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Home >> Saturn >> 2006 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 136 (Rear Suspension System) >> Repair Instructions >> Rear Axle Replacement >> Installation Procedure

Installation 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. Install the rear coil spring lower insulators to the axle.
  2. Install the axle brackets to the axle bushings, with the alignment slot on the outboard side.
    3. IMPORTANT: The axle bushing through bolts must be installed with the bolt head facing inboard.
  3. Loosely install the bushing bolts and nuts.
  4. Place the axle on the hydraulic lift table.
  5. Raise the axle into position.
  6. Hand tighten the axle bracket to body bolts just enough to hold the brackets flush to the body.
    7. IMPORTANT: The axle through bolts must be tightened with the axle at the correct trim height and prior to torquing the axle bracket to body bolts.
  7. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance between the bottom edge of the upper spring seat and the bottom of the notch in the lower spring seat. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis for D height measurement.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Tighten the axle bushing through bolts.

    Tighten:  Tighten the bolts to 90 N.m (66 lb ft) +60 degrees.

    9. Fig 1: View Of Rear Axle Bushing Bracket
    GM855059Courtesy of GENERAL MOTORS CORP.
  9. Insert two 12 mm diameter pins through the axle brackets into the underbody.
  10. Align the left side axle bracket and snug down the bolts.
    11. Fig 2: View Of Left Side Of Axle Bracket
    GM855056Courtesy of GENERAL MOTORS CORP.
  11. Align the right side axle bracket and snug down the bolts.
    12. Fig 3: View Of Right Side Of Axle Bracket
    GM855058Courtesy of GENERAL MOTORS CORP.
  12. Tighten all the bracket to body bolts.

    Tighten:  Tighten the bolts to 90 N.m (66 lb ft) +30 degrees.

  13. Install the wheel bearing/hubs, with the brakes and backing plate assemblies.
  14. Install the bearing/hub nuts.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft) + 30 degrees.

    15. Fig 4: Identifying Wheel Bearing/Hubs
    GM888335Courtesy of GENERAL MOTORS CORP.
  15. Connect the brake hoses to the rear axle brackets.
  16. Connect the brake pipes to the brake hoses at the axle.

    Tighten:  Tighten the brake pipe fittings to 19 N.m (14 lb ft).

  17. Install the rear coil springs. Refer to Coil Spring Replacement .
    18. Fig 5: View Of Coil Spring
    GM855051Courtesy of GENERAL MOTORS CORP.
  18. Install the lower shock bolts. Refer to Shock Absorber Replacement .
    19. Fig 6: View Of Shock Absorber
    GM855039Courtesy of GENERAL MOTORS CORP.
  19. Lower and remove the hydraulic lift table.
  20. If applicable, connect the ABS sensor harness connector and harness to axle retainer.
  21. Connect the park brake cables to the axle brackets and rear brakes. Refer to Park Brake Cable Replacement - Rear (Disc Brake) or Park Brake Cable Replacement - Rear (Drum Brake) in Park Brake.
  22. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
  23. Install the rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  24. Lower the vehicle.
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