Replace the inner tie rod end on a 1966 Chevrolet Corvette with 327ci V8, requiring steering linkage disassembly and alignment upon completion.

Warnings

Tools required

Parts

• Inner tie rod end × 1 — Use OEM specification or Moog DS299
• Outer tie rod end (if worn) × 1 — Use OEM specification or Moog ES2020
• Cotter pins (1/8 inch) × 3 — Standard 1/8 inch castle nut cotter pin

Preparation

1. Park vehicle on level, paved surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/2 turn while vehicle is on ground
4. Mark current tie rod adjustment position with permanent marker and measure thread engagement for reference
5. Apply penetrating oil to all steering linkage fasteners and tapers at least 15 minutes before disassembly

Procedure

1. 1

   Raise and support vehicle
   Jack up the front of the vehicle using the frame rails near the lower control arm mounts. Place jack stands under solid frame sections behind the front suspension crossmember. Lower vehicle onto stands and verify stability before working underneath. Remove both front wheels completely.
2. 2

   Document tie rod adjustment
   With the outer tie rod end still attached to the inner, count the exact number of visible threads on the inner tie rod where it enters the outer tie rod end sleeve. Measure and record the distance from the inner tie rod end body to the outer tie rod adjustment sleeve jam nut. Mark both components with permanent marker for reference during reassembly. This preserves approximate toe setting.
3. 3

   Remove outer tie rod end from steering knuckle
   Remove the cotter pin from the outer tie rod end castle nut at the steering knuckle. Using a wrench, remove the castle nut completely. Strike the steering knuckle boss sharply with a hammer while applying upward pressure to the tie rod to break the taper loose. Alternatively, use a tie rod end separator tool. Do not strike the tie rod threads directly.
4. 4

   Separate outer tie rod from inner tie rod
   Loosen the adjustment sleeve clamp bolt(s) that connect the outer tie rod to the inner tie rod. The 1966 Corvette uses a threaded tubular adjusting sleeve with a clamp at each end. Unscrew the outer tie rod end from the inner tie rod assembly, counting the turns required for complete removal. Record this number to match during reassembly.
5. 5

   Access inner tie rod connection at center link
   Locate the inner tie rod end connection point at the steering center link (relay rod). The inner tie rod connects to the center link near the idler arm side. Remove the cotter pin and castle nut from the inner tie rod ball stud where it passes through the center link.
6. 6

   Separate inner tie rod from center link
   Use a tie rod separator or pickle fork to separate the inner tie rod ball stud taper from the center link. Position the separator between the center link and the inner tie rod body, then strike or tighten to break the taper joint. Once loose, remove the inner tie rod completely from the vehicle. Inspect the center link taper bore for damage or excessive wear.
7. 7

   Prepare new inner tie rod end
   Clean the threads of the new inner tie rod end with a wire brush. Inspect the ball stud boot for proper seating and no tears. If the new tie rod has a grease fitting, pump 2-3 strokes of chassis grease into the fitting until grease appears at the boot seal. Verify the taper on the ball stud is clean and undamaged.
8. 8

   Install inner tie rod to center link
   Insert the new inner tie rod ball stud through the center link from below. Thread the castle nut onto the ball stud and tighten to the factory-specified torque (verify against the 1966 Corvette shop manual; approximately 30-40 ft-lbs). Continue tightening only as needed to align the next castle nut slot with the ball stud hole (do not back off to align). Install a new cotter pin and bend the ends to secure.
9. 9

   Reinstall outer tie rod end
   Thread the outer tie rod end onto the new inner tie rod the same number of turns recorded during disassembly, matching the thread engagement marks made earlier. Do not fully tighten the adjustment sleeve clamp bolts yet; leave them snug but movable for alignment adjustments.
10. 10

    Connect outer tie rod to steering knuckle
    Insert the outer tie rod ball stud through the steering knuckle arm. Install the castle nut and torque to the factory-specified value (verify against the 1966 Corvette shop manual; approximately 30-40 ft-lbs). Tighten further only as needed to align castle nut slots with the cotter pin hole. Install new cotter pin and bend ends securely. Verify ball stud has no vertical play.
11. 11

    Verify steering system integrity
    With wheels still off ground, have an assistant slowly turn the steering wheel from lock to lock while you observe all steering linkage connections for looseness, binding, or interference. Check that the new inner tie rod ball stud moves smoothly without binding. Verify all cotter pins are properly installed and bent.
12. 12

    Reinstall wheels and lower vehicle
    Reinstall both front wheels and hand-tighten lug nuts in a star pattern. Raise vehicle slightly to remove jack stands, then lower completely to ground. Torque lug nuts to the factory-specified value (verify against the 1966 Corvette shop manual; typically around 65-80 ft-lbs) in a star pattern with wheels on ground.

Reassembly

1. Tighten the tie rod adjustment sleeve clamp bolts to 20 ft-lbs after confirming toe measurement marks align
2. Ensure all castle nuts are secured with new cotter pins properly bent
3. Grease all steering linkage fittings with chassis grease until fresh grease appears

Verification

• Start engine and verify power steering operation with no unusual noises or binding
• Turn steering wheel slowly from lock to lock and verify smooth operation with no catching or resistance
• Visually inspect all tie rod connections for proper seating and cotter pin installation
• Test drive at low speed in a safe area to verify straight-line tracking (vehicle will likely pull due to altered toe setting)
• Schedule immediate front-end alignment - vehicle is not safe for normal driving until alignment is completed

More procedures for this vehicle