GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Montana SV6 Ext. 🢒 General Information 🢒 General Information 🢒 Crossmember Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the rear tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Inspect the rear ball joints. Refer to Ball Joint Inspection in Suspension General Diagnosis.
  4. Support rear differential carrier using a utility stand.

    5. Object Number: 690531 Size: SH
  5. Remove the rear differential carrier mounting bolts (5) from the rear crossmember. Refer to Differential Replacement in Rear Drive Axle.
  6. Remove the rear suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  7. Disconnect the wheel speed sensor harness from the lower control arm and from the rear cross member.
  8. Remove the rivets that attach the park brake cable to the rear crossmember.
  9. Remove the automatic level control (ALC) height sensor and link from the crossmember bar and lower control arm. Refer to Automatic Level Control Sensor Replacement in Automatic Level Control.
  10. Secure the ALC wiring harness out of the way.
  11. Using a utility jack, support the rear crossmember.
  12. Remove the rear crossmember mounting bolts.

    13. Object Number: 771995 Size: SH
  13. Lower the rear crossmember.
  14. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement in Rear Suspension.
  15. Remove the rear axle upper control arms from the rear crossmember. Refer to Rear Axle Upper Control Arm Replacement in Rear Suspension.
  16. Remove the rear axle lower control arms from the rear crossmember. Refer to Rear Axle Lower Control Arm Replacement in Rear Suspension.
  17. Remove the tie rods from the rear crossmember. Refer to Tie Rod Replacement in Rear Suspension.

Installation Procedure
  1. Install the tie rods to the crossmember. Refer to Tie Rod Replacement in Rear Suspension.
  2. Install the rear axle lower control arms onto the rear crossmember. Refer to Rear Axle Lower Control Arm Replacement in Rear Suspension.
  3. Install the rear axle upper control arms onto the rear crossmember. Refer to Rear Axle Upper Control Arm Replacement in Rear Suspension.
  4. Install the rear stabilizer shaft onto the rear crossmember. Refer to Stabilizer Shaft Replacement in Rear Suspension.

    5. Object Number: 1594412 Size: SH
  5. Raise the rear crossmember.
  6. Align the rear crossmember using guide pins through the rail holes (1).
  7. Install the rear crossmember mounting bolts.

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

  8. Tighten the mounting bolts.

    9. Tighten
    Tighten the rear crossmember mounting bolts to 130 N·m (96 lb ft) .

  9. Install the ALC height sensor onto the crossmember and lower control arm. Refer to Automatic Level Control Sensor Replacement in Automatic Level Control.

    10. Object Number: 690531 Size: SH
  10. Install the rear differential carrier mounting bolts (5). Refer to Differential Replacement in Rear Drive Axle.
  11. Attach the parking brake cable onto the rear crossmember. Refer to Parking Brake Rear Cable Replacement - Left Side and Parking Brake Rear Cable Replacement - Right Side in Park Brake.
  12. Connect the wheel speed sensor harness onto the rear crossmember and the lower control arm.
  13. Install the rear suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  14. Install the rear tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  15. Lower the vehicle.
  16. Inspect for rear wheel alignment and adjust as necessary. Refer to Wheel Alignment Measurement in Wheel Alignment.