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Frame and Underbody Chevrolet Corvette C6

Frames, Subframes & Crossmembers 9 illustrations ~3508 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Crossmember Bolt Nut110 N.m81 lb ft
Fuel Door Pocket Screws2 N.m18 lb in
Fuel Door Screws2 N.m18 lb in
Power Steering Gear Mounting Bolts100 N.m74 lb ft
Quarter Panel Screws5 N.m44 lb in
Quarter Panel to Brace Screws5 N.m44 lb in
Rear Bumper Fascia Bolts2 N.m18 lb in
Shock Absorber Lower Mounting Nuts28 N.m21 lb ft
Skid Bar to Frame Bolts50 N.m36 lb ft

Removal Procedure

  1. Disable the SIR system. Refer to «SIR Disabling and Enabling»(/chevrolet/corvette/c6-2004-2014/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling) .
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  3. Remove all related panels and components.
  4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/chevrolet/corvette/c6-2004-2014/remont/paintcoatings/#paint-and-coatings__anti-corrosion-treatment-and-repair) .
  5. Remove the welds (1) attaching the tow hook to the impact bar.
  6. Remove the tow hook (1) from the impact bar.

Installation Procedure

  1. Clean and prepare all of the welded surface and apply 3M weld-thru coating P/N 05916 or equivalent as necessary.
  2. Position the tow hook (1) to the passenger side of the impact bar.
  3. From the right outer edge of the impact bar (2) measure 269 mm (10 5/8 in) to the center of the tow hook (1).
  4. Using a metal inert gas (MIG) welder, weld a 51 mm (2 in) stitch along the tow hook to the impact bar in 4 places (1). Front Rear Inboard side Outboard side
  5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/chevrolet/corvette/c6-2004-2014/remont/paintcoatings/#paint-and-coatings__anti-corrosion-treatment-and-repair) .
  6. Paint the repair area. Refer to «Basecoat/Clearcoat Paint Systems»(/chevrolet/corvette/c6-2004-2014/remont/paintcoatings/#paint-and-coatings__basecoatclearcoat-paint-systems) .
  7. Install all related panels and components.
  8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  9. Enable the SIR system. Refer to «SIR Disabling and Enabling»(/chevrolet/corvette/c6-2004-2014/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling) .
  1. Disable the SIR system. Refer to «SIR Disabling and Enabling»(/chevrolet/corvette/c6-2004-2014/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling) .
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  3. Remove all related panels and components.
  4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/chevrolet/corvette/c6-2004-2014/remont/paintcoatings/#paint-and-coatings__anti-corrosion-treatment-and-repair) .
  5. Remove the welds (1) attaching the tow hook to the impact bar.
  6. Remove the tow hook (1) from the impact bar.
  1. Clean and prepare all of the welded surface and apply 3M weld-thru coating P/N 05916 or equivalent as necessary.
  2. Position the tow hook (1) to the center of the impact bar.
  3. Using a metal inert gas (MIG) welder, weld a 51 mm (2 in) stitch along the tow hook to the impact bar in 4 places (1). Front Rear Inboard side Outboard side
  4. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to «Anti-Corrosion Treatment and Repair»(/chevrolet/corvette/c6-2004-2014/remont/paintcoatings/#paint-and-coatings__anti-corrosion-treatment-and-repair) .
  5. Paint the repair area. Refer to «Basecoat/Clearcoat Paint Systems»(/chevrolet/corvette/c6-2004-2014/remont/paintcoatings/#paint-and-coatings__basecoatclearcoat-paint-systems) .
  6. Install all related panels and components.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  8. Enable the SIR system. Refer to «SIR Disabling and Enabling»(/chevrolet/corvette/c6-2004-2014/remont/airbag/#supplemental-inflatable-restraint-system__sir-disabling-and-enabling) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the front fascia. Refer to «Front Bumper Fascia Replacement»(/chevrolet/corvette/c6-2004-2014/remont/exterior-body-panels/#bumper-system-and-fascia) .
  3. Remove all related panels and components.
  4. Support the radiator assembly.
  5. Support the skid bar.
  6. Remove the 4 bolts (1) attaching the skid bar to the frame rails.
  7. Remove the skid bar.
  8. Save all of the brackets, mounting studs, and accessories for transfer to the new skid bar.
  1. Transfer all of the brackets, mounting studs, and accessories to the new skid bar.
  2. Position the skid bar to the frame rails.
  3. Install the 4 bolts (1) attaching the skid bar to the frame rails. Tighten: Tighten the bolts to 50 N.m (36 lb ft).
  4. Install all related panels and components.
  5. Install the front fascia. Refer to «Front Bumper Fascia Replacement»(/chevrolet/corvette/c6-2004-2014/remont/exterior-body-panels/#bumper-system-and-fascia) .
  6. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  2. Use hand tools to remove the nut from the bolt that you are replacing.
  3. Lower the vehicle.
  4. Open the hood.
  5. Use snap ring pliers to remove the spring clip.
  6. Remove the bolt.
  1. Install the crossmember bolt.
  2. Use snap ring pliers to install the spring clip.
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  4. Install a new nut to the crossmember bolt and tighten the nut with hand tools and tighten to 110 N.m (81 lb ft).
  5. Lower the vehicle.
  1. Use hand tools to remove the nut from the forward bolt that you are replacing.
  2. Remove the rear compartment floor carpet. Refer to «Rear Compartment Floor Panel Carpet Replacement (Convertible)»(/chevrolet/corvette/c6-2004-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) or «Rear Compartment Floor Panel Carpet Replacement (Coupe)»(/chevrolet/corvette/c6-2004-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
  3. Locate the scribed marks labeled XMBR BOLT in the floor which identifies the area directly over the front bolt to be replaced. The scribed marks are located approximately 230 mm (9 in) inward from the rear compartment side panel and 255 mm (10 in) rearward of the intermediate panel.
  4. Drill an access hole with a 50-mm (2-in) hole saw directly over the bolt.
  5. Use snap ring pliers to remove the spring clip.
  6. Remove the bolt.
  1. Install the crossmember bolt.
  2. Use snap ring pliers to install the spring clip.
  3. Install a new nut to the crossmember bolt and tighten the nut with hand tools. Tighten: Tighten the nut to 110 N.m (81 lb in).
  4. Cut a suitable piece of galvanized steel or fiber reinforced plastic sized to cover the hole in the floor with at least a 25-mm (1-in) overlap on all sides.
  5. Lightly scuff sand the bonding surfaces of both the panel and the cover.
  6. Wipe each bonding surface with alcohol.
  7. Apply a 3-6 mm (1/8 -1/4 in) bead of adhesive around the perimeter of the cover.
  8. Install the cover over the hole in the floor. Apply pressure to the cover to squeeze out the adhesive and form a consistent leak-proof seal.
  9. Smooth out the adhesive around the cover. Verify that no skips or gaps occur.
  10. Allow the bonding adhesive to cure.
  11. Install the rear compartment carpet. Refer to «Rear Compartment Floor Panel Carpet Replacement (Convertible)»(/chevrolet/corvette/c6-2004-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) or «Rear Compartment Floor Panel Carpet Replacement (Coupe)»(/chevrolet/corvette/c6-2004-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .

Special Tools

  1. J 28467-B Universal Engine Support Fixture
  2. J 33432-A Transverse Spring Compressor. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. J 41803 Engine Support Fixture. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  1. Remove the generator from the accessory mounting bracket. Refer to «Generator Replacement (LS3 or LS7)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  2. Install J 41803 and J 28467-B and support the engine. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  4. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
  5. Remove the steering linkage outer tie rod end stud nuts (3). Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/corvette/c6-2004-2014/remont/manual-power-steering/#power-steering-system) .
  6. Remove the stabilizer shaft from the vehicle. Refer to «Stabilizer Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  7. Disconnect the intermediate shaft lower coupling from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/steering-column-switches/#steering-wheel-and-steering-column) .
  8. Remove the bolts from the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket. Refer to «Brake Pressure Modulator Valve Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/anti-locktraction-control/#antilock-brake-system) .
  9. Support and reposition the EBCM/BPMV and bracket away from the crossmember.
  10. Remove the power steering gear mounting bolts.
  11. Remove the power steering fluid cooler from the crossmember.
  12. Lift the power steering gear off of the crossmember and support.
  13. Remove the engine oil line hose bracket from the crossmember.
  14. Using the J 33432-A , remove the transverse spring from the vehicle. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) . Refer to «Front Transverse Spring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  15. Disconnect the lower shock absorber bolts from the lower control arms.
  16. Remove the lower control arm bolts from the crossmember.
  17. Place a transmission jack under the crossmember.
  18. Remove the engine mount lower nuts. Refer to the following procedures: «Engine Mount Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) «Engine Mount Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8)
  19. Disconnect the wheel speed sensor wiring harness (1) from the crossmember.
  20. Disconnect the electrical harness from the clips on the crossmember.
  21. Disconnect the brake pipe from the clips on the crossmember.
  22. Remove the crossmember mounting nuts.
  23. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.
  1. Carefully inspect the magnesium crossmember. Replace any damaged or missing spacers prior to installation.
  2. Raise the crossmember to the vehicle. Align the crossmember dowel pins to the frame rails. Align the engine mount studs.
  3. Install new crossmember mounting nuts. Tighten: Tighten the new crossmember mounting nuts to 110 N.m (81 lb ft).
  4. Install the engine mount lower nuts. Refer to one of the following procedures: «Engine Mount Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) «Engine Mount Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8)
  5. Fasten the wheel speed sensor wiring harness retaining clips (1) to the crossmember.
  6. Fasten the brake pipe to the retaining clips on the crossmember.
  7. Connect the electrical harness to the clips on the crossmember.
  8. Connect the brake pipe to the clips on the crossmember.
  9. Install the transverse spring with the J 33432-A connected, to the crossmember. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) . Refer to «Front Transverse Spring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  10. Install the engine oil line hose bracket to the crossmember.
  11. Install the lower control arm to the crossmember. Refer to «Lower Control Arm Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  12. Install the shock absorbers to the lower control arms. Tighten: Tighten the shock absorber lower mounting nuts to 28 N.m (21 lb ft).
  13. Install the power steering gear to the crossmember. Tighten: Tighten the power steering gear mounting bolts to 100 N.m (74 lb ft).
  14. Install the bolts to the BPMV. Refer to «Brake Pressure Modulator Valve Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/anti-locktraction-control/#antilock-brake-system) .
  15. Connect the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/steering-column-switches/#steering-wheel-and-steering-column) .
  16. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/corvette/c6-2004-2014/remont/manual-power-steering/#power-steering-system) .
  17. Install the stabilizer shaft to the vehicle. Refer to «Stabilizer Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  18. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
  19. Lower the vehicle.
  20. Remove J 41803 and J 28467-B from the engine. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  21. Install the generator. Refer to «Generator Replacement (LS3 or LS7)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  23. Perform a vehicle front end alignment. Refer to «Wheel Alignment Measurement»(/chevrolet/corvette/c6-2004-2014/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-measurement) .
  1. J 28467-B Universal Engine Support Fixture
  2. J 33432-A Transverse Spring Compressor. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. J 41803 Engine Support Fixture. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  1. Remove the generator from the accessory mounting bracket. Refer to «Generator Replacement (LS3 or LS7)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  2. Install J 41803 and J 28467-B and support the engine. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  4. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
  5. Remove the steering linkage outer tie rod end stud nuts (3). Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/corvette/c6-2004-2014/remont/manual-power-steering/#power-steering-system) .
  6. Disconnect the shock absorber solenoid electrical connector, if equipped.
  7. Disconnect the electronic suspension control (ESC) sensor links.
  8. Remove the stabilizer shaft from the vehicle. Refer to «Stabilizer Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  9. Disconnect the intermediate shaft lower coupling from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/steering-column-switches/#steering-wheel-and-steering-column) .
  10. Remove the bolts from the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket. Refer to «Brake Pressure Modulator Valve Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/anti-locktraction-control/#antilock-brake-system) .
  11. Support and reposition the EBCM/BPMV and bracket away from the crossmember.
  12. Remove the power steering gear mounting bolts.
  13. Remove the power steering fluid cooler from the crossmember.
  14. Lift the power steering gear off of the crossmember and support.
  15. Using the J 33432-A , remove the transverse spring from the vehicle. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) . Refer to «Front Transverse Spring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  16. Disconnect the lower shock absorber bolts from the lower control arms.
  17. Remove the lower control arm bolts from the crossmember.
  18. Place a transmission jack under the crossmember.
  19. Remove the engine mount lower nuts. Refer to the following procedures: «Engine Mount Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) «Engine Mount Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8)
  20. Disconnect the wheel speed sensor wiring harness (3) from the crossmember.
  21. Disconnect the electrical harness from the clips on the crossmember.
  22. Disconnect the brake pipe from the clips on the crossmember.
  23. Remove the crossmember mounting nuts.
  24. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.
  1. Raise the crossmember to the vehicle. Align the crossmember dowel pins to the frame rails. Align the engine mount studs.
  2. Install new crossmember mounting nuts. Tighten: Tighten the new crossmember mounting nuts to 110 N.m (81 lb ft).
  3. Install the engine mount lower nuts. Refer to one of the following procedures: «Engine Mount Replacement - Right Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8) «Engine Mount Replacement - Left Side»(/chevrolet/corvette/c6-2004-2014/remont/mechanical/#engine-mechanical-62l-or-70l-2-of-8)
  4. Fasten the wheel speed sensor wiring harness retaining clips (3) to the crossmember.
  5. Fasten the brake pipe to the retaining clips on the crossmember.
  6. Connect the electrical harness to the clips on the crossmember.
  7. Connect the brake pipe to the clips on the crossmember.
  8. Install the transverse spring with the J 33432-A connected, to the crossmember. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) . Refer to «Front Transverse Spring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  9. Install the lower control arm to the crossmember. Refer to «Lower Control Arm Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  10. Install the shock absorbers to the lower control arms. Tighten: Tighten the shock absorber lower mounting nuts to 28 N.m (21 lb ft).
  11. Install the power steering gear to the crossmember. Tighten: Tighten the power steering gear mounting bolts to 100 N.m (74 lb ft).
  12. Install the bolts to the BPMV. Refer to «Brake Pressure Modulator Valve Bracket Replacement»(/chevrolet/corvette/c6-2004-2014/remont/anti-locktraction-control/#antilock-brake-system) .
  13. Connect the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/steering-column-switches/#steering-wheel-and-steering-column) .
  14. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/corvette/c6-2004-2014/remont/manual-power-steering/#power-steering-system) .
  15. Connect the electronic suspension control (ESC) sensor links to the upper control arm, if equipped.
  16. Connect the shock absorber solenoid electrical connector, if equipped.
  17. Install the stabilizer shaft to the vehicle. Refer to «Stabilizer Shaft Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#front-suspension-system) .
  18. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
  19. Lower the vehicle.
  20. Remove J 41803 and J 28467-B from the engine. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  21. Install the generator. Refer to «Generator Replacement (LS3 or LS7)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LS7 or LS9)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (LS3)»(/chevrolet/corvette/c6-2004-2014/remont/charging-system/#battery-charging-system-starting-system) .
  23. Perform a vehicle front end alignment. Refer to «Wheel Alignment Measurement»(/chevrolet/corvette/c6-2004-2014/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-measurement) .

J 42055 Drivetrain Support Fixture. See Special Tools .

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
  3. Disconnect the wheel speed sensor harness connectors.
  4. Disconnect the park brake cables from the actuator levers.
  5. Disconnect the electrical connectors from the electronic suspension control (ESC) shock absorbers harnesses, if equipped.
  6. Remove the rear suspension position sensors. Refer to «Electronic Suspension Rear Position Sensor Replacement (ZR1)»(/chevrolet/corvette/c6-2004-2014/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) or «Electronic Suspension Rear Position Sensor Replacement (w/O ZR1)»(/chevrolet/corvette/c6-2004-2014/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) .
  7. Disconnect the inner tie rod end studs from the rear crossmember. Refer to «Tie Rod Replacement (Inner)»(/chevrolet/corvette/c6-2004-2014/remont/suspension-rear/#rear-suspension-system) .
  8. Disconnect the lower control arms from the crossmember. Refer to «Rear Axle Lower Control Arm Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-rear/#rear-suspension-system) .
  9. Support the lower control arms, tie rods, and rear suspension knuckles.
  10. Remove the transverse spring. Refer to «Rear Transverse Spring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-rear/#rear-suspension-system) .
  11. Assemble the J 42055 and install it to a transmission jack. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  12. Position and firmly secure the J 42055 with the transmission jack to the transmission. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) . Support the transmission.
  13. Remove the transaxle mount lower nuts. Refer to «Transmission Mount Replacement»(/chevrolet/corvette/c6-2004-2014/remont/differentials-drive-axles/#rear-drive-axle) .
  14. Disconnect all the electrical harness retainers from the crossmember.
  15. Disconnect the brake pipe retainers from the crossmember.
  16. Position a transmission jack under the rear crossmember and firmly secure the crossmember to the jack. Support the crossmember.
  17. Using HAND TOOLS ONLY, remove the rear crossmember mounting nuts.
  18. Remove the crossmember from the vehicle.
  19. Discard the rear crossmember mounting nuts.
  1. Install the crossmember to the vehicle. Align the crossmember dowel pins to the holes in the frame rails. Align the transaxle mount studs to the crossmember.
  2. Using HAND TOOLS ONLY, install NEW rear suspension crossmember mounting nuts and tighten to 110 N.m (81 lb ft).
  3. Remove the J 42055 transmission jack from the transmission. See «Special Tools»(/chevrolet/corvette/c6-2004-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  4. Remove the transmission jack from the crossmember.
  5. Connect all electrical harness retainers to the crossmember.
  6. Connect the brake pipes retainers to the crossmember.
  7. Install the transaxle mount lower nuts. Refer to «Transmission Mount Replacement»(/chevrolet/corvette/c6-2004-2014/remont/differentials-drive-axles/#rear-drive-axle) .
  8. Install the transverse spring to the crossmember. Refer to «Rear Transverse Spring Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-rear/#rear-suspension-system) .
  9. Install the lower control arms to the crossmember. Refer to «Rear Axle Lower Control Arm Replacement»(/chevrolet/corvette/c6-2004-2014/remont/suspension-rear/#rear-suspension-system) .
  10. Install the inner tie rod end studs to the crossmember. Refer to «Tie Rod Replacement (Inner)»(/chevrolet/corvette/c6-2004-2014/remont/suspension-rear/#rear-suspension-system) .
  11. Install the rear suspension position sensors. Refer to «Electronic Suspension Rear Position Sensor Replacement (ZR1)»(/chevrolet/corvette/c6-2004-2014/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) or «Electronic Suspension Rear Position Sensor Replacement (w/O ZR1)»(/chevrolet/corvette/c6-2004-2014/remont/electronic-suspension/#suspension-control-system-real-time-damping-control) .
  12. Connect the electrical connectors to the ESC shock absorber harnesses, if equipped.
  13. Connect the park brake cables to the actuator levers.
  14. Connect the wheel speed sensor harness connector.
  15. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/corvette/c6-2004-2014/remont/wheel-tire-system/#tires-and-wheels) .
  16. Lower the vehicle.
  17. Measure and adjust the rear trim height as necessary. Refer to «Trim Height Inspection»(/chevrolet/corvette/c6-2004-2014/remont/suspension-front/#suspension-general-diagnosis) .
  18. Perform a rear wheel alignment. Refer to «Wheel Alignment Measurement»(/chevrolet/corvette/c6-2004-2014/remont/wheel-alignment/#wheel-alignment-system__wheel-alignment-measurement) .

CH-48106 Suspension Thread Repair Kit. See Special Tools .

Thread Repair Procedure

  1. The suspension thread repair procedure involves a solid, thin-walled, key-locking, stainless steel keysert. Use the keysert when the parent material of the original threaded insert is damaged. Install the CH-48106-1 extracting tool (1) into the damaged wire insert.
  2. Set the extracting tool by lightly tapping the tool with a mallet.
  3. Remove the wire insert by turning the tool counterclockwise, while applying light forward pressure on the tool.
  4. Use the CH-48106-2 12.8 mm drill bit to drill out the threads of the damaged hole. Drill to a minimum depth of 14.5 mm (3/8 in).
  5. Use compressed air (1) to clean out any chips.
  6. Use a CH-48106-3 chamfering tool or an oversize drill bit of 14.25 mm (3/8 in) to countersink the drilled-out hole.
  7. Use compressed air (1) to clean out any chips.
  8. Use CH-48106-8 cutting oil to lubricate the threads of the tap.
  9. Install the CH-48106-6 tap socket or equivalent tool to the CH-48106-4 tap.
  10. Use the CH-48106-4 M14-1.5 6H Tap (1) to tap new threads in the drilled hole. Tap the threads to a minimum depth of 13.5 mm (5/16 in).
  11. Use compressed air (1) to clean out any chips.
  12. Install the CH-48106-7 keysert into the slotted sections of the CH-48106-5 installation tool (1).
  13. Use the CH-48106-5 installation tool to install the keysert in the tap hole slightly below the bottom of the countersunk surface (1).
  14. Remove the CH-48106-5 installation tool from the keys. Rotate the tool so that the keys are aligned on the flat surface of the tool. NOTE: The keys mechanically lock the keysert to the threaded parent material.
  15. Use a mallet to strike the top of the CH-48106-5 installation tool (1) as necessary to drive the keys into the threaded parent material until the keys are even or slightly below the surface.
  16. Inspect the keysert (1) for proper installation into the hole.
  17. Temporarily install the suspension bolt, then tighten to 91 N.m (67 lb ft).
  18. Verify that the suspension bolt is seated flush to the surface.

Scheme 1

Scheme 1: Front Wheelhouse Liner Replacement (Front Liner)
Scheme 1: Front Wheelhouse Liner Replacement (Front Liner)
CalloutComponent Name
Preliminary Procedures Remove the appropriate front wheel and tire assembly. Refer to Tire and Wheel Removal and Installation . Remove the appropriate wheelhouse extension. Refer to Wheelhouse Extension Replacement .
1Front Wheelhouse (Front Liner) Liner Plastic Retainer (Qty: 7)
2Front Wheelhouse (Front Liner) Liner

Scheme 2

Scheme 2: Front Wheelhouse Liner Replacement (Rear Liner)
Scheme 2: Front Wheelhouse Liner Replacement (Rear Liner)
CalloutComponent Name
Preliminary Procedure: Remove the appropriate front wheel and tire assembly. Refer to Tire and Wheel Removal and Installation .
1Front Wheelhouse (Rear Liner) Liner Screw (Qty: 1) CAUTION: Refer to Fastener Caution . Tighten: 2 N.m (18 lb in)
2Front Wheelhouse (Rear Liner) Liner Bolts (Qty: 2) Tighten: 9 N.m (80 lb in)
3Front Wheelhouse (Rear Liner) Liner Plastic Retainers (Qty: 6)
4Front Wheelhouse (Rear Liner) Liner
CAUTION
Refer to Fastener Caution .

Scheme 3

Scheme 3: Rear Wheelhouse Panel Liner Replacement
Scheme 3: Rear Wheelhouse Panel Liner Replacement
CalloutComponent Name
Preliminary Procedure: Remove the appropriate rear wheel and tire assembly. Refer to Tire and Wheel Removal and Installation .
1Rear Wheelhouse Panel Plastic Retainers (Qty: 4)
2Rear Wheelhouse Panel Bolts (Qty: 7) CAUTION: Refer to Fastener Caution . Tighten: 2 N.m (18 lb in)
3Rear Wheelhouse Liner
CAUTION
Refer to Fastener Caution .

Scheme 4

Scheme 4: Wheelhouse Extension Replacement
Scheme 4: Wheelhouse Extension Replacement
CalloutComponent Name
Preliminary Procedures Remove the overlapping plastic retainer from the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Front Liner) or Front Wheelhouse Liner Replacement (Rear Liner) . Remove the appropriate lower valence panel piece. Refer to Front Bumper Valance Panel Replacement (ZR1) or Front Bumper Valance Panel Replacement (Outer) or Front Bumper Valance Panel Replacement (Z06) .
1Wheelhouse Extension Panel Screws (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 2 N.m (18 lb in)
2Front Fascia Lower Nut (Qty: 1) Tighten: 7 N.m (62 lb in)
3Wheelhouse Extension Panel
CAUTION
Refer to Fastener Caution .

Scheme 5

Scheme 5: Rear Brake Caliper Cooling Air Scoop Replacement
Scheme 5: Rear Brake Caliper Cooling Air Scoop Replacement
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedures Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . Remove the front portion of the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
1Rear Brake Caliper Cooling Air Scoop - Outer Tip: Remove the rear brake caliper cooling air scoop from the inside of the wheelhouse opening by releasing the 4 integral tabs with a flat-bladed tool on the inboard side of the rear brake caliper cooling air scoop. Push the scoop outward in order to remove.
2Rear Brake Caliper Cooling Air Scoop - Inner Tip: Release the 6 tabs with a flat-bladed tool securing the rear brake caliper cooling air scoop to the inner quarter body panel. Pull inward in order to remove the cooling scoop.

Scheme 6

Scheme 6: Front Brake Caliper Cooling Duct Replacement (Y67)
Scheme 6: Front Brake Caliper Cooling Duct Replacement (Y67)
CalloutComponent Name
Preliminary Procedure: Remove the appropriate front wheelhouse (front liner) liner. Refer to Front Wheelhouse Liner Replacement (Front Liner) or Front Wheelhouse Liner Replacement (Rear Liner) .
1Brake Caliper Cooling Duct Plastic Retainer (Qty: 1)
2Brake Caliper Cooling Duct Tip: Turn the brake caliper cooling duct counterclockwise to disengage tab.

Scheme 7

Scheme 7: Front Brake Caliper Cooling Duct Replacement (Y87)
Scheme 7: Front Brake Caliper Cooling Duct Replacement (Y87)
CalloutComponent Name
Preliminary Procedure: Remove the appropriate front wheelhouse (front liner) liner. Refer to Front Wheelhouse Liner Replacement (Front Liner) or Front Wheelhouse Liner Replacement (Rear Liner) .
1Brake Caliper Cooling Duct Bolt (Qty: 1) CAUTION: Refer to Fastener Caution . Tighten: 3 N.m (27 lb in)
2Brake Caliper Cooling Duct Plastic Retainer (Qty: 1)
3Brake Caliper Cooling Duct
CAUTION
Refer to Fastener Caution .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/corvette/c6-2004-2014/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) and «Catalytic Converter Replacement - Right Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
  3. Remove the floor panel tunnel reinforcement bolts.
  4. Remove the reinforcement.
  1. Install the reinforcement into position.
  2. Install the bolt into the reinforcement locating hole (1).
  3. Install the bolt into the reinforcement slotted hole (2)
  4. Install the remaining bolts. Tighten: Tighten the reinforcement bolts to 10 N.m (89 lb in).
  5. Install the catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) and «Catalytic Converter Replacement - Right Side (7.0L)»(/chevrolet/corvette/c6-2004-2014/remont/exhaust/#engine-exhaust-system) .
  6. Lower the vehicle.

Illustration Tool Number/Description CH 48106 Suspension Thread Repair Kit J-28467-B Universal Engine Support Fixture J-33432-A Spring Compressor J-41803 Engine Support Fixture J-42055 Transmission Support Fixture

Scheme 8

Scheme 8: Special Tools
Scheme 8: Special Tools

Scheme 9

Scheme 9
Scheme 9

See also:
• SIR Disabling and Enabling
• Battery Negative Cable Disconnection and Connection (LS7 or LS9)
• Anti-Corrosion Treatment and Repair
• Basecoat/Clearcoat Paint Systems
• Lifting and Jacking the Vehicle
• Front Bumper Fascia Replacement
• Fastener Caution
• Rear Compartment Floor Panel Carpet Replacement (Convertible)
• Tire and Wheel Removal and Installation
• Steering Linkage Outer Tie Rod Replacement
• Stabilizer Shaft Replacement
• Intermediate Steering Shaft Replacement
• Brake Pressure Modulator Valve Bracket Replacement
• Engine Mount Replacement - Left Side
• Wheel Alignment Measurement
• Electronic Suspension Rear Position Sensor Replacement (ZR1)
• Tie Rod Replacement (Inner)
• Transmission Mount Replacement
• Trim Height Inspection
• Safety Glasses Warning
• Catalytic Converter Replacement - Left Side (7.0L)
• Special Tools
• Fastener Tightening Specifications