Front Suspension Crossmember Replacement (With Z06)

Front Suspension Crossmember Replacement (With Z06)


Special Tools
* J 28467-B Universal Engine Support Fixture
* J 33432-A Transverse Spring Compressor
* J 41803 Engine Support Fixture



Removal Procedure

1. Remove the generator from the accessory mounting bracket. Refer to Generator Replacement (Generator Replacement) .
2. Install J 41803 and J 28467-B and support the engine.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service Intervals) .
4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair) .




5. Remove the steering linkage outer tie rod end stud nuts (3). Refer to Rack and Pinion Outer Tie Rod End Replacement (Service and Repair) .
6. Remove the stabilizer shaft from the vehicle. Refer to Stabilizer Shaft Replacement (Front Suspension) .
7. Disconnect the intermediate shaft lower coupling from the steering gear. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement) .
8. Remove the bolts from the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement (Service and Repair) .
9. Support and reposition the EBCM/BPMV and bracket away from the crossmember.




10. Remove the power steering gear mounting bolts.
11. Remove the power steering fluid cooler from the crossmember.
12. Lift the power steering gear off of the crossmember and support.
13. Remove the engine oil line hose bracket from the crossmember.




14. Using the J 33432-A , remove the transverse spring from the vehicle. Refer to Front Transverse Spring Replacement (Front Suspension Leaf Spring) .




15. Disconnect the lower shock absorber bolts from the lower control arms.




16. Remove the lower control arm bolts from the crossmember.
17. Place a transmission jack under the crossmember.
18. Remove the engine mount lower nuts. Refer to the following procedures:

* Engine Mount Replacement - Left Side (Service and Repair)
* Engine Mount Replacement - Right Side (Service and Repair)





19. Disconnect the wheel speed sensor wiring harness (1) from the crossmember.




20. Disconnect the electrical harness from the clips on the crossmember.
21. Disconnect the brake pipe from the clips on the crossmember.




22. Remove the crossmember mounting nuts.
23. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.



Installation Procedure


Notice: The magnesium crossmember requires aluminum spacers at all metal contact points. Failure to reinstall these spacers will result in severe corrosion damage.

1. Carefully inspect the magnesium crossmember. Replace any damaged or missing spacers prior to installation.




2. Raise the crossmember to the vehicle.

1. Align the crossmember dowel pins to the frame rails.
2. Align the engine mount studs.


Notice: Refer to Fastener Notice (Fastener Notice) .

3. Install new crossmember mounting nuts.

Tighten the new crossmember mounting nuts to 110 N.m (81 lb ft).

4. Install the engine mount lower nuts. Refer to one of the following procedures:

* Engine Mount Replacement - Left Side (Service and Repair)
* Engine Mount Replacement - Right Side (Service and Repair)





5. Fasten the wheel speed sensor wiring harness retaining clips (1) to the crossmember.
6. Fasten the brake pipe to the retaining clips on the crossmember.




7. Connect the electrical harness to the clips on the crossmember.
8. Connect the brake pipe to the clips on the crossmember.




9. Install the transverse spring with the J 33432-A connected, to the crossmember. Refer to Front Transverse Spring Replacement (Front Suspension Leaf Spring) .
10. Install the engine oil line hose bracket to the crossmember.





Notice: The magnesium crossmember requires the use of unique lower control arm cam bolts, washers, and aluminum bushing ferrules. Failure to use these specific components during assembly will result in severe corrosion damage.

11. Install the lower control arm to the crossmember. Refer to Lower Control Arm Replacement (Lower Control Arm Replacement) .




12. Install the shock absorbers to the lower control arms.

Tighten the shock absorber lower mounting nuts to 28 N.m (21 lb ft).






Notice: The power steering gear utilizes aluminum spacers to isolate the gear from the magnesium crossmember. To avoid severe corrosion damage, new spacers are to be installed each time the gear is removed from the crossmember.

13. Install the power steering gear to the crossmember.

Tighten the power steering gear mounting bolts to 100 N.m (74 lb ft).

14. Install the bolts to the BPMV. Refer to Brake Pressure Modulator Valve Bracket Replacement (Service and Repair) .
15. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement) .
16. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement (Service and Repair) .
17. Install the stabilizer shaft to the vehicle. Refer to Stabilizer Shaft Replacement (Front Suspension) .
18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair) .
19. Lower the vehicle.
20. Remove J 41803 and J 28467-B from the engine.
21. Install the generator. Refer to Generator Replacement (Generator Replacement) .
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) (Service and Repair)Battery Negative Cable Disconnection and Connection (7.0L) (Service and Repair) .

23. Perform a vehicle front end alignment. Refer to Wheel Alignment Measurement (Service and Repair) .