GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Preface 🢒 Cautions and Notices 🢒 Front Suspension Crossmember Replacement

Removal Procedure

    Object Number: 1290581 Size: SH
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the wheels. Refer to Tire and Wheel Removal and Installation .
  3. Remove the nuts and bolts from the steering gear mounting bracket.
  4. Remove the return line bolt from the clip on the crossmember.
  5. Remove the exhaust pipe forward of the catalytic converter. Refer to Front Pipe Replacement .
  6. Disconnect the tie rod from the knuckle assembly. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  7. Disconnect the ball joint from the knuckle assembly. Refer to Steering Knuckle Replacement .
  8. Disconnect the stabilizer link from the strut assembly. Refer Stabilizer Shaft Link Replacement .
  9. Remove the crossmember link-to-transaxle bracket nut.
  10. Support the crossmember with a transaxle support jack.

    11. Object Number: 1290626 Size: SH
  11. Remove the rear crossmember-to-body bolts.

    12. Object Number: 1290659 Size: SH
  12. Remove the front crossmember-to-body bolts.
  13. Lower the crossmember assembly from the vehicle.

Installation Procedure

    Object Number: 1290659 Size: SH
  1. Raise the crossmember assembly with a transaxle support jack.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the rear crossmember-to-body bolts.

    3. Tighten
    Tighten the rear crossmember-to-body bolts to 196 N·m (145 lb ft).

  3. Install the front crossmember-to-body bolts.

    4. Tighten
    Tighten the front crossmember-to-body bolts to 130 N·m (96 lb ft).


    Object Number: 1290581 Size: SH
  4. Install the bolts and nuts on the steering gear mounting brackets.

    5. Tighten
    Tighten the steering gear mounting bracket bolts and nuts to 60 N·m (44 lb ft).

  5. Install the return line bolt into the clip on the crossmember.

    6. Tighten
    Tighten the return line clip bolt to 8 N·m (71 lb in).


    Object Number: 1290593 Size: SH
  6. Install the crossmember link-to-transaxle bracket nut.

    7. Tighten
    Tighten the crossmember link-to-transaxle nut to 169 N·m (125 lb ft).

  7. Connect the stabilizer link to the strut assembly. Refer Stabilizer Shaft Link Replacement .
  8. Connect the ball joint to the knuckle assembly. Refer to Steering Knuckle Replacement .
  9. Connect the tie rod to the knuckle assembly. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  10. Install the exhaust pipe into the vehicle. Refer to Front Pipe Replacement .
  11. Install the wheels. Refer to Tire and Wheel Removal and Installation .
  12. Lower the vehicle.