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Home › Saturn › 2005 › Ion Red Line › Repair and Diagnosis › External Pages › Different car › Section 118 (Frame And Underbody) › Repair Instructions › Frame Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Ion Red Line, 2007 Saturn Ion 3, and 2007 Saturn Ion 2. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the frame, perform the following steps:
    1. Install the radiator brackets to the frame.
    2. Install the lower control arms to the frame. Refer to Lower Control Arm Replacement .
    3. Install the stabilizer bar to the frame. Refer to Stabilizer Shaft Replacement .
    4. Install the steering gear to the frame. Refer to Power Steering Gear Replacement .
  2. With the frame on the lift table, raise the frame to the vehicle.
    3. Fig 1: View Of Frame Bolts
    GM851651Courtesy of GENERAL MOTORS CORP.
  3. Hand start all the frame bolts while aligning the frame to the paint marks.
    4. NOTE: Refer to Fastener Notice .
  4. Tighten the frame bolts.

    Tighten:  Tighten the bolts to 100 N.m + 180 degrees (74 lb ft) + 180 degrees.

  5. Lower and remove the hydraulic table.
    6. Fig 2: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  6. Connect the lower control arm to the steering knuckle.
    7. IMPORTANT: The torque sequence must be followed in the order that is listed.
  7. Install the ball joint pinch bolt and nut.

    Tighten: 

    1. First Pass: Tighten the nut to 50 N.m (37 lb ft).
    2. Reverse the nut 3/4 turn.
    3. Second Pass: Tighten the nut to 50 N.m (37 lb ft) + 30 degrees.

    8. Fig 3: View Of Front Transmission Mount Through Bolt
    GM851568Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The front and rear transmission mounts must be allowed to settle with the through bolts loosened.
  8. Hand start the front transaxle mount through bolt.
  9. Loosen the rear transmission mount through bolt.
    10. Fig 4: View Of Rear Transaxle Mount To Frame Bolts
    GM851572Courtesy of GENERAL MOTORS CORP.
  10. Tighten the rear transaxle mount to frame bolts.

    Tighten:  Tighten the rear bolts to 50 N.m (37 lb ft).

  11. Tighten the front and rear transaxle mount through bolts in the following order.

    Tighten: 

    1. Tighten the rear bolt to 100 N.m (74 lb ft).
    2. Tighten the front bolt to 100 N.m (74 lb ft).

    12. Fig 5: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  12. Install the outer tie rods to the steering knuckles.
  13. Install the new outer tie rod to the knuckle nuts.

    Tighten:  Tighten the nuts to 20 N.m (15 lb ft) + 180 degrees.

    14. Fig 6: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  14. Connect the stabilizer links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .
  15. Connect the intermediate shaft to the steering gear.
  16. Install a new intermediate shaft pinch bolt.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

  17. Install the left and right splash shields. Refer to Splash Shield Replacement - Engine .
    18. Fig 7: Installing Wheels
    GM855038Courtesy of GENERAL MOTORS CORP.
  18. Install the front wheels. Refer to Tire and Wheel Removal and Installation (4 Lug Wheel) or Tire and Wheel Removal and Installation (5 Lug Wheel) .
  19. Lower the vehicle.
  20. Road test the vehicle in order to test for the following conditions:
    • Steering leads or pulls-Refer to Measuring Wheel Alignment .
    • Abnormal powertrain noise or vibration at idle-Inspect the engine and transmission mounts for proper alignment and torque.
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