Frame and Underbody: Removal & Installation Chevrolet HHR I

Frame Replacement

Tools Required

1. J 24319-B Steering Linkage and Tie Rod Puller. See «Special Tools»(ref-299582-S02261478642008092400000) .
2. J 43631 Ball Joint Remover. See «Special Tools»(ref-299582-S02261478642008092400000) .

Removal Procedure

1. With the wheels in the straight ahead position, remove the key from the ignition switch.
2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-299588-S03118927942008092400000) for the 2.2L engine or «Engine Support Fixture»(ref-299589-S09105512942008092400000) for the 2.4L engine.
3. Secure the cooling module to the upper body structure.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
5. Remove the front wheels from the vehicle. Refer to «Tire and Wheel Removal and Installation»(ref-299581-S20474869482008092400000) .
6. Remove the left and right engine splash shields and the 3 screws in the inner fenders. Refer to «Engine Splash Shield Replacement»(ref-299582-S41891143532008092400000) .
7. Remove the left and right wheelhouse liners. Refer to «Front Wheelhouse Liner Replacement»(ref-299582-S41445953912008092400000) .
8. Remove the front transaxle mount to frame through bolt.
9. Remove the rear transaxle mount to frame bolts.
10. Remove both stabilizer link to stabilizer shaft nuts. Refer to «Stabilizer Shaft Link Replacement»(ref-299590-S12039534752008092400000) .
11. Remove both tie rod to steering knuckle nuts.
12. Use the J 24319-B to separate the outer tie rods from the steering knuckles. See «Special Tools»(ref-299582-S02261478642008092400000) .
13. Remove the intermediate steering shaft to steering gear pinch bolt and discard.
14. Disconnect the intermediate steering shaft from the steering gear.
15. Remove both lower control arm ball stud to steering knuckle pinch bolts.
16. Lower the lower control arms in order to disengage the steering knuckle. If necessary, use the J 43631 . See «Special Tools»(ref-299582-S02261478642008092400000) .
17. Mark the frame to body position with a paint pen or permanent marker.
18. Lower the vehicle to approximately 1 meter (3 feet) off the ground in order to place a hydraulic lift table under the frame.
19. Use two 2 x 4s between the lift table and the frame and lift the table to the frame.
20. Slowly remove the frame bolts using the following sequence: Remove the front frame bolts. Remove the rear frame bolts.
21. Slowly lower the lift table and frame to the floor.
22. Continue with the following steps when replacing the frame: Remove the steering gear from the frame. Refer to «Steering Gear Replacement (L61 and LE5)»(ref-299591-S37343997132008092400000) or «Steering Gear Replacement (LNF)»(ref-299591-S34833562482008092400000) . Remove the stabilizer bar from the frame. Refer to «Stabilizer Shaft Replacement»(ref-299590-S13713886522008092400000) . Remove the lower control arms from the frame. Refer to «Lower Control Arm Replacement»(ref-299590-S08969225152008092400000) . Remove the radiator brackets from the frame.

Installation Procedure

1. If replacing the frame, perform the following steps: Install the radiator brackets to the frame. Install the lower control arms to the frame. Refer to «Lower Control Arm Replacement»(ref-299590-S08969225152008092400000) . Install the stabilizer bar to the frame. Refer to «Stabilizer Shaft Replacement»(ref-299590-S13713886522008092400000) . Install the steering gear to the frame. Refer to «Steering Gear Replacement (L61 and LE5)»(ref-299591-S37343997132008092400000) or «Steering Gear Replacement (LNF)»(ref-299591-S34833562482008092400000) .
2. With the frame on the lift table, raise the frame to the vehicle.
3. Hand start all the frame bolts while aligning the frame to the paint marks.
4. Tighten the frame bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft) plus 180 degrees.
5. Lower and remove the hydraulic table.
6. Connect the lower control arm to the steering knuckle.
7. Install the ball joint pinch bolt and nut. Tighten: First Pass-Tighten the nut to 50 N.m (37 lb ft). Reverse the nut 3/4 turn. Second Pass-Tighten the nut to 50 N.m (37 lb ft) plus 30 degrees.
8. Hand start the front transaxle mount through bolt.
9. Loosen the rear transmission mount through bolt.
10. Tighten the rear transaxle mount to frame bolts. Tighten: Tighten the rear bolts to 50 N.m (37 lb ft).
11. Tighten the front and rear transaxle mount through bolts in the following order. Tighten: Tighten the rear bolt to 100 N.m (74 lb ft). Tighten the front bolt to 100 N.m (74 lb ft).
12. Install the outer tie rods to the steering knuckles.
13. Install the new outer tie rod to the knuckle nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft) plus 180 degrees.
14. Connect the stabilizer links to the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(ref-299590-S12039534752008092400000) .
15. Connect the intermediate shaft to the steering gear.
16. Install a new intermediate shaft pinch bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
17. Install the left and right wheelhouse liners. Refer to «Front Wheelhouse Liner Replacement»(ref-299582-S41445953912008092400000) .
18. Install the left and right engine splash shields and the 3 inner fender screws. Refer to «Engine Splash Shield Replacement»(ref-299582-S41891143532008092400000) .
19. Install the front wheels. Refer to «Tire and Wheel Removal and Installation»(ref-299581-S20474869482008092400000) .
20. Lower the vehicle.
21. Remove the engine support fixture.
22. Road test the vehicle in order to test for the following conditions: Steering leads or pulls-Refer to «Wheel Alignment Measurement»(ref-299592-S18617489842008092400000) . Abnormal powertrain noise or vibration at idle-Inspect the engine and transmission mounts for proper alignment and torque.

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