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Home › Chevrolet › 2004 › Classic › Repair and Diagnosis › Body & Frame › Frames, Subframes & Crossmembers › Frame And Underbody › Repair Instructions › Frame Replacement › Removal Procedure

Removal Procedure

  1. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 2.2L (L61).
  2. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  4. Remove the splash shields. Refer to Front Fender Liner Replacement in Body Front End.
  5. Disconnect the Antilock Brake System (ABS) harness from the wheel speed sensor and frame. Refer to ABS Component Views in Antilock Brake System.
  6. Remove the lower ball joints from the steering knuckles. Refer to Lower Ball Joint Replacement .
  7. Remove the brake modulator assembly from the front suspension crossmember. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Antilock Brake System.
  8. Remove the tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
  9. Remove the bolt from the steering gear to intermediate shaft and disconnect the shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  10. Remove the power steering lines from the steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
  11. Remove the front transmission mount bracket through bolts. Refer to Transmission Mount Replacement - Front in Automatic Transaxle - 4T40-E/4T45-E.
  12. Remove the rear transmission mount bracket through bolts. Refer to Transmission Mount Replacement - Rear in Automatic Transaxle - 4T40-E/4T45-E.
    13. Fig 1: View of Front Suspension Crossmember
    GM486720Courtesy of GENERAL MOTORS CORP.
  13. Remove the brake lines from the retainers on the front suspension crossmember (3).
  14. Lower the vehicle until the front suspension crossmember (3) rests on the jack stands.
  15. Remove the front suspension crossmember front support bolts (4).
  16. Remove the front suspension crossmember rear support bolts (1).
  17. Remove the front suspension Control Arm to body bolts (2).
  18. Raise the vehicle off of the front suspension crossmember (3).
  19. Remove the following components if replacing the front suspension crossmember:
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