Front Suspension Crossmember Replacement

REMOVAL PROCEDURE

- Tools Required
- J 6627-A Tie Rod/Wheel Stud Puller
- J 28467-A Engine Support Fixture
- J 28467-450 Engine Support Fixture Adapters
- J 36660-A Torque/Angle Meter
- J 36857 Lift Brackets
- J 42089 Linkage Installer

1. Attach the engine support fixture at the engine lift points.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.

2. Raise and support the vehicle.
3. Remove the front wheel assemblies.
4. Remove the wheel speed sensor from the strut assemblies.
5. Remove the brake wear indicator wires from the strut assemblies.





6. Remove the brake flex hose clips from the strut assemblies.
7. Remove the hoses from the strut assemblies.





8. Remove the wheel speed sensor bolts.
9. Remove the wheel speed sensors.





10. Remove the brake caliper assembly bolts from the steering knuckles.
11. Remove the brake caliper assemblies from the steering knuckles. Do NOT open the brake hydraulic system.

Important: Support the brake caliper assemblies. Do NOT allow the brake caliper assemblies to hang freely or damage may occur to the flex hose.

12. Remove the outer tie rod nuts.





13. Use J 6627-A to remove the outer tie rod ball studs from the steering knuckles.





14. Remove the lower control arm ball stud pinch bolts (1).
15. Remove the steering knuckles from the lower control arm ball studs.





16. Remove the stabilizer shaft link nuts.
17. Remove the stabilizer shaft links from the stabilizer shaft.





18. Remove the engine mount nuts.





19. Support the crossmember frame.
20. Remove the engine front crossmember frame bolts.
21. Lower the front crossmember frame.

INSTALLATION PROCEDURE





1. Position the front crossmember frame.

Important: Properly seat the radiator lower guide pins and the engine mounts. Verify that no lines, wires, etc. are pinched.

2. Use J 36660-A in order to install the front crossmember frame bolts.
2.1. Tighten the 4 engine front crossmember frame to body bolts to 150 Nm (111 ft. lbs.) + 37°.
2.2. Tighten the engine front crossmember frame to the radiator support bolts to 65 Nm (48 ft. lbs.) + 37°.

Notice: Refer to Fastener Notice in Service Precautions.

Important: Use new engine front crossmember frame bolts.





3. Install the engine mount nuts.
- Tighten the engine mount nuts to 55 Nm (41 ft. lbs.).





4. Install the stabilizer shaft links to the stabilizer shaft.
5. Install the stabilizer shaft link nuts.
- Tighten the stabilizer shaft link nuts to 65 Nm (48 ft. lbs.).
6. Install the steering knuckles to the lower control arm ball studs.
7. Install new lower control arm ball stud pinch bolts from the rear toward the front of the vehicle.





8. Install the lower control arm ball stud pinch bolts (1).
- Tighten the lower control arm ball stud pinch bolts to 100 Nm (74 ft. lbs.).





9. Install the outer tie rods into the steering knuckles.
10. Install the J 42089 to the tie rod ball studs.
- Tighten the J 42089 to 30 Nm (22 ft. lbs.) in order to allow the ball stud taper to seat.
11. Remove the J 42089 from the tie rod ball studs.
12. Install the outer tie rod nuts.
- Tighten the outer tie rod nuts to 60 Nm (44 ft. lbs.).

Important: Use new self-locking tie rod nuts.

13. Install the brake caliper assemblies to the steering knuckles using J 36660-A.
- Tighten the brake caliper assembly bolts to 95 Nm (70 ft. lbs.) + 37°.

Important:
- Run a M12 x 1.5 tap through the holes for the brake caliper assembly bolts to clean out the old locking compound.
- Use new bolts for the brake caliper assembly connection to the steering knuckle. Coat the bolts with locking compound. Use GM P/N 12345493 Goodwrench 272 Threadlocker, or equivalent.
14. Install the wheel speed sensor wiring to the strut assemblies.
15. Install the brake wear indicator wires to the strut assemblies.





16. Install the brake hoses to the strut brackets with the clip.





17. Install the wheel speed sensors.
18. Install the wheel speed sensor bolts.
- Tighten the wheel speed sensor bolt to 8 Nm (71 inch lbs.).
19. Install the front wheel assemblies.
20. Lower the vehicle.
21. Adjust the wheel alignment.