Replace the rack and pinion steering gear boots to prevent contamination and moisture from damaging the steering rack assembly on the electric AWD delivery van.

Warnings

Tools required

Parts

• Rack and pinion boot kit (inner and outer boots) × 2 — Use OEM specification
• Boot clamps (various sizes) × 4 — Typically included with boot kit
• Tie rod end jam nut (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Power down vehicle completely and remove key fob from cabin
4. Wait 5 minutes for high-voltage system to discharge capacitors
5. Lift front of vehicle and secure on jack stands rated for vehicle weight at manufacturer lift points
6. Remove both front wheels
7. Document or photograph steering wheel position for reference
8. Spray tie rod connections and jam nuts with penetrating oil if corrosion is present

Procedure

1. 1

   Access the steering rack assembly
   Remove any underbody panels or skid plates that obstruct access to the steering rack assembly. On the EDV 500, this typically includes the front center splash shield. Remove fasteners and carefully lower panels, noting their orientation for reinstallation.
2. 2

   Mark tie rod position
   Before loosening any components, measure and record the exposed thread length on the tie rod end past the jam nut. Use a marker to make a reference line on the tie rod threads at the jam nut position. This will help maintain approximate toe alignment during reassembly.
3. 3

   Loosen tie rod jam nut
   Using appropriate size wrench, loosen but do not remove the jam nut that locks the tie rod end to the inner tie rod. This nut is located between the tie rod end and the steering rack boot. Keep the inner tie rod from rotating using a second wrench on the flats if provided.
4. 4

   Separate tie rod end from knuckle
   Remove the castle nut securing the tie rod end to the steering knuckle. Use a tie rod end separator tool to press the taper out of the knuckle. Do not strike the tie rod end with a hammer as this can damage the steering rack. Once separated, unthread the tie rod end from the inner tie rod by counting the number of turns for reference.
5. 5

   Remove outer boot clamps
   Locate the boot clamps on the outer end of the rack boot (near the tie rod connection). Using boot clamp pliers or cutters, carefully remove both the large and small diameter clamps. Note the orientation and position of the clamps for new installation.
6. 6

   Remove inner boot clamps
   Access the inner boot clamps at the steering rack housing end. These may be band-type or wire-type clamps. Carefully cut or release these clamps without damaging the rack housing surface. The boot should now be free to slide off.
7. 7

   Remove old boot and inspect rack
   Slide the old boot off the inner tie rod and rack assembly. Thoroughly clean the rack surface with brake cleaner and inspect for any damage, scoring, or excessive wear. Check for proper grease presence on the rack teeth and ball joint area. If rack is dry or damaged, further service may be required.
8. 8

   Clean mating surfaces
   Use wire brush and brake cleaner to thoroughly clean the rack housing groove where the inner boot clamp seats, and the tie rod area where the outer boot clamp seats. Remove all old grease, dirt, and debris. Dry completely with clean rags.
9. 9

   Install new boot
   Slide the new boot onto the tie rod end first (small end), then work it over the rack area and onto the rack housing (large end). Ensure the boot is fully seated in the grooves on both the housing and tie rod. The boot should not be twisted and should sit naturally without stress.
10. 10

    Install inner boot clamp
    Position the new inner boot clamp (large diameter) in the groove on the rack housing end of the boot. Using boot clamp pliers, tighten the clamp securely. Ensure the boot has not shifted and remains properly seated in the housing groove. The clamp should be tight enough to prevent moisture entry but not so tight as to cut the boot.
11. 11

    Install outer boot clamp
    Position the new outer boot clamp (small diameter) in the groove on the tie rod end of the boot. Verify the boot is properly positioned and not twisted. Secure the clamp using boot clamp pliers. Check that the boot can flex naturally without restriction.
12. 12

    Reinstall tie rod end
    Thread the tie rod end back onto the inner tie rod, using your reference marks and turn count to achieve approximately the same position. Do not fully tighten the jam nut yet. Insert the tie rod end taper into the steering knuckle and install the castle nut. Tighten castle nut to specification and install new cotter pin if equipped.
13. 13

    Repeat for opposite side
    Perform steps 2 through 12 for the opposite side steering rack boot. Ensure both boots are properly installed and all clamps are secure before proceeding.
14. 14

    Final adjustments
    Once both tie rod ends are reconnected to the steering knuckles, tighten both jam nuts securely while holding the inner tie rod to prevent rotation. Verify steering linkage moves smoothly through full range of motion without binding or boot interference.

Reassembly

1. Reinstall all underbody panels and skid plates removed during disassembly
2. Reinstall front wheels and torque lug nuts to specification in star pattern
3. Lower vehicle to ground
4. Verify steering wheel is still centered and operates smoothly
5. Test vehicle in safe area at low speed to confirm steering operation before driving

Verification

• Visually inspect both rack boots for proper installation, no twisting, and secure clamps
• Check for grease leaks around boot clamps after initial test drive
• Verify steering operates smoothly without noise or binding through full lock-to-lock rotation
• Confirm no contact between boots and other suspension components during steering movement
• Schedule professional wheel alignment to restore factory specifications

More procedures for this vehicle