2007 Chevy Malibu Steering Rack and Pinion Replacement

4046 Views 15 Replies 4 Participants Last post by smithluke52, Mar 25, 2022

ST42Curell

Discussion Starter · Mar 12, 2022

Hello all,
I brought my car in for an alignment (slight drift, just replace rear shocks, front struts, power steering torque sensor) and was told they cannot do the alignment due to the power steering rack being loose internally and that I need a left front tie rod and to replace the rack and pinion assembly. I did some research and am noticing people having a clunk-like noise sometimes while driving which happens often for me as well.

I did not find many helpful tutorials when searching for DIY rack and pinion replacement on the 2007 Chevy Malibu, does anyone have any helpful links that could help me get this job done?

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Drunken Elvis

· #2 · Mar 13, 2022

The steering rack is not know for problems so I would be sure to check other things first. The intermediate shaft can cause a clunk and is subject to a TSB or recall. The torque sensor was also the subject of a recall. Perhaps a second opinion from another alignment shop is in order.

Reactions: 3

ST42Curell

Discussion Starter · #3 · Mar 13, 2022

Drunken Elvis said:
The steering rack is not know for problems so I would be sure to check other things first. The intermediate shaft can cause a clunk and is subject to a TSB or recall. The torque sensor was also the subject of a recall. Perhaps a second opinion from another alignment shop is in order.

Thanks for the response. I brought it to a Big O Tires and wouldn’t put it past them to misdiagnose and was already thinking about getting a second opinion, I think that’s what I’ll do now for sure!

Darthz

· #4 · Mar 15, 2022

I have this clunk aswell..... there s a thread on here somewhere.....where someone swapped the u joint to fix this.....i need to find it too.

I just went through the front,t end alignment issue aswell...... both front bearings...both front outter tierods. 1130 dollars. And it still isnt right

Reactions: 1

smithluke52

· #5 · Mar 17, 2022

Darthz said:
I have this clunk aswell..... there s a thread on here somewhere.....where someone swapped the u joint to fix this.....i need to find it too.

I just went through the front,t end alignment issue aswell...... both front bearings...both front outter tierods. 1130 dollars. And it still isnt right

hey man, that might be my thread you are referring to..
I have a 2006 Malibu LT.. and I replaced the intermediate shaft as well as the rack and pinion.. as well as the electric power steering column.. if you need help with the repair (if you are comfortable doing it on your own) I can do my best to help.. I have pictures

Reactions: 1

smithluke52

· #6 · Mar 17, 2022

Post Title: 2006 Malibu LT 3.5L Rack and Pinion/Intermediate Shaft.. tags: 2006 3.5l malibu rack shaft

smithluke52

· #7 · Mar 17, 2022

smithluke52 said:
Post Title: 2006 Malibu LT 3.5L Rack and Pinion/Intermediate Shaft.. tags: 2006 3.5l malibu rack shaft

..just type in those tags and you will be able to find the post.. had to use a grinder to cut the pinch bolt.. jack it up and remove left wheel.. pinch bolt is an 11mm.. the rack is a different story. not terribly difficult. its a couple long bolts holding it in place.. tight fit to pull it out through the wheel well.. I had to remove another unrelated bolt to slide it out. the clunk on mine was solved by replacing the rack and pinion and intermediate shaft both at once.. used the aftermarket Dorman one.. I believe the clunk was intermediate shaft but I did both to be sure. has not come back.

smithluke52

· #8 · Mar 17, 2022

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the pink is where the bottom of the two bolts are.. you will have to figure which ones, but I marked in purple where the top of the one is.. right next to intermediate shaft.. you can also see where I cut the pinch bolt to remove intermediate shaft.. the other end of int shaft is in the cabin.. you will have to remove a body panel under steering wheel to get to it.. requires some flexibility to say the least.

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smithluke52

· #9 · Mar 17, 2022

some people have said you need to move transmission out of the way and all sorts of stuff.. its not necessary. there will be one bolt head blocking it from sliding out, remove that and you are good, assuming you have the electric power steering like I do.. otherwise there are some hydraulic lines to remove, which I have not done personally. I believe the bolts holding the rack in place are 15mm. you will need an alignment afterwards, of course. the entire steering everything on Malibu from that time period seems to have trouble.. hope this helps.

smithluke52

· #10 · Mar 17, 2022 (Edited)

It is also worth mentioning that my clunk seemed to me like the rack and pinion based on having someone else turn wheel while shining light on it and spraying it with lubricant at U joint while turning it, and there was no indication that it was coming from there. however, it was so rusty that I decided to get the aftermarket Dorman shaft for about $130 and got a good used rack and pinion from a junk yard near me for $50.. which is a good deal since new ones are about 400-500 range.. I hope you find a good deal too.

smithluke52

· #11 · Mar 17, 2022

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that one circled in light blue..
I removed that and was able to slide the whole thing out from the drivers side...

which is also where you will be working on the int shaft.. of course you will have to remove the passenger wheel as well in order to get to the rack and pinion bolt on that side. this is a tip that may be hard to come by, as I havent seen anyone else mention it.

just as a disclaimer, I cannot guarantee that your vehicle is like mine, and I cant guarantee something wont shift when you remove it..

but in my case.. nothing even slightly budged from removing it. just replaced it after pulling the rack and sliding new one in place.
honestly the intermediate shaft was more difficult than the rack, due to the position of it.. you will see what I mean.

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ST42Curell

Discussion Starter · #12 · Mar 18, 2022

smithluke52 said:
View attachment 72174

that one circled in light blue..
I removed that and was able to slide the whole thing out from the drivers side...

which is also where you will be working on the int shaft.. of course you will have to remove the passenger wheel as well in order to get to the rack and pinion bolt on that side. this is a tip that may be hard to come by, as I havent seen anyone else mention it.

just as a disclaimer, I cannot guarantee that your vehicle is like mine, and I cant guarantee something wont shift when you remove it..

but in my case.. nothing even slightly budged from removing it. just replaced it after pulling the rack and sliding new one in place.
honestly the intermediate shaft was more difficult than the rack, due to the position of it.. you will see what I mean.

Thanks so much for taking the time to help me out, this information will be very helpful for a novice like myself. I was quoted about $700 for this job at two places, I briefly checked rockauto and found some steering racks relatively cheap so I will be ordering that soon and come back to this thread with any questions!

smithluke52

· #13 · Mar 18, 2022

ST42Curell said:
Thanks so much for taking the time to help me out, this information will be very helpful for a novice like myself. I was quoted about $700 for this job at two places, I briefly checked rockauto and found some steering racks relatively cheap so I will be ordering that soon and come back to this thread with any questions!

ST42Curell said:
Thanks so much for taking the time to help me out, this information will be very helpful for a novice like myself. I was quoted about $700 for this job at two places, I briefly checked rockauto and found some steering racks relatively cheap so I will be ordering that soon and come back to this thread with any questions!

Im sure you will do fine.
I wish I got 700 for that amount of work haha
sounds good ill keep an eye out.

Drunken Elvis

· #14 · Mar 18, 2022

Spraying some lube into/onto the intermediate shaft might cure the clunking sound. If this alone is the cure, changing the rack may be unnecessary. It could also be just the pinch bolt [rack to shaft] that needs to be re-seated. There used to be a lot of information about this problem on the web.
Point is, address the intermediate steering shaft before replacing the rack.
Here is an old video about the problem.

Darthz

· #15 · Mar 20, 2022

Man you are awesome for posting all that

smithluke52

· #16 · Mar 25, 2022

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ST42Curell said:
Thanks so much for taking the time to help me out, this information will be very helpful for a novice like myself. I was quoted about $700 for this job at two places, I briefly checked rockauto and found some steering racks relatively cheap so I will be ordering that soon and come back to this thread with any questions!

no problem.. bonus: here is the rack I pulled off.. for anyone's reference that has never seen it off the vehicle.

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