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Home › Saturn › 2005 › Relay AWD › Repair and Diagnosis › Body & Frame › Frames, Subframes & Crossmembers › Frame And Underbody › Repair Instructions › Crossmember Replacement › Installation Procedure

Installation Procedure

  1. Install the tie rods to the crossmember. Refer to Tie Rod Replacement (Front Wheel Drive) or Tie Rod Replacement (All Wheel Drive) in Rear Suspension.
  2. Install the rear axle lower control arms onto the rear crossmember. Refer to Rear Axle Lower Control Arm Replacement in Rear Suspension.
  3. Install the rear axle upper control arms onto the rear crossmember. Refer to Rear Axle Upper Control Arm Replacement in Rear Suspension.
  4. Install the rear stabilizer shaft onto the rear crossmember. Refer to Stabilizer Shaft Replacement in Rear Suspension.
    5. Fig 1: Raising Rear Crossmember
    GM1594412Courtesy of GENERAL MOTORS CORP.
  5. Raise the rear crossmember.
  6. Align the rear crossmember using guide pins through the rail holes (1).
  7. Install the rear crossmember mounting bolts.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Tighten the mounting bolts.

    Tighten:  Tighten the rear crossmember mounting bolts to 130 N.m (96 lb ft).

  9. Install the ALC height sensor onto the crossmember and lower control arm. Refer to Automatic Level Control Sensor Replacement in Automatic Level Control.
    10. Fig 2: View Of Rear Differential Carrier Mounting Bolts
    GM690531Courtesy of GENERAL MOTORS CORP.
  10. Install the rear differential carrier mounting bolts (5). Refer to Differential Replacement in Rear Drive Axle.
  11. Attach the parking brake cable onto the rear crossmember. Refer to Park Brake Cable Replacement - Left Rear and Park Brake Cable Replacement - Right Rear in Park Brake.
  12. Connect the wheel speed sensor harness onto the rear crossmember and the lower control arm.
  13. Install the rear suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  14. Install the rear tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  15. Lower the vehicle.
  16. Inspect for rear wheel alignment and adjust as necessary. Refer to Measuring Wheel Alignment in Wheel Alignment.
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