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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 53 (Frame And Underbody) >> Repair Instructions >> Frame Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2005 Saturn Ion Red Line, 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the wheels in the straight ahead position, remove the key from the ignition switch.
  2. Secure the radiator and condenser assembly to the radiator support.
    3. Fig 1: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the front wheels from the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  5. Remove the left and right splash shields. Refer to Splash Shield Replacement - Engine .
  6. Remove the front transaxle mount to cradle through bolt.
    7. Fig 2: View Of Front Transmission Mount Through Bolt
    GM851568Courtesy of GENERAL MOTORS CORP.
  7. Remove the rear transaxle mount to frame bolts.
    8. Fig 3: View Of Rear Transaxle Mount To Frame Bolts
    GM851572Courtesy of GENERAL MOTORS CORP.
  8. Remove both stabilizer link to stabilizer shaft nuts. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    9. Fig 4: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  9. Remove both tie rod to steering knuckle nuts.
    10. Fig 5: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  10. Use the SA91100C  to separate the outer tie rods from the steering knuckles. See Special Tools .
    11. Fig 6: Separating Outer Tie Rod End From Steering Knuckle
    GM854983Courtesy of GENERAL MOTORS CORP.
  11. Remove the intermediate steering shaft to steering gear pinch bolt and discard.
    12. Fig 7: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: DO NOT rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur.
  12. Disconnect the intermediate steering shaft from the steering gear.
  13. Remove both lower control arm ball stud to steering knuckle pinch bolts.
    14. Fig 8: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.
  14. Lower the lower control arms in order to disengage the steering knuckle. If necessary, use the J 43631  .
  15. Mark the frame to body position with a paint pen or permanent marker.
  16. Lower the vehicle to about 3 feet off the ground in order to place an hydraulic lift table under the frame.
  17. Use two 2 x 4s between the lift table and the frame and lift the table to the frame.
  18. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Remove the rear frame bolts.
    19. Fig 9: View Of Frame Bolts
    GM851651Courtesy of GENERAL MOTORS CORP.
  19. Slowly lower the lift table to the floor.
  20. Continue with the following steps when replacing the frame:
    1. Remove the steering gear from the frame. Refer to Power Steering Gear Replacement in Power Steering System.
    2. Remove the stabilizer bar from the frame. Refer to Stabilizer Shaft Replacement in Front Suspension.
    3. Remove the lower control arms from the frame. Refer to Lower Control Arm Replacement in Front Suspension.
    4. Remove the radiator brackets from the frame.
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