GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Sunfire 🢒 Body 🢒 Frame and Underbody 🢒 Crossmember Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
  4. Remove the engine strut from the lower engine mount and frame. Refer to Engine Mount Strut Replacement in Engine Mechanical - 2.2L (L61) .
  5. Remove the front exhaust pipe. Refer to Intermediate Pipe Replacement in Engine Exhaust.
  6. Disconnect the ABS harness from the lower control arms.
  7. Disconnect the ball joints from the steering knuckles. Refer to Stabilizer Shaft Replacement .
  8. Disconnect the tie rods from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.

    9. Object Number: 490128 Size: SH
  9. On vehicles with a brake pipe running along the crossmember, disconnect the brake pipe from the retainers.
  10. Remove the power steering gear to crossmember mounting bolts.
  11. Secure the power steering gear to the body, taking care not to over extend the intermediate shaft.
  12. Remove the front suspension support brace. Refer to Front Suspension Support Brace Replacement .
  13. Support the crossmember , using suitable jack stands.
  14. Remove the front suspension crossmember mounting bolts.
  15. Lower the crossmember from the vehicle.
  16. If replacing the crossmember, remove the following components:
    17. • The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.
    • The stabilizer shaft. Refer to Stabilizer Shaft Replacement .

Installation Procedure
  1. If replacing the crossmember, Install the following components:
    2. • The stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    • The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.

    Object Number: 490128 Size: SH
  2. Using suitable jack stands, raise the crossmember to the vehicle.

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

  3. Install the front suspension crossmember mounting bolts.

    4. Tighten

    1. Tighten the left rear outboard bolt to 110 N·m (81 lb ft) plus an additional 90 degrees.
    2. Tighten the right rear outboard bolt to 110 N·m (81 lb ft) plus an additional 90 degrees.
    3. Tighten the front upper bolts to 110 N·m (81 lb ft) plus an additional 90 degrees.
    4. Tighten the rear inboard bolts to 110 N·m (81 lb ft) plus an additional 90 degrees.
  4. Install the front suspension support brace. Refer to Front Suspension Support Brace Replacement .
  5. Reposition the steering gear to the crossmember.
  6. Install the power steering gear to crossmember mounting bolts.

    7. Tighten
    Tighten the bolts to 120 N·m (89 lb ft).

  7. On vehicles with the brake pipe running along the support frame, install the brake pipe into the retainers.
  8. Connect the tie rods to the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
  9. Connect the lower control arms to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
  10. Connect the ABS harness to the lower control arms. Refer to Front Wheel Speed Sensor Replacement in Antilock Brake System.
  11. Install the front exhaust pipe. Refer to Intermediate Pipe Replacement in Engine Exhaust.
  12. Install the engine strut to the lower engine mount and frame. Refer to Engine Mount Strut Replacement in Engine Mechanical - 2.2L (L61).
  13. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
  14. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.