GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Epica 🢒 Body Repair 🢒 Frame and Underbody 🢒 Front Suspension Crossmember Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Turn the steering wheel to the straight-ahead position. Ensure the front tires are in the straight-ahead position.
  3. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
  4. Place a drain pan under the power steering gear in order to catch the power steering fluid.
  5. Remove the power steering pipes from the steering gear. Refer to Steering Gear Replacement.

    6. Object Number: 1256241 Size: SH
  6. Place a match mark on the stub shaft housing that lines up with the groove of the intermediate shaft. This mark will be used for proper alignment during installation.

    7. Object Number: 1255622 Size: SH
  7. Remove the lower pinch bolt from the universal joint on the intermediate shaft.

    8. Object Number: 1255623 Size: SH
  8. If the vehicle has a manual transaxle, remove the gear shift control bracket and fixing clip.
  9. Remove the center member. Refer to Engine Front Crossmember Replacement.
  10. Remove the front exhaust pipe. Refer to Front Pipe Replacement.

    11. Object Number: 1255624 Size: SH
  11. Separate the outer tie rod from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
  12. Separate the control arm ball joint from the steering knuckle. Refer to Control Arm Replacement.

    13. Object Number: 1255625 Size: SH
  13. Remove the crossmember bolts-to-control arm and nuts-to-longitudinal frame.

    14. Warning: Failure to support crossmember can cause crossmember to drop to the ground when crossmember mounting bolts are removed.

  14. Lower the crossmember.

    15. Object Number: 1255626 Size: SH
  15. Remove the power steering gear from the crossmember assembly. Refer to Steering Gear Replacement.
  16. Remove the stabilizer shaft from the crossmember assembly. Refer to Stabilizer Shaft Replacement.
  17. Remove the control arm from the crossmember assembly. Refer to Control Arm Replacement.

Installation Procedure

    Object Number: 1255627 Size: SH
  1. Install the control arm to the crossmember assembly. Refer to Control Arm Replacement.
  2. Install the stabilizer shaft to the crossmember assembly. Refer to Stabilizer Shaft Replacement.
  3. Install the power steering gear to the crossmember assembly. Refer to Steering Gear Replacement.
  4. Raise the crossmember assembly up to the vehicle.

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the crossmember bolts-to-control arm, nuts-to-longitudinal frame and crossmember.

    6. Tighten
    Tighten the crossmember bolts-to-control arm and nuts-to-longitudinal frame to 150 N·m (110 lb ft).


    Object Number: 1255624 Size: SH
  6. Install the control arm ball joint to the steering knuckle. Refer to Control Arm Replacement.
  7. Install the outer tie rod end to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
  8. Install the front exhaust pipe. Refer to Front Pipe Replacement.
  9. Install the center member. Refer to Engine Front Crossmember Replacement.

    10. Object Number: 1255623 Size: SH
  10. If the vehicle has a manual transaxle, install the shift control bracket and clip.

    11. Object Number: 1256241 Size: SH

    Note: The steering gear must be in the straight-ahead position.

  11. Align the match marks on the steering shafts in order to ensure proper positioning. Seat the steering gear stub shaft into the intermediate shaft.

    12. Object Number: 1255622 Size: SH
  12. Install the lower intermediate shaft pinch bolt.

    13. Tighten
    Tighten the intermediate shaft pinch bolt to 25 N·m (18 lb ft).

  13. Install the power steering pipes to the steering gear. Refer to Steering Gear Replacement.
  14. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
  15. Lower the vehicle.