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Home >> Saturn >> 2005 >> Relay FWD >> Repair and Diagnosis >> Suspension >> Front Suspension >> Front Suspension System >> Repair Instructions >> Lower Control Arm Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Lower Control Arm
    GM156958Courtesy of GENERAL MOTORS CORP.
  1. Install the lower control arm.
  2. Install the control arm bolts and nuts.
    3. IMPORTANT: Align the ball stud cotter pin hole parallel to the knuckle in order to ease the cotter pin installation.
  3. Install the ball stud to the knuckle.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the ball stud castle nut.

    Tighten:  Tighten the ball stud castle nut to 55 N.m (40 lb ft).

    5. Fig 2: Aligning Ball Stud Castle Nut Slot To The Ball Stud Cotter Pin Hole
    GM384426Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do NOT loosen the ball stud nut in order to align the ball stud nut slots to the ball stud cotter pin hole.
  5. If necessary, tighten the ball stud castle nut in order to align the ball stud castle nut slot (1) to the ball stud cotter pin hole (2) as shown.
    6. Fig 3: Securing Cotter Pin In Ball Joint Castle Nut
    GM384428Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the cotter pin ends do NOT contact the ABS wheel speed sensor, the ABS sensor connector or the drive axle.
  6. Install a NEW cotter pin and bend the ends as shown in either example.
  7. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (FWD)  or Stabilizer Shaft Link Replacement (AWD) .
  8. Install the ABS wheel speed sensor jumper harness to the harness retainer clips. Refer to Wheel Speed Sensor Replacement - Front in Antilock Brake System.
    9. Fig 4: View Of Wheel Speed Sensor, Connector And Harness
    GM188809Courtesy of GENERAL MOTORS CORP.
  9. Install the ABS wheel speed sensor connector (2).
    10. IMPORTANT: This is a prevailing torque type fastener. This fastener may be reused ONLY if:
    • The fastener and its counterpart are clean and free from rust.
    • The fastener develops 3 N.m (27 lb in) of torque/drag against its counterpart prior to the fastener seating.

    If the fastener does not meet these criteria, replace the fastener.
  10. Install the lower control arm nuts.

    Tighten:  Tighten the lower control arm nuts to 113 N.m (83 lb ft).

  11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation  in Tires and Wheels.
  12. Lower the vehicle.
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