Front Suspension Crossmember Replacement With Z06 or ZR1

Special Tools

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



10. Remove the power steering gear mounting bolts.
11. Remove the power steering fluid cooler from the crossmember.
12. Lift the power steering gear off of the crossmember and support.
13. Remove the engine oil line hose bracket from the crossmember.



14. Using the J 33432-A , remove the transverse spring from the vehicle. Refer to Front Transverse Spring Replacement.



15. Disconnect the lower shock absorber bolts from the lower control arms.



16. Remove the lower control arm bolts from the crossmember.
17. Place a transmission jack under the crossmember.
18. Remove the engine mount lower nuts. Refer to the following procedures:

•	Engine Mount Replacement - Left Side

•	Engine Mount Replacement - Right Side




19. Disconnect the wheel speed sensor wiring harness (1) from the crossmember.



20. Disconnect the electrical harness from the clips on the crossmember.
21. Disconnect the brake pipe from the clips on the crossmember.



22. Remove the crossmember mounting nuts.
23. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.

Caution: 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.

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



2. Raise the crossmember to the vehicle.

2.1.	Align the crossmember dowel pins to the frame rails.

2.2.	Align the engine mount studs.

Caution: Refer to Fastener Caution in the Preface section.

3. Install new crossmember mounting nuts.

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

4. Install the engine mount lower nuts. Refer to one of the following procedures:

•	Engine Mount Replacement - Left Side

•	Engine Mount Replacement - Right Side




5. Fasten the wheel speed sensor wiring harness retaining clips (1) to the crossmember.
6. Fasten the brake pipe to the retaining clips on the crossmember.



7. Connect the electrical harness to the clips on the crossmember.
8. Connect the brake pipe to the clips on the crossmember.



9. Install the transverse spring with the J 33432-A connected, to the crossmember. Refer to Front Transverse Spring Replacement.
10. Install the engine oil line hose bracket to the crossmember.




Caution: 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.

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



12. Install the shock absorbers to the lower control arms.

Tighten
Tighten the shock absorber lower mounting nuts to 28 N·m (21 lb ft).





Caution: 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.

13. Install the power steering gear to the crossmember.

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

14. Install the bolts to the BPMV. Refer to Brake Pressure Modulator Valve Bracket Replacement.
15. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement.
16. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
17. Install the stabilizer shaft to the vehicle. Refer to Stabilizer Shaft Replacement.
18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
19. Lower the vehicle.
20. Remove J 41803 and J 28467-B from the engine.
21. Install the generator. Refer to Generator Replacement.
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
23. Perform a vehicle front end alignment. Refer to Wheel Alignment Measurement.

Front Suspension Crossmember Replacement Without Z06

Special Tools

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. Remove the steering linkage outer tie rod end stud nuts (3). Refer to Steering Linkage Outer Tie Rod Replacement.



6. Disconnect the shock absorber solenoid electrical connector, if equipped.



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



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. Using the J 33432-A , remove the transverse spring from the vehicle. Refer to Front Transverse Spring Replacement.



16. Disconnect the lower shock absorber bolts from the lower control arms.



17. Remove the lower control arm bolts from the crossmember.
18. Place a transmission jack under the crossmember.
19. Remove the engine mount lower nuts. Refer to the following procedures:

•	Engine Mount Replacement - Right Side

•	Engine Mount Replacement - Left Side




20. Disconnect the wheel speed sensor wiring harness (3) from the crossmember.



21. Disconnect the electrical harness from the clips on the crossmember.
22. Disconnect the brake pipe from the clips on the crossmember.



23. Remove the crossmember mounting nuts.
24. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.

1. Raise the crossmember to the vehicle.

1.1.	Align the crossmember dowel pins to the frame rails.

1.2.	Align the engine mount studs.

Caution: Refer to Fastener Caution in the Preface section.

2. Install new crossmember mounting nuts.

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

3. Install the engine mount lower nuts. Refer to one of the following procedures:

•	Engine Mount Replacement - Right Side

•	Engine Mount Replacement - Left Side




4. Fasten the wheel speed sensor wiring harness retaining clips (3) to the crossmember.
5. Fasten the brake pipe to the retaining clips on the crossmember.



6. Connect the electrical harness to the clips on the crossmember.
7. Connect the brake pipe to the clips on the crossmember.



8. Install the transverse spring with the J 33432-A connected, to the crossmember. Refer to Front Transverse Spring Replacement.



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



10. Install the shock absorbers to the lower control arms.

Tighten
Tighten the shock absorber lower mounting nuts to 28 N·m (21 lb ft).




11. Install the power steering gear to the crossmember.

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

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



14. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
15. Connect the electronic suspension control (ESC) sensor links to the upper control arm, if equipped.



16. Connect the shock absorber solenoid electrical connector, if equipped.
17. Install the stabilizer shaft to the vehicle. Refer to Stabilizer Shaft Replacement.
18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
19. Lower the vehicle.
20. Remove J 41803 and J 28467-B from the engine.
21. Install the generator. Refer to Generator Replacement.
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
23. Perform a vehicle front end alignment. Refer to Wheel Alignment Measurement.