GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 VUE - AWD 🢒 Body Repair 🢒 Frame and Underbody 🢒 Frame Replacement

Frame Replacement L66

Tools Required

    • J 43828 Ball Joint Remover
    • SA9140E Torque Angle Gage

Removal Procedure

    Object Number: 857193 Size: SH
  1. Tie the radiator, air conditioning condenser, and fan module assembly to the upper radiator support to keep the assembly with the vehicle when the frame is lowered.
  2. Install the engine support fixture. Refer to Engine Support Fixture .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .
  5. Remove the side splash shield-to-frame fasteners.
  6. Remove the front air dam-to-frame fasteners.

    7. Object Number: 1260852 Size: SH
  7. Remove the rear transmission mount-to-frame bolts.

    8. Object Number: 1239273 Size: SH
  8. Remove the front transmission mount-to-frame bolts.

    9. Object Number: 927957 Size: SH
  9. Remove the steering gear-to-frame bolts.
  10. Using mechanics wire, secure the steering gear to the exhaust.

    11. Object Number: 929945 Size: SH
  11. Remove the stabilizer shaft clamp-to-frame bolts.

    12. Object Number: 929893 Size: SH
  12. Remove the lower ball joint cotter pins. Discard the cotter pins.

    13. Object Number: 932518 Size: SH
  13. Loosen the lower ball joint castle nut until the nut is level with the top of the ball stud.

    14. Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.

  14. Using the J 43828 , release the ball stud.

    15. Object Number: 1548950 Size: SH
  15. Remove the reinforcement bolts (3).
  16. Remove the rear frame to body bolts (2). DISCARD the bolts.
  17. Remove the reinforcement (1) from the vehicle.

    18. Object Number: 933087 Size: SH
  18. Remove the front frame-to-body bolts. DISCARD the bolts.
  19. Carefully lower the frame from the vehicle.
  20. Remove the lower control arms. Refer to Lower Control Arm Replacement .

Installation Procedure
  1. Install the lower control arms. Refer to Lower Control Arm Replacement .
  2. Raise the frame to the body.

    3. Object Number: 933087 Size: SH

    Important: Do not tighten the fasteners at this time.

  3. Loosely install NEW front frame-to-body bolts.

    4. Object Number: 1548950 Size: SH
  4. Position the reinforcement (1) to the vehicle.
  5. Loosely install NEW rear frame to body bolts (2).
  6. Loosely install the reinforcement bolts (3).

    7. Object Number: 932518 Size: SH
  7. Connect the ball joint stud to the steering knuckle.

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

  8. Using the SA9140E , secure the ball stud.

    9. Tighten
    Tighten the nut to 40 N·m (30 lb ft).

    Important: 

       • Do not loosen the castle nut in order to align the cotter pin slots.
       • Ensure the cutter pin ends do not contact the wheel speed sensor harness.

  9. Continue to tighten the castle nut to align the slots with the opening in the ball stud and install the ball stud cotter pin.

    10. Object Number: 927957 Size: SH
  10. Remove the mechanics wire and install the steering gear to the frame.

    11. Tighten
    Tighten the bolts to 110 N·m (81 lb ft).


    Object Number: 1239273 Size: SH
  11. Install the transmission mount-to-frame bolts.

    12. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).


    Object Number: 1260852 Size: SH
  12. Install the rear transmission mount-to-frame bolts.

    13. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  13. Install the stabilizer shaft clamp.

    14. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 1548950 Size: SH
  14. Tighten the frame-to-body reinforcement bolts (3).

    15. Tighten
    Tighten the bolts (3) to 50 N·m (37 lb ft).


    Object Number: 933087 Size: SH
  15. Tighten the frame-to-body bolts.

    16. Tighten
    Tighten the bolts to 155 N·m (114 lb ft).

  16. Install the front air dam fasteners.
  17. Install the side splash shield-to-frame fasteners.
  18. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
  19. Lower the vehicle.
  20. Remove the engine support fixture.
  21. Untie the radiator, air conditioning condenser, and fan module assembly from the upper radiator support.
  22. Align the front suspension. Refer to Front Toe Adjustment .

Frame Replacement L61

Tools Required

    • J 43828 Ball Joint Remover
    • SA9140E Torque Angle Gage

Removal Procedure

    Object Number: 857193 Size: SH
  1. Secure the radiator to the upper radiator support.
  2. Install the engine support fixture. Refer to Engine Support Fixture .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .
  5. Remove the side splash shield-to-frame fasteners.
  6. Remove the front air dam-to-frame fasteners.

    7. Object Number: 929708 Size: SH
  7. Remove the rear transaxle mount-to-frame bolts.

    8. Object Number: 928767 Size: SH
  8. Remove the front transaxle mount through bolt.

    9. Object Number: 927957 Size: SH
  9. Remove the steering gear-to-frame bolts.
  10. Using mechanics wire, secure the steering gear to the exhaust.

    11. Object Number: 929945 Size: SH
  11. Remove the stabilizer shaft clamp-to-frame bolts.

    12. Object Number: 929893 Size: SH
  12. Remove the lower ball joint cotter pins. Discard the cotter pins.

    13. Object Number: 932518 Size: SH
  13. Loosen the lower ball joint castle nut until the nut is level with the top of the ball stud.

    14. Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.

  14. Using the J 43828 , release the ball stud.

    15. Object Number: 933087 Size: SH
  15. Remove the frame-to-body bolts. Discard the bolts.
  16. Carefully lower the frame from the vehicle.
  17. Remove the lower control arms. Refer to Lower Control Arm Replacement .

Installation Procedure
  1. Install the lower control arms. Refer to Lower Control Arm Replacement .
  2. Raise the frame to the body.

    3. Object Number: 933087 Size: SH

    Important: Do not tighten the fasteners at this time.

  3. Loosely install new frame-to-body bolts.

    4. Object Number: 932518 Size: SH
  4. Connect the ball joint stud to the steering knuckle.

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

  5. Using the SA9140E , secure the ball stud.

    6. Tighten
    Tighten the nut to 40 N·m (30 lb ft).

    Important: 

       • Do not loosen the castle nut in order to align the cotter pin slots.
       • Ensure the cutter pin ends do not contact the wheel speed sensor harness.

  6. Continue to tighten the castle nut to align the slots with the opening in the ball stud and install the ball stud cotter pin.

    7. Object Number: 927957 Size: SH
  7. Remove the mechanics wire and install the steering gear to the frame.

    8. Tighten
    Tighten the bolts to 110 N·m (81 lb ft).


    Object Number: 928767 Size: SH
  8. Install the front transaxle mount through bolt.

    9. Tighten
    Tighten the bolt to 110 N·m (81 lb ft).


    Object Number: 929708 Size: SH
  9. Install the rear transaxle mount-to-frame bolts.

    10. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  10. Install the stabilizer shaft clamp.

    11. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  11. Tighten the frame-to-body bolts.

    12. Tighten
    Tighten the bolts to 155 N·m (114 lb ft).

  12. Install the front air dam fasteners.
  13. Install the side splash shield-to-frame fasteners.
  14. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
  15. Lower the vehicle.
  16. Remove the engine support fixture. Refer to Engine Support Fixture .
  17. Unsecure the radiator from the upper radiator support.
  18. Align the front suspension. Refer to Front Toe Adjustment .