LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2004 >> Classic >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Frame And Underbody >> Repair Instructions >> Frame Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

  1. Install the following components on the front suspension crossmember if removed:
    2. Fig 1: View of Front Suspension Crossmember
    GM486720Courtesy of GENERAL MOTORS CORP.
  2. Lower the vehicle on to the front suspension crossmember (3).
  3. Install the front suspension Control Arm to body bolts (2). Hand tighten the bolts.
  4. Install the front suspension crossmember rear bolts (1). Hand tighten the bolts.
  5. Install the front suspension crossmember front bolts (4). Hand tighten the bolts.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Tighten the front suspension crossmember bolts in the following order:
    1. Tighten the front suspension crossmember rear bolts (1) to 70 N.m (52 lb ft).
    2. Tighten the front suspension crossmember front bolts (4) to 245 N.m (180 lb ft).
    3. Tighten the front suspension Control Arm to body bolts (2) to 245 N.m (180 lb ft).
  7. Raise the vehicle and support with jack stands. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Install the brake lines to the retainers on the front suspension crossmember (3).
  9. Install the rear transmission mount bracket through bolts. Refer to Transmission Mount Replacement - Rear in Automatic Transaxle - 4T40-E/4T45-E.
  10. Install the front transmission mount bracket through bolts. Refer to Transmission Mount Replacement - Front in Automatic Transaxle - 4T40-E/4T45-E.
  11. Install the power steering lines to the steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
  12. Install the bolt from the steering gear to intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  13. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
  14. Install the brake modulator assembly to the front suspension crossmember. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Antilock Brake System.
  15. Install the lower ball joints to the steering knuckles. Refer to Lower Ball Joint Replacement .
  16. Connect the ABS sensor to the wheel speed sensor and front suspension crossmember. Refer to ABS Component Views in Antilock Brake System.
  17. Install the splash shields. Refer to Front Fender Liner Replacement in Body Front End.
  18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  19. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 2.2L (L61).
  20. Bleed the power steering system. Refer to Bleeding the Power Steering System in Power Steering System.
scientia non olet · About LEMON Manuals