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Home >> Saturn >> 2006 >> Relay 3.9 1, AWD >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Frame And Underbody >> Repair Instructions >> Front Frame Replacement >> Removal Procedure

Removal Procedure

  1. Support the engine. Refer to Engine Support Fixture in Engine Mechanical - 3.5L.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  4. Remove the front fender liner enough to gain access to the front frame bolts. Refer to Front Wheelhouse Liner Replacement in Exterior Trim.
  5. Remove both outer tie rod ends from the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  6. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement (with Rear Twist Axle) or Stabilizer Shaft Replacement (with Rear IRS) in Front Suspension.
  7. Remove the propeller shaft, if equipped with all wheel drive (AWD). Refer to Propeller Shaft Replacement in Propeller Shaft.
    8. IMPORTANT: It is NOT necessary to remove the catalytic converter pipe on FWD models.
  8. Remove the catalytic converter pipe, if equipped with AWD. Refer to Catalytic Converter Replacement in Engine Exhaust.
  9. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement in Power Steering System.
  10. Remove the power steering gear bolts. Refer to Steering Gear Replacement in Power Steering System.
  11. Remove the power steering gear from the frame. Refer to Steering Gear Replacement in Power Steering System.
  12. Use mechanics wire secure the power steering gear to the exhaust pipe.
  13. Remove the front engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  14. Remove the power steering cooler pipe from the frame. Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
  15. Use mechanics wire to secure the power steering cooler line out of the way.
  16. Disconnect the front wheel speed sensor connectors.
  17. Remove the front wheel speed sensor wiring harnesses from the lower control arms.
  18. Remove the lower ball joints from the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  19. Remove the engine mount nuts. Refer to Engine Mount Replacement - Right Side (FWD) or Engine Mount Replacement - Right Side (AWD) in Engine Mechanical - 3.5L.
  20. Remove the transaxle mount nuts. Refer to Transmission Mount Replacement in Automatic Transaxle - 4T65-E.
    21. Fig 1: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  21. Lower the vehicle until the frame contacts the J 39580  . See Special Tools .
    22. Fig 2: Identifying Front Frame Bolts
    GM1548651Courtesy of GENERAL MOTORS CORP.
  22. Remove the frame front bolts (2).
  23. Remove the frame rear bolts (4).
  24. Remove the frame strap bolts (3) and straps (5).
  25. Raise the vehicle in order to separate the frame from the vehicle.
  26. If you are replacing the frame, perform the following steps:
    1. Remove the frame insulators from the frame. Refer to Front Frame Cushion or Insulator Replacement .
    2. Remove the lower control arms from the frame. Refer to Lower Control Arm Replacement in Front Suspension.
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