For 1990-2009 cars

## Front Suspension Crossmember Replacement Automatic Transmission

### Removal Procedure

1. Install the engine support fixture. Refer to Engine Support Fixture for the 2.2L engine or Engine Support Fixture for the 3.4L engine.
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .
4. Remove the front fender liner. Refer to Front Fender Liner Replacement .
5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
6. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
7. Remove the brake modulator assembly from the support bracket. Refer to Electronic Brake Control Module Replacement .
8. Remove the tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
9. Remove the power steering gear mounting bolts and secure out of the way with mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to Steering Gear Replacement .
10. Remove the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.
11. Remove the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.
12. Remove the brake lines from the retainers on the crossmember (2).
13. Lower the vehicle until the suspension crossmember (2) rests on the jack stands.
14. Remove the front suspension crossmember front support bolts (3).
15. Remove the front suspension crossmember rear support bolts (4).
16. Remove the suspension control arm to body bolts (1).
17. Raise the vehicle off of the suspension crossmember (2).
18. Remove the following components if replacing the suspension crossmember:

• | The lower control arms. Refer to Lower Control Arm Replacement .

• | The front transmission mount. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.

• | The rear transmission mount. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.

• | The stabilizer shaft. Refer to Stabilizer Shaft Replacement .

• | The lower radiator support. Refer to Radiator Support Replacement .

### Installation Procedure

1. Install the following components on the suspension crossmember if removed:

• | The stabilizer shaft. Refer to Stabilizer Shaft Replacement .

• | The rear transmission mount. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.

• | The front transmission mount. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.

• | The lower control arms. Refer to Lower Control Arm Replacement .

• | The lower radiator support. Refer to Radiator Support Replacement .

2. Lower the vehicle on to the crossmember support (2).
3. Install the suspension control arm support to body bolts (1). Hand tighten the bolts.
4. Install the rear suspension crossmember support bolts (4). Hand tighten the bolts.
5. Install the front suspension crossmember support bolts (3). Hand tighten the bolts.

Notice: Refer to Fastener Notice in the Preface section.

6. Tighten the suspension crossmember bolts in the following order:

Tighten

• | Tighten the front suspension crossmember rear bolts to 70 N·m (52 lb ft).

• | Tighten the front suspension crossmember front bolts to 100 N·m (74 lb ft) plus 180 degrees.

• | Tighten the front suspension control arm to body bolts to 100 N·m (70 lb ft) plus 180 degrees.

7. Raise the vehicle and support with jack stands. Refer to Lifting and Jacking the Vehicle .
8. Install the brake lines to the retainers on the crossmember (2).
9. Install the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.
10. Install the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.
11. Remove the mechanic's wire or equivalent and install the power steering gear mounting bolts. Refer to Steering Gear Replacement .
12. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
13. Install the brake modulator assembly to the support bracket. Refer to Electronic Brake Control Module Replacement .
14. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
15. Connect the ABS sensor to the wheel speed sensor and frame.
16. Install the front fender liner. Refer to Front Fender Liner Replacement .
17. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
18. Remove the engine support fixture. Refer to Engine Support Fixture for the 2.2L engine or Engine Support Fixture for the 3.4L engine.

## Front Suspension Crossmember Replacement Manual Transmission

### Removal Procedure

1. Install the engine support fixture. Refer to Engine Support Fixture for the 2.2L engine or Engine Support Fixture for the 3.4L engine.
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .
4. Remove the front fender liner. Refer to Front Fender Liner Replacement .
5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
6. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
7. Remove the stabilizer shaft insulators. Refer to Stabilizer Shaft Insulator Replacement .
8. Remove the brake modulator assembly from the support bracket. Refer to Electronic Brake Control Module Replacement .
9. Remove the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement for the M86/M94 Getrag transmission.
10. Remove the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement for the M86/M94 Getrag transmission.
11. Remove the side transmission mount bracket bolts. Refer to Transmission Mount Replacement - Side for the M86/M94 Getrag transmission.
12. Remove the mounting bolts from the power steering gear and secure out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to Steering Gear Replacement .
13. Remove the right front brake line from the vehicle. Refer to Front Brake Hose Replacement .
14. Remove the brake lines from the retainers on the crossmember (2).
15. Lower the vehicle until the suspension crossmember (2) rests on the jack stands.
16. Remove the front suspension crossmember front support bolts (3).
17. Remove the front suspension crossmember rear support bolts (4).
18. Remove the suspension control arm to body bolts (1).
19. Raise the vehicle off of the suspension crossmember (2).
20. Remove the following components if replacing the suspension crossmember:

• | The lower control arms. Refer to Lower Control Arm Replacement .

• | The front transmission mount. Refer to Transmission Front Mount Replacement for the M86/M94 Getrag transmission.

• | The rear transmission mount. Refer to Transmission Rear Mount Replacement for the M86/M94 Getrag transmission.

• | The side transmission mount. Refer to Transmission Mount Replacement - Side for the M86/M94 Getrag transmission.

• | The stabilizer shaft. Refer to Stabilizer Shaft Replacement .

• | The lower radiator support. Refer to Radiator Replacement .

### Installation Procedure

1. Install the following components on the suspension crossmember if removed:

• | The lower radiator support. Refer to Radiator Replacement .

• | The stabilizer shaft. Refer to Stabilizer Shaft Replacement .

• | The rear transmission mount. Refer to Transmission Rear Mount Replacement for the M86/M94 Getrag transmission.

• | The front transmission mount. Refer to Transmission Front Mount Replacement for the M86/M94 Getrag transmission.

• | The side transmission mount. Refer to Transmission Mount Replacement - Side for the M86/M94 Getrag transmission.

• | The lower control arms. Refer to Lower Control Arm Replacement .

2. Lower the vehicle onto the crossmember support (2).
3. Install the suspension crossmember support to body bolts (1). Hand tighten the bolts.
4. Install the rear suspension crossmember support bolts (4). Hand tighten the bolts.
5. Install the front suspension crossmember support bolts (3). Hand tighten the bolts.

Notice: Refer to Fastener Notice in the Preface section.

6. Tighten the suspension crossmember bolts in the following order:

Tighten

• | Tighten the front suspension crossmember rear bolts to 70 N·m (52 lb ft).

• | Tighten the front suspension crossmember bolts to 100 N·m (74 lb ft) plus 180 degrees.

• | Tighten the front suspension control arm to body bolts to 100 N·m (74 lb ft) plus 180 degrees.

7. Raise the vehicle and support with jack stands. Refer to Lifting and Jacking the Vehicle .
8. Install the brake lines to the retainers on the crossmember (2).
9. Remove the mechanic's wire or equivalent and install the power steering gear mounting bolts. . Refer to Steering Gear Replacement .
10. Install the right front brake line from the vehicle. Refer to Front Brake Hose Replacement .
11. Install the side transmission mount bracket bolts. Refer to Transmission Mount Replacement - Side for the M86/M94 Getrag transmission.
12. Install the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement for the M86/M94 Getrag transmission.
13. Install the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement for the M86/M94 Getrag transmission.
14. Install the brake modulator assembly to the support bracket. Refer to Electronic Brake Control Module Replacement .
15. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
16. Install the front fender liner. Refer to Front Fender Liner Replacement .
17. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
18. Remove the engine support fixture. Refer to Engine Support Fixture for the 2.2L engine or Engine Support Fixture for the 3.4L engine.
19. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .