GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Alero Export 🢒 Suspension 🢒 Front Suspension 🢒 Front Suspension Crossmember Replacement

Front Suspension Crossmember Replacement Automatic Transmission

Tools Required

J 28467-500UPD Utility Straps

Removal Procedure
  1. Install the engine support fixture. Refer to Engine Support Fixture for the 2.4L engine or Engine Support Fixture for the 3.4L engine.
  2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .
  4. Remove the front fender liner. Refer to Front Fender Liner Replacement .
  5. Disconnect the antilock brake system (ABS) sensor from the wheel speed sensor and frame.
  6. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
  7. Remove the brake modulator assembly from the support bracket. Refer to Electronic Brake Control Module Replacement .
  8. Remove the tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  9. Remove the power steering gear mounting bolts and secure the power steering gear out of the way using the J 28467-500UPD . Refer to Steering Gear Replacement .
  10. Remove the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.
  11. Remove the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.

    12. Object Number: 486720 Size: SH
  12. Remove the brake lines from the retainers on the crossmember (2).
  13. Lower the vehicle until the suspension crossmember (2) rests on the jack stands.
  14. Remove the front suspension crossmember front support bolts (3).
  15. Remove the front suspension crossmember rear support bolts (4).
  16. Remove the suspension control arm to body bolts (1).
  17. Raise the vehicle off of the suspension crossmember (2).
  18. Remove the following components if replacing the suspension crossmember:
    19. • The lower control arms. Refer to Lower Control Arm Replacement .
    • The power steering gear. Refer to Steering Gear Replacement .
    • The front transmission mount. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.
    • The rear transmission mount. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.
    • The stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    • The lower radiator support. Refer to Radiator Lower Mounting Panel Replacement .

Installation Procedure
  1. Install the following components on the suspension crossmember if removed:
    2. • The lower radiator support. Refer to Radiator Lower Mounting Panel Replacement .
    • The stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    • The rear transmission mount. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.
    • The front transmission mount. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.
    • The power steering gear. Refer to Steering Gear Replacement .
    • The lower control arms. Refer to Lower Control Arm Replacement .

    Object Number: 486720 Size: SH
  2. Lower the vehicle on to the crossmember support (2).
  3. Install the suspension control arm support to body bolts (1). Hand tighten the bolts.
  4. Install the rear suspension crossmember support bolts (4). Hand tighten the bolts.
  5. Install the front suspension crossmember support bolts (3). Hand tighten the bolts.

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Tighten the suspension crossmember bolts in the following order:

    7. Tighten

    1. Tighten the front suspension crossmember rear bolts to 70 N·m (52 lb ft).
    2. Tighten the front suspension crossmember front bolts to 100 N·m (74 lb ft) plus 180 degrees.
    3. Tighten the front suspension control arm to body bolts to 100 N·m (74 lb ft) plus 180 degrees.
  7. Raise the vehicle and support with jack stands. Refer to Lifting and Jacking the Vehicle .
  8. Install the brake lines to the retainers on the crossmember (2).
  9. Install the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement for the 4T40-E/4T45-E transmission.
  10. Install the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement for the 4T40-E/4T45-E transmission.
  11. Remove the J 28467-500UPD . Install the power steering gear mounting bolts. Refer to Steering Gear Replacement .
  12. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  13. Install the brake modulator assembly to the support bracket. Refer to Electronic Brake Control Module Replacement .
  14. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
  15. Connect the ABS sensor to the wheel speed sensor and frame.
  16. Install the front fender liner. Refer to Front Fender Liner Replacement .
  17. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  18. Remove the engine support fixture. Refer to Engine Support Fixture for the 2.4L engine or Engine Support Fixture for the 3.1L engine.
  19. Bleed the power steering system. Refer to Power Steering System Bleeding .