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For 1990-2009 cars only

Front Suspension Crossmember Replacement Without Z06

Special Tools

    • J 28467-B Universal Engine Support Fixture
    • J 33432-A Transverse Spring Compressor
    • J 41803 Engine Support Fixture

Removal Procedure

  1. Remove the generator from the accessory mounting bracket. Refer to Generator Replacement .
  2. Install J 41803 and J 28467-B and support the engine.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .

  5. Object Number: 82236  Size: SH
  6. Remove the steering linkage outer tie rod end stud nuts (3). Refer to Rack and Pinion Outer Tie Rod End Replacement .

  7. Object Number: 581266  Size: SH
  8. Disconnect the shock absorber solenoid electrical connector, if equipped.

  9. Object Number: 581252  Size: SH
  10. Disconnect the electronic suspension control (ESC) sensor links.
  11. Remove the stabilizer shaft from the vehicle. Refer to Stabilizer Shaft Replacement .
  12. Disconnect the intermediate shaft lower coupling from the steering gear. Refer to Intermediate Steering Shaft Replacement .
  13. Remove the bolts from the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement .
  14. Support and reposition the EBCM/BPMV and bracket away from the crossmember.

  15. Object Number: 65352  Size: SH
  16. Remove the power steering gear mounting bolts.
  17. Remove the power steering fluid cooler from the crossmember.
  18. Lift the power steering gear off of the crossmember and support.

  19. Object Number: 65337  Size: SH
  20. Using the J 33432-A , remove the transverse spring from the vehicle. Refer to Front Transverse Spring Replacement .

  21. Object Number: 65335  Size: SH
  22. Disconnect the lower shock absorber bolts from the lower control arms.

  23. Object Number: 65339  Size: SH
  24. Remove the lower control arm bolts from the crossmember.
  25. Place a transmission jack under the crossmember.
  26. Remove the engine mount lower nuts. Refer to the following procedures:
  27. •  Engine Mount Replacement - Right Side
    •  Engine Mount Replacement - Left Side

    Object Number: 1696482  Size: SH
  28. Disconnect the wheel speed sensor wiring harness (3) from the crossmember.

  29. Object Number: 581567  Size: SH
  30. Disconnect the electrical harness from the clips on the crossmember.
  31. Disconnect the brake pipe from the clips on the crossmember.

  32. Object Number: 581372  Size: SH
  33. Remove the crossmember mounting nuts.
  34. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.

Installation Procedure


    Object Number: 581372  Size: SH
  1. Raise the crossmember to the vehicle.
  2. 1.1. Align the crossmember dowel pins to the frame rails.
    1.2. Align the engine mount studs.

    Notice: Refer to Fastener Notice in the Preface section.

  3. Install new crossmember mounting nuts.
  4. Tighten
    Tighten the new crossmember mounting nuts to 110 N·m (81 lb ft).

  5. Install the engine mount lower nuts. Refer to one of the following procedures:
  6. •  Engine Mount Replacement - Right Side
    •  Engine Mount Replacement - Left Side

    Object Number: 1696482  Size: SH
  7. Fasten the wheel speed sensor wiring harness retaining clips (3) to the crossmember.
  8. Fasten the brake pipe to the retaining clips on the crossmember.

  9. Object Number: 581567  Size: SH
  10. Connect the electrical harness to the clips on the crossmember.
  11. Connect the brake pipe to the clips on the crossmember.

  12. Object Number: 65337  Size: SH
  13. Install the transverse spring with the J 33432-A connected, to the crossmember. Refer to Front Transverse Spring Replacement .

  14. Object Number: 65339  Size: SH
  15. Install the lower control arm to the crossmember. Refer to Lower Control Arm Replacement .

  16. Object Number: 65335  Size: SH
  17. Install the shock absorbers to the lower control arms.
  18. Tighten
    Tighten the shock absorber lower mounting nuts to 28 N·m (21 lb ft).


    Object Number: 65352  Size: SH
  19. Install the power steering gear to the crossmember.
  20. Tighten
    Tighten the power steering gear mounting bolts to 100 N·m (74 lb ft).

  21. Install the bolts to the BPMV. Refer to Brake Pressure Modulator Valve Bracket Replacement .
  22. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement .

  23. Object Number: 581252  Size: SH
  24. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  25. Connect the electronic suspension control (ESC) sensor links to the upper control arm, if equipped.

  26. Object Number: 581266  Size: SH
  27. Connect the shock absorber solenoid electrical connector, if equipped.
  28. Install the stabilizer shaft to the vehicle. Refer to Stabilizer Shaft Replacement .
  29. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  30. Lower the vehicle.
  31. Remove J 41803 and J 28467-B from the engine.
  32. Install the generator. Refer to Generator Replacement .
  33. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  34. Perform a vehicle front end alignment. Refer to Wheel Alignment Measurement .

Front Suspension Crossmember Replacement With Z06 or ZR1

Special Tools

    • J 28467-B Universal Engine Support Fixture
    • J 33432-A Transverse Spring Compressor
    • J 41803 Engine Support Fixture

Removal Procedure

  1. Remove the generator from the accessory mounting bracket. Refer to Generator Replacement.
  2. Install J 41803 and J 28467-B and support the engine.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.

  5. Object Number: 82236  Size: SH
  6. Remove the steering linkage outer tie rod end stud nuts (3). Refer to Steering Linkage Outer Tie Rod Replacement.
  7. Remove the stabilizer shaft from the vehicle. Refer to Stabilizer Shaft Replacement.
  8. Disconnect the intermediate shaft lower coupling from the steering gear. Refer to Intermediate Steering Shaft Replacement.
  9. Remove the bolts from the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement.
  10. Support and reposition the EBCM/BPMV and bracket away from the crossmember.

  11. Object Number: 65352  Size: SH
  12. Remove the power steering gear mounting bolts.
  13. Remove the power steering fluid cooler from the crossmember.
  14. Lift the power steering gear off of the crossmember and support.
  15. Remove the engine oil line hose bracket from the crossmember.

  16. Object Number: 65337  Size: SH
  17. Using the J 33432-A , remove the transverse spring from the vehicle. Refer to Front Transverse Spring Replacement.

  18. Object Number: 65335  Size: SH
  19. Disconnect the lower shock absorber bolts from the lower control arms.

  20. Object Number: 1696557  Size: SH
  21. Remove the lower control arm bolts from the crossmember.
  22. Place a transmission jack under the crossmember.
  23. Remove the engine mount lower nuts. Refer to the following procedures:
  24. •  Engine Mount Replacement - Left Side
    •  Engine Mount Replacement - Right Side

    Object Number: 1696554  Size: SH
  25. Disconnect the wheel speed sensor wiring harness (1) from the crossmember.

  26. Object Number: 581567  Size: SH
  27. Disconnect the electrical harness from the clips on the crossmember.
  28. Disconnect the brake pipe from the clips on the crossmember.

  29. Object Number: 581372  Size: SH
  30. Remove the crossmember mounting nuts.
  31. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.

Installation Procedure

    Notice: The magnesium crossmember requires aluminum spacers at all metal contact points. Failure to reinstall these spacers will result in severe corrosion damage.

  1. Carefully inspect the magnesium crossmember. Replace any damaged or missing spacers prior to installation.

  2. Object Number: 581372  Size: SH
  3. Raise the crossmember to the vehicle.
  4. 2.1. Align the crossmember dowel pins to the frame rails.
    2.2. Align the engine mount studs.

    Notice: Refer to Fastener Notice in the Preface section.

  5. Install new crossmember mounting nuts.
  6. Tighten
    Tighten the new crossmember mounting nuts to 110 N·m (81 lb ft).

  7. Install the engine mount lower nuts. Refer to one of the following procedures:
  8. •  Engine Mount Replacement - Left Side
    •  Engine Mount Replacement - Right Side

    Object Number: 1696554  Size: SH
  9. Fasten the wheel speed sensor wiring harness retaining clips (1) to the crossmember.
  10. Fasten the brake pipe to the retaining clips on the crossmember.

  11. Object Number: 581567  Size: SH
  12. Connect the electrical harness to the clips on the crossmember.
  13. Connect the brake pipe to the clips on the crossmember.

  14. Object Number: 65337  Size: SH
  15. Install the transverse spring with the J 33432-A connected, to the crossmember. Refer to Front Transverse Spring Replacement.
  16. Install the engine oil line hose bracket to the crossmember.

  17. Object Number: 1696557  Size: SH

    Notice: The magnesium crossmember requires the use of unique lower control arm cam bolts, washers, and aluminum bushing ferrules. Failure to use these specific components during assembly will result in severe corrosion damage.

  18. Install the lower control arm to the crossmember. Refer to Lower Control Arm Replacement.

  19. Object Number: 65335  Size: SH
  20. Install the shock absorbers to the lower control arms.
  21. Tighten
    Tighten the shock absorber lower mounting nuts to 28 N·m (21 lb ft).


    Object Number: 65352  Size: SH

    Notice: The power steering gear utilizes aluminum spacers to isolate the gear from the magnesium crossmember. To avoid severe corrosion damage, new spacers are to be installed each time the gear is removed from the crossmember.

  22. Install the power steering gear to the crossmember.
  23. Tighten
    Tighten the power steering gear mounting bolts to 100 N·m (74 lb ft).

  24. Install the bolts to the BPMV. Refer to Brake Pressure Modulator Valve Bracket Replacement.
  25. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement.
  26. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
  27. Install the stabilizer shaft to the vehicle. Refer to Stabilizer Shaft Replacement.
  28. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
  29. Lower the vehicle.
  30. Remove J 41803 and J 28467-B from the engine.
  31. Install the generator. Refer to Generator Replacement.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  33. Perform a vehicle front end alignment. Refer to Wheel Alignment Measurement.