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Home › Saturn › 2007 › Ion Red Line › Repair and Diagnosis › External Pages › Different car › Section 113 (Frame And Underbody) › Repair Instructions › Frame Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2005 Saturn Ion Red Line, 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. 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 in Front Suspension.
    3. Install the stabilizer bar to the frame. Refer to Stabilizer Shaft Replacement in Front Suspension.
    4. Install the steering gear to the frame. Refer to Power Steering Gear Replacement in Power Steering System.
  2. With the frame on the lift table, raise the frame to the vehicle.
  3. Hand start all the frame bolts while aligning the frame to the paint marks.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the frame bolts.

    Tighten:  Tighten the bolts to 200 N.m (148 lb ft).

    5. Fig 1: View Of Frame Bolts
    GM851651Courtesy of GENERAL MOTORS CORP.
  5. Lower and remove the hydraulic table.
  6. Connect the lower control arm to the steering knuckle.
    7. Fig 2: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
    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 nut 3/4 turn
    3. Second Pass: Tighten the nut to 50 N.m (37 lb ft) + 30 degrees.

    8. 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. Fig 3: View Of Front Transmission Mount Through Bolt
    GM851568Courtesy of GENERAL MOTORS CORP.
  9. Loosen the rear transmission mount through bolt.
  10. Tighten the rear transaxle mount to frame bolts.

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

    11. Fig 4: View Of Rear Transaxle Mount To Frame Bolts
    GM851572Courtesy of GENERAL MOTORS CORP.
  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. 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 5: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  14. Connect the stabilizer links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    15. Fig 6: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  15. Connect the intermediate shaft to the steering gear.
  16. Install a new intermediate shaft pinch bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  17. Install the left and right splash shields. Refer to Splash Shield Replacement - Engine .
  18. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    19. Fig 7: Installing Front Wheels
    GM855038Courtesy of GENERAL MOTORS CORP.
  19. Lower the vehicle.
  20. Road test the vehicle in order to test for the following conditions:
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