soak

Procedure

1. 1

   Measure and mark existing tie rod length
   Before removing any components, measure the distance from the center of the inner tie rod mounting bolt to the center of the outer tie rod end stud. Record this measurement. Alternatively, count and mark the number of threads showing on the outer tie rod end adjustment sleeve with paint marker or tape. This will allow you to install the new tie rod at approximately the same length to minimize post-repair alignment offset.
2. 2

   Remove outer tie rod end cotter pin and castle nut
   Locate the outer tie rod end where it connects to the steering knuckle arm. Straighten and remove the cotter pin from the castle nut using pliers or side cutters. Using the correct socket or wrench for the outer tie rod end castle nut (verify size against the factory service manual, commonly 11/16 inch), remove the castle nut from the tie rod end stud. Do not discard the nut if the new tie rod end did not include a replacement castle nut.
3. 3

   Separate outer tie rod end from steering knuckle
   Position the tie rod separator tool (pickle fork) between the steering knuckle arm and the tie rod end. Strike the tool firmly with a ball peen hammer to drive the wedge between the taper surfaces. The tie rod stud will pop free from the knuckle. If using a screw-type separator, tighten until the taper releases. Be prepared for sudden release of tension.
   ⚠Keep fingers clear of the gap between knuckle and tie rod end during separation to avoid pinching.
4. 4

   Loosen outer tie rod end jam nut
   The outer tie rod end threads into an adjustment sleeve, secured by a jam nut. Using a 7/8 inch wrench, loosen (but do not remove) the jam nut that locks the outer tie rod end to the adjustment sleeve. The jam nut may be very tight; use penetrating oil and a longer wrench if necessary.
5. 5

   Remove outer tie rod end
   Count the number of complete turns as you unscrew the outer tie rod end from the adjustment sleeve. Record this number. Completely remove the outer tie rod end and jam nut from the sleeve. Clean the threads on the adjustment sleeve with a wire brush.
6. 6

   Remove inner tie rod end castle nut and cotter pin
   Locate where the inner tie rod connects to the center link (relay rod). Straighten and remove the cotter pin from the castle nut. Using the correct wrench or socket for the inner tie rod end castle nut (verify size against the factory service manual), remove the castle nut from the inner tie rod stud.
7. 7

   Separate inner tie rod from center link
   Position the tie rod separator tool between the center link and the inner tie rod end. Strike firmly with a hammer or tighten the screw-type separator until the tapered stud releases from the center link. The entire tie rod assembly (inner tie rod, adjustment sleeve, and dust boots) is now free.
8. 8

   Install new inner tie rod end to center link
   Insert the new inner tie rod end stud into the center link taper. Thread the castle nut onto the stud and tighten to the factory-specified torque (verify against the 1966 Corvette service manual; do not rely on a generic estimate). Continue tightening to the next castle nut slot that aligns with the stud hole (do not back off to align). Install a new cotter pin through the castle nut and stud, then bend the ends of the cotter pin to secure.
9. 9

   Install outer tie rod end to adjustment sleeve
   Thread the new outer tie rod end into the adjustment sleeve the same number of turns you counted during removal (Step 5). If you measured the overall length in Step 1, verify that the measurement matches before tightening. Thread the jam nut onto the sleeve but leave it loose for now to allow fine adjustment.
10. 10

    Install outer tie rod end to steering knuckle
    Insert the outer tie rod end stud into the steering knuckle arm taper. Thread the castle nut onto the stud and tighten to the factory-specified torque (verify against the 1966 Corvette service manual; do not rely on a generic estimate). Continue tightening to the next castle nut slot that aligns with the stud hole. Install a new cotter pin through the castle nut and stud, then bend the ends to secure.
11. 11

    Tighten outer tie rod jam nut
    Hold the outer tie rod end with an adjustable wrench to prevent it from turning. Secure the adjustment sleeve clamps (or jam nut, depending on configuration) and tighten to the factory-specified torque (verify against the 1966 Corvette service manual; clamp bolts are typically a much lower torque than 40 ft-lb). This locks the outer tie rod position.
12. 12

    Lubricate tie rod ends
    Locate the grease fittings (zerks) on both the inner and outer tie rod ends. Using a grease gun filled with chassis grease, pump grease into each fitting until fresh grease appears at the dust boot seal. Wipe away excess grease.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and hand-tighten the lug nuts in a star pattern. Raise the vehicle slightly with the floor jack to remove weight from the jack stands, then remove the jack stands. Lower the vehicle to the ground. Torque the wheel lug nuts to the factory-specified value in a star pattern (verify against the 1966 Corvette service manual).

Reassembly

1. If both sides were replaced, repeat all steps for the opposite side before driving
2. Double-check that all castle nuts have cotter pins properly installed and bent
3. Verify all jam nuts are tight and tie rod ends cannot rotate in the adjustment sleeves

Verification

• Start engine and turn steering wheel slowly from lock to lock while stationary, listening for any binding, clicking, or unusual noises
• With wheels straight, verify that the steering wheel is reasonably centered (minor offset is acceptable before alignment)
• Rock each front wheel by hand at 3 and 9 o'clock positions to check for any looseness in the tie rod connections
• Test drive vehicle at low speed in a safe area, verifying that steering responds predictably and there is no excessive play in the wheel
• Schedule a professional wheel alignment immediately, as toe settings will be incorrect after tie rod replacement

More procedures for this vehicle