GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Vibe - AWD 🢒 Engine 🢒 Engine Electrical 🢒 Front Suspension Crossmember Replacement

Front Suspension Crossmember Replacement FWD

Removal Procedure

    Important: If you are removing the front suspension crossmember in order to gain access to other components, you may remove the following components together as a unit:

       • The front suspension crossmember
       • The trans support
       • The 2 lower control arms
       • The front stabilizer shaft
       • The steering gear, if necessary
    If removal of the steering gear is not necessary, you may use wire in order to suspend the steering gear in the vehicle.

  1. If you are removing the crossmember WITH the steering gear, remove the following components. Refer to Steering Gear Replacement in Power Steering.
    2. • The lower steering shaft coupling bolt
    • The steering column hole cover
    • The 2 outer tie rod ends
    • The pressure and return pipes
    • The pipe bracket
  2. Install the Engine Support Fixture. Refer to Engine Support Fixture in Engine Mechanical - 1.8L (LV6) or to Engine Support Fixture in Engine Mechanical - 1.8L (LNK).
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the front tire and wheel assemblies from the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

    5. Object Number: 821347 Size: SH
  5. Use a 6 mm wrench in order to hold the left front stabilizer shaft link stud. Remove the nut from the stud in order to separate the link (3) from the left front strut.
  6. Use a 6 mm wrench in order to hold the right front stabilizer shaft link stud. Remove the nut from the stud in order to separate the link from the right front strut.
  7. Remove the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side in Body Front End.
  8. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side in Body Front End.

    9. Object Number: 821222 Size: SH
  9. Remove the following components from the left control arm:
    10. • The bolt (3)
    • The 2 nuts (1,2)
  10. Remove the following components from the right control arm:
    11. • The bolt
    • The 2 nuts

    Object Number: 820261 Size: SH
  11. If you are removing the crossmember WITHOUT the steering gear, complete the following steps:
    12. 11.1. Use wire in order to suspend the steering gear (11).
    11.2. Remove the 4 bolts (7,12,13,14).

    Object Number: 820289 Size: SH
  12. Remove the 5 bolts (1,2,3,4,5).
  13. Remove the 3 nuts (9,10,11).
  14. Support the crossmember with a jack.
  15. Remove the 4 bolts (6,8,13,15).
  16. Use the jack in order to lower the crossmember.

    17. Important: If you are replacing the components on the crossmember, continue with this procedure.

  17. Remove the 2 bolts and the trans support from the crossmember.
  18. Remove the 2 control arms. Refer to Lower Control Arm Replacement .
  19. Remove the following components from the crossmember. Refer to Stabilizer Shaft Replacement .
    20. • The 2 stabilizer shaft link nuts
    • The 2 stabilizer shaft links
    • The 4 stabilizer clamp bolts
    • The 2 stabilizer clamps
    • The 2 stabilizer shaft insulators
    • The stabilizer shaft
  20. If you removed the crossmember WITH the steering gear, remove the steering gear from the crossmember. Refer to Steering Gear Replacement in Power Steering.

Installation Procedure
  1. If you are installing the crossmember WITH the steering gear, install the steering gear to the crossmember. Refer to Steering Gear Replacement in Power Steering.
  2. Install the following components to the crossmember. Refer to Stabilizer Shaft Replacement .
    3. • The 2 stabilizer shaft link nuts
    • The 2 stabilizer shaft links
    • The 4 stabilizer clamp bolts
    • The 2 stabilizer clamps
    • The 2 stabilizer shaft insulators
    • The stabilizer shaft

    Object Number: 821351 Size: SH

    Important: DO NOT tighten the nut and bolts completely. The weight of the vehicle must be on the tire and wheel assemblies before tightening the nut and the bolts.

  3. Install the following components to the crossmember:
    4. • The left lower control arm (2)
    • The 2 bolts (1,4)
    • The nut (3)

    Important: DO NOT tighten the nut and bolts completely. The weight of the vehicle must be on the tire and wheel assemblies before tightening the nut and the bolts.

  4. Install the following components to the crossmember:
    5. • The right lower control arm
    • The 2 bolts
    • The nut

    Notice: Refer to Fastener Notice in the Preface section.

  5. Install the trans support and the 2 bolts to the crossmember.

    6. Tighten
    Tighten the bolts to 52 N·m (38.4 lb ft).

  6. Use a jack in order to raise and support the crossmember with the attached components as a unit.

    7. Object Number: 828025 Size: SH
  7. Insert a wood dowel (1) into the hole in the right side of the crossmember (3) and the hole in the body.
  8. Use the dowel in order to align the bolt holes.

    9. Object Number: 828026 Size: SH
  9. Install the 2 bolts (1,2) to the crossmember.
  10. Insert the dowel into the hole in the left side of the crossmember and the hole in the body.
  11. Use the dowel in order to align the bolt holes.

    12. Object Number: 820289 Size: SH
  12. Install the 2 bolts to the crossmember (8,6).
  13. Insert the dowel into the hole in the right side of the crossmember and the hole in the body.
  14. Use the dowel in order to align the bolt holes.
  15. Tighten the bolt (13).

    16. Tighten
    Tighten the bolt to 157 N·m (115.8 lb ft).

  16. Tighten the bolt (15).

    17. Tighten
    Tighten the bolt to 113 N·m (83.3 lb ft).

  17. Insert the dowel into the hole in the left side of the crossmember and the hole in the body.
  18. Use the dowel in order to align the bolt holes.
  19. Tighten the bolt (8).

    20. Tighten
    Tighten the bolt to 157 N·m (115.8 lb ft).

  20. Tighten the bolt (6).

    21. Tighten
    Tighten the bolt to 113 N·m (83.3 lb ft).

  21. Remove the jack from the crossmember.
  22. Install the 3 nuts (9,10,11).

    23. Tighten
    Tighten the nuts to 52 N·m (38.4 lb ft).

  23. Install the 5 bolts (1,2,3,4,5).

    24. Tighten
    Tighten the bolts to 52 N·m (38.4 lb ft).


    Object Number: 820261 Size: SH
  24. If you are installing the crossmember WITHOUT the steering gear, complete the following steps:
    25. 24.1. Install the 4 bolts (7,12,13,14).

    Tighten
    Tighten the bolts to 58 N·m (42.8 lb ft).

    24.2. Remove the wire from the steering gear (11).

    Object Number: 821222 Size: SH
  25. Install the following to the left front control arm:
    26. • The 2 nuts (1,2)
    • The bolt (3)

    Tighten
    Tighten the 2 nuts and the bolt to 89 N·m (65.6 lb ft).

  26. Install the following to the right front control arm:
    27. • The 2 nuts
    • The bolt

    Tighten
    Tighten the 2 nuts and the bolt to 89 N·m (65.6 lb ft).

  27. Install the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side in Body Front End.
  28. Install the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side in Body Front End.

    29. Object Number: 821347 Size: SH
  29. Use a 6 mm wrench in order to hold the left front stabilizer shaft link stud. Install the nut and the stud to the strut bracket.

    30. Tighten
    Tighten the nut to 74 N·m (54.6 lb ft).

  30. Use a 6 mm wrench in order to hold the right front stabilizer shaft link stud. Install the nut and the stud to the strut bracket.

    31. Tighten
    Tighten the nut to 74 N·m (54.6 lb ft).

  31. Install the front tire and wheel assemblies to the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  32. Lower the vehicle.
  33. Remove the Engine Support Fixture. Refer to Engine Support Fixture in Engine Mechanical - 1.8L (LV6) or to Engine Support Fixture in Engine Mechanical - 1.8L (LNK).
  34. If you are installing the crossmember WITH the steering gear, install the following components. Refer to Steering Gear Replacement in Power Steering.
    35. • The lower steering shaft coupling bolt
    • The steering column hole cover
    • The 2 outer tie rod ends
    • The pressure and return pipes
    • The pipe bracket
  35. With the weight of the vehicle on the tire and wheel assemblies, push down on the front bumper 3 times in order to bounce the vehicle and stabilize the suspension.

    36. Object Number: 821351 Size: SH
  36. Tighten the nut (3) and the 2 bolts (1,4) on the left lower control arm.

    37. Tighten
    Tighten the nut and the 2 bolts to 137 N·m (101.0 lb ft).

  37. Tighten the nut and the 2 bolts on the right lower control arm.

    38. Tighten
    Tighten the nut and the 2 bolts to 137 N·m (101.0 lb ft).

  38. Measure the wheel alignment. Adjust if necessary. Refer to Wheel Alignment Measurement in Wheel Alignment.

Front Suspension Crossmember Replacement AWD

Removal Procedure

    Important: If you are removing the front suspension crossmember in order to gain access to other components, you may remove the following components together as a unit:

       • The front suspension crossmember
       • The 2 lower control arms
       • The front stabilizer shaft
       • The steering gear, if necessary
    If removal of the steering gear is not necessary, you may use wire in order to suspend the steering gear in the vehicle.

  1. If you are removing the steering gear WITH the crossmember, remove the following components. Refer to Steering Gear Replacement in Power Steering.
    2. • The lower steering shaft coupling bolt
    • The steering column hole cover
    • The 2 outer tie rod ends
    • The pressure and return pipes
    • The pipe bracket
  2. Install the Engine Support Fixture. Refer to Engine Support Fixture in Engine Mechanical - 1.8L (LV6).
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the front tire and wheel assemblies from the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

    5. Object Number: 821347 Size: SH
  5. Use a 6 mm wrench in order to hold the left front stabilizer shaft link stud. Remove the nut from the stud in order to separate the link (3) from the left front strut.
  6. Use a 6 mm wrench in order to hold the right front stabilizer shaft link stud. Remove the nut from the stud in order to separate the link from the right front strut.
  7. Remove the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side in Body Front End.
  8. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side in Body Front End.

    9. Object Number: 821222 Size: SH
  9. Remove the following components from the left control arm:
    10. • The bolt (3)
    • The 2 nuts (1,2)
  10. Remove the following components from the right control arm:
    11. • The bolt
    • The 2 nuts

    Object Number: 820272 Size: SH
  11. If you are removing the crossmember WITHOUT the steering gear, complete the following steps:
    12. 11.1. Use wire in order to suspend the steering gear (11).
    11.2. Remove the 2 nuts (6,7) and the 2 bolts (12,13).

    Object Number: 828024 Size: SH
  12. Remove the 2 nuts (2,5) and the bolt (6).
  13. Support the crossmember with a jack.
  14. Remove the 4 bolts (1,3,4,7).
  15. Use the jack in order to lower the crossmember.

    16. Important: If you are replacing the components on front suspension crossmember, continue with this procedure.

  16. Remove the 2 control arms. Refer to Lower Control Arm Replacement .
  17. Remove the following components from the crossmember. Refer to Stabilizer Shaft Replacement .
    18. • The 2 stabilizer shaft link nuts
    • The 2 stabilizer shaft links
    • The 4 stabilizer shaft insulator clamp bolts
    • The 2 stabilizer shaft insulator clamps
    • The 2 stabilizer shaft insulators
    • The stabilizer shaft
  18. If you removed the crossmember WITH the steering gear, remove the steering gear from the crossmember. Refer to Steering Gear Replacement in Power Steering.

Installation Procedure
  1. If you are installing the crossmember WITH the steering gear, install the steering gear to the crossmember. Refer to Steering Gear Replacement in Power Steering.
  2. Install the following components to the crossmember. Refer to Stabilizer Shaft Replacement .
    3. • The 2 stabilizer shaft link nuts
    • The 2 stabilizer shaft links
    • The 4 stabilizer shaft insulator clamp bolts
    • The 2 stabilizer shaft insulator clamps
    • The 2 stabilizer shaft insulators
    • The stabilizer shaft

    Object Number: 821351 Size: SH

    Important: DO NOT tighten the nut and bolts completely. The weight of the vehicle must be on the tire and wheel assemblies before tightening the nut and the bolts.

  3. Install the following components to the crossmember:
    4. • The left lower control arm (2)
    • The 2 bolts (1,4)
    • The nut (3)

    Important: DO NOT tighten the nut and bolts completely. The weight of the vehicle must be on the tire and wheel assemblies before tightening the nut and the bolts.

  4. Install the following components to the crossmember:
    5. • The right lower control arm
    • The 2 bolts
    • The nut
  5. Use a jack in order to raise and support the crossmember with the attached components as a unit.

    6. Object Number: 828025 Size: SH
  6. Insert a wood dowel (1) into the hole in the right side of the crossmember (3) and the hole in the body.
  7. Use the dowel in order to align the bolt holes.

    8. Object Number: 828026 Size: SH
  8. Install the 2 bolts (1,2) to the crossmember.
  9. Insert a wood dowel into the hole in the left side of the crossmember and the hole in the body.
  10. Use the dowel in order to align the bolt holes.

    11. Object Number: 828024 Size: SH
  11. Install the 2 bolts to the crossmember (3,4).
  12. Insert a wood dowel into the hole in the right side of the crossmember and the hole in the body.
  13. Use the dowel in order to align the bolt holes.

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

  14. Tighten the bolt (7).

    15. Tighten
    Tighten the bolt to 157 N·m (115.8 lb ft).

  15. Tighten the bolt (1).

    16. Tighten
    Tighten the bolt to 113 N·m (83.3 lb ft).

  16. Insert a wood dowel into the hole in the left side of the crossmember and the hole in the body.
  17. Use the dowel in order to align the bolt holes.
  18. Tighten the bolt (4).

    19. Tighten
    Tighten the bolt to 157 N·m (115.8 lb ft).

  19. Tighten the bolt (3).

    20. Tighten
    Tighten the bolt to 113 N·m (83.3 lb ft).

  20. Remove the jack from the crossmember.
  21. Install the 2 nuts (2,5) and the bolt (6).

    22. Tighten
    Tighten the nuts and the bolt to 52 N·m (38.4 lb ft).


    Object Number: 820272 Size: SH
  22. If you are installing the crossmember WITHOUT the steering gear, complete the following steps:
    23. 22.1. Install the 2 nuts (6,7) and the 2 bolts (12,13).

    Tighten
    Tighten the bolts to 127 N·m (93.7 lb ft).

    22.2. Remove the wire from the steering gear (11).

    Object Number: 821222 Size: SH
  23. Install the following to the left front control arm:
    24. • The 2 nuts (1,2)
    • The bolt (3)

    Tighten
    Tighten the 2 nuts and the bolt to 89 N·m (65.6 lb ft).

  24. Install the following to the right front control arm:
    25. • The 2 nuts
    • The bolt

    Tighten
    Tighten the 2 nuts and the bolt to 89 N·m (65.6 lb ft).

  25. Install the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side in Body Front End.
  26. Install the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side in Body Front End.

    27. Object Number: 821347 Size: SH
  27. Use a 6 mm wrench in order to hold the left front stabilizer shaft link stud. Install the nut and the stud to the strut bracket (1).

    28. Tighten
    Tighten the nut to 74 N·m (54.6 lb ft).

  28. Use a 6 mm wrench in order to hold the right front stabilizer shaft link stud. Install the nut and the stud to the strut bracket.

    29. Tighten
    Tighten the nut to 74 N·m (54.6 lb ft).

  29. Install the front tire and wheel assemblies to the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  30. Lower the vehicle.
  31. Remove the Engine Support Fixture. Refer to Engine Support Fixture in Engine Mechanical - 1.8L (LV6).
  32. If you are installing the crossmember WITH the steering gear, install the following components. Refer to Steering Gear Replacement in Power Steering.
    33. • The lower steering shaft coupling bolt
    • The steering column hole cover
    • The 2 outer tie rod ends
    • The pressure and return pipes
    • The pipe bracket
  33. With the weight of the vehicle on the tire and wheel assemblies, push down on the front bumper 3 times in order to bounce the vehicle and stabilize the suspension.

    34. Object Number: 821351 Size: SH
  34. Tighten the nut (3) and the 2 bolts (1,4) on the left lower control arm.

    35. Tighten
    Tighten the nut and the 2 bolts to 137 N·m (101.0 lb ft).

  35. Tighten the nut and the 2 bolts on the right lower control arm.

    36. Tighten
    Tighten the nut and the 2 bolts to 137 N·m (101.0 lb ft).

  36. Measure the wheel alignment. Adjust if necessary. Refer to Wheel Alignment Measurement in Wheel Alignment.