Front Suspension System Chevrolet Malibu VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Removal Procedure

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Disconnect the stabilizer links from the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
4. Using a suitable jack stand, support the rear of the frame assembly.
5. Remove the frame support to body bolts.
6. Remove the rear frame assembly mounting bolts.
7. Lower the rear of the cradle in order to gain clearance to the stabilizer shaft.
8. Remove the stabilizer bar clamps and insulators. Refer to «Stabilizer Shaft Insulator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
9. Remove the stabilizer shaft through the opening between the frame and body.

Installation Procedure

1. Position the stabilizer shaft to the frame.
2. Install the stabilizer bar clamps and insulators. Refer to «Stabilizer Shaft Insulator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
3. Raise the rear of the cradle.
4. Install the frame support brackets. Loosely install the bracket and frame to body bolts.
5. Tighten the frame and bracket support bolts. Tighten: Tighten the rear frame to body bolt to 100 N.m (74 lb ft). Tighten the frame support bracket to body bolt to 100 N.m (74 lb ft). Tighten all the bolts 90 degrees plus an additional 15 degrees.
6. Remove the jack stand.
7. Connect the stabilizer link to the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
8. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Disconnect the stabilizer link from the stabilizer shaft.
4. Disconnect the stabilizer link from the strut assembly and remove from the vehicle.

1. Connect the stabilizer link to the strut assembly. Tighten: Tighten the stabilizer link nut to 65 N.m (48 lb ft).
2. Connect the stabilizer link to the stabilizer shaft. Tighten: Tighten the stabilizer link nut to 65 N.m (48 lb ft).
3. Install the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
4. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the front wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Remove the stabilizer shaft mounting clamp bolts and clamps from both sides of the vehicle.
4. Remove the bushings from the stabilizer shaft.

1. Install the stabilizer bushings on the stabilizer shaft with the cut line facing rearward.
2. Install the stabilizer shaft clamps and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the front wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
4. Lower the vehicle.

Tools Required

J 42129 Wheel Hub Removal

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Remove the wheel drive shaft nut.
4. Remove the brake rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-replacement-front) in Disc Brakes.
5. Disconnect the electrical connector from the wheel speed sensor, if equipped with ABS.
6. Remove the wheel speed sensor connector from the bracket by depressing the locking tabs, if equipped with ABS.
7. Remove the 3 hub and bearing assembly bolts.
8. Install the J 42129 to the hub and bearing assembly in order to remove the hub and bearing assembly from the wheel drive shaft.
9. Remove the hub and bearing assembly from the steering knuckle.

1. Install the hub and bearing assembly to the steering knuckle.
2. Install the 3 hub and bearing assembly bolts. Tighten: Tighten the hub and bearing assembly bolts to 115 N.m (85 lb ft).
3. Install the wheel speed sensor connector into the bracket until the locking tabs click into place, if equipped with ABS.
4. Connect the electrical connector to the wheel speed sensor, if equipped with ABS.
5. Install the axle nut to the wheel drive shaft, hand tighten the wheel drive shaft nut.
6. Install the brake rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-replacement-front) in Disc Brakes.
7. Install the wheel drive shaft nut to the wheel drive shaft.
8. Use a screw driver or similar tool to stop the rotation of the brake rotor. Tighten: Tighten the wheel drive shaft nut to 215 N.m (159 lb ft).
9. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.

J 24319-B Universal Steering Linkage Puller

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the wheel bearing. Refer to «Wheel Bearing/Hub Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
3. Remove the outer tie rod to knuckle nut.
4. Using the J 24319-B , separate the tie rod from the steering knuckle.
5. Remove the lower control arm. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
6. Remove the strut to steering knuckle nuts and bolts.
7. Remove the steering knuckle from the vehicle.

1. Install the steering knuckle to the strut assembly and if applicable the ABS harness bracket. Tighten: Tighten the bolts and nuts to 120 N.m (89 lb ft).
2. Guide the axle through the steering knuckle.
3. Install the lower control arm. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
4. Install the outer tie rod to the steering knuckle. Tighten: Tighten the nut to 20 N.m (15 lb ft). Turn the nut an additional 180 degrees. Verify the torque to 50 N.m (37 lb ft).
5. Install the wheel bearing, brake rotor, brake caliper and front wheels. Refer to «Wheel Bearing/Hub Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
6. Lower the vehicle.
7. Road test the vehicle in order to verify alignment. If a lead or pull is present refer to «Measuring Wheel Alignment»(/chevrolet/malibu/vi-2003-2006/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. If equipped with a LX9 engine, perform one of the following steps: If removing the left lower control arm, remove the side transmission mount. Refer to «Transmission Mount Replacement - Side (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) or «Transmission Mount Replacement - Side (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E. If removing the right lower control arm, remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L (LX9).
4. Remove the lower control arm front bushing to frame bolt.
5. Remove the lower control arm rear bushing to frame bolts and nuts.
6. Prior to removal, note the orientation of the lower control arm ball stud to steering knuckle pinch bolt and remove the pinch bolt and discard.
7. Separate the ball stud from the steering knuckle.
8. Remove the control arm from the vehicle.
9. Remove the lower control arm rear bushing. Refer to «Lower Control Arm Bushings Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .

1. Install the lower control arm rear bushing. Refer to «Lower Control Arm Bushings Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
2. Position the lower control arm to the frame assembly and steering knuckle.
3. Note the previous orientation and install the lower control arm to steering knuckle pinch bolt. Hand tighten only.
4. Install the lower control arm front bushing to frame bolt. Hand tighten only.
5. Install the lower control arm rear bushing to frame bolts and nuts. Tighten: Tighten the nuts with the lower control arm at the proper Z trim height. Refer to «Trim Height Inspection Procedure»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#suspension-system-general-diagnosis) in Suspension General Diagnosis. Install a new ball stud to steering knuckle pinch bolt. Tighten the ball stud to steering knuckle pinch nut to 50 N.m (37 lb ft). Reverse the nut 3/4 of a turn. Tighten to 50 N.m (37 lb ft) +40 degrees. Tighten the bolts with the front suspension loaded by using the proper jackstand. Tighten the front bushing to frame bolt to 50 N.m (37 lb ft) plus 90 degrees. Tighten the rear bushing to frame bolts to 50 N.m (37 lb ft) plus 90 degrees.
6. If equipped with a LX9 engine, perform one of the following steps: If the right lower control arm was removed, install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L (LX9). If the left lower control arm was removed, install the side transmission mount. Refer to «Transmission Mount Replacement - Side (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) or «Transmission Mount Replacement - Side (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
7. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
8. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Remove the lower control arm. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
4. Remove the lower control arm to rear bushing bolt.
5. Note the position of the bushing during removal. Remove the bushing off the lower control arm.

1. Install the bushing on the lower control arm as previously noted.
2. Using LOCKTITE™ 234 or equivalent on the bolt threads, install the lower control arm to bushing bolt.
3. Hold the rear bushing inner sleeve when tightening the rear bushings to control arm bolt. Tighten: Tighten the bolt to 44 N.m (32 lb ft).
4. Install the lower control arm. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
5. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
6. Lower the vehicle.

J 43631 Ball Joint Remover. See Special Tools and Equipment .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-replacement-front) in Disc Brakes.
4. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists.
5. Using the J 43631 , release the wheel stud from the bearing hub and discard the stud. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .

1. Install the NEW stud into the bearing/hub assembly. Add enough washers (1) in order to draw the stud into the hub.
2. Install and tighten a wheel nut (2) until the head of the wheel stud is fully seated against the back of the bearing hub flange.
3. Remove the wheel nut (2) and the washers (1).
4. Install the brake rotor, and install the brake caliper and bracket as an assembly. Refer to «Brake Rotor Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-replacement-front) in Disc Brakes.
5. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Disconnect the stabilizer link from the strut.
4. Remove the strut to steering knuckle nuts.
5. If applicable, reposition the wheel speed sensor/ABS harness and bracket.
6. Remove the strut to steering knuckle bolts.
7. Remove the upper strut cap to body nuts.
8. Remove the strut from the vehicle.
9. For strut replacement, refer to «Strut, Strut Component and/or Spring Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .

1. Position the strut to the vehicles strut tower, using the alignment pin as a guide.
2. Install the upper strut cap to body nuts. Tighten: Tighten the nut to 25 N.m (18 lb ft).
3. Install the strut to steering knuckle bolts leaving the nuts off.
4. If applicable, place the wheel speed sensor harness and bracket to the bolt end.
5. Install the strut to steering knuckle nuts. Tighten: Tighten the nuts to 120 N.m (89 lb ft).
6. Connect the stabilizer link to the strut. Tighten: Tighten the link to 65 N.m (48 lb ft).
7. Install the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
8. Lower the vehicle.
9. Road test the vehicle and test for leads and pulls. If vehicle leads or pulls refer to «Measuring Wheel Alignment»(/chevrolet/malibu/vi-2003-2006/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Suspension Strut Disposal

1. Clamp the strut in a vise horizontally with the rod (1) completely extended.
2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in order to contain the escaping oil.
3. Remove the strut from the vise.
4. Hold the strut over a drain pan vertically with the hole down.
5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut.

J 45400 Strut Spring Compressor. See Special Tools and Equipment .

Disassembly Procedure

1. Remove the strut assembly. Refer to «Strut Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
2. Place the strut assembly into the J 45400 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
3. Adjust the compressing arms to contact the coils farthest away from the center of the spring.
4. Using the J 45400 , compress the spring to remove the spring tension from the upper strut mount. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
5. Remove the strut shaft nut, while holding the strut shaft.
6. Lower the strut from the spring and the J 45400 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
7. Remove the upper strut mount assembly and mount bearing. Inspect for damage and replace as necessary.
8. Remove the upper spring seat and insulator from the spring and the J 45400 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) . Inspect for damage and replace as necessary.
9. Using the J 45400 , remove the spring tension in order to remove the spring. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) . Inspect for damage and replace as necessary.
10. Remove the dust shield and jounce bumper assembly from the strut shaft. Inspect for damage and replace as necessary.
11. Remove the lower spring seat insulator. Inspect for damage and replace as necessary.

Assembly Procedure

1. Install the spring into the J 45400 . Make sure the spring is level.
2. Use the J 45400 to compress the spring evenly. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
3. Install the lower spring seat insulator.
4. Extend the strut shaft to the upper limit of its travel.
5. Insert the jounce bumper into the dust shield.
6. Slide the dust shield assembly onto the strut shaft.
7. Load the strut through the coil spring and the J 45400 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
8. Firmly align the lower spring coil in the spring seat pocket.
9. Place the upper spring insulator and spring seat onto the top of the coil spring.
10. Place the bearing and strut mount on the top of the spring seat.
11. Install the upper strut shaft nut. Tighten: Tighten the nut to 70 N.m (52 lb ft).
12. Using the J 45400 , remove the spring tension. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
13. Remove the strut assembly from the J 45400 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .
14. Install the strut assembly. Refer to «Strut Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) .

General Description (Strut)

The front suspension has 2 primary purposes

1. Isolate the driver from irregularities in the road surface.
2. Define the ride and handling characteristics of the vehicle.

The front suspension absorbs the impact of the tires travelling over irregular road surfaces and dissipates this energy throughout the suspension system. This process isolates the vehicle occupants from the road surface. The rate at which the suspension dissipates the energy and the amount of energy that is absorbed is how the suspension defines the vehicles ride characteristics. Ride characteristics are designed into the suspension system and are not adjustable. The ride characteristics are mentioned in this description in order to aid in the understanding of the functions of the suspension system. The suspension system must allow for the vertical movement of the tire and wheel assembly as the vehicle travels over irregular road surfaces while maintaining the tire's horizontal relationship to the road.

This requires that the steering knuckle be suspended between a lower control arm and a strut assembly. The lower control arm attaches from the steering knuckle at the outermost point of the control arm. The attachment is through a ball and socket type joint. The innermost end of the control arm attached at 2 points to the vehicle frame through semi-rigid bushings. The upper portion of the steering knuckle is attached to a strut assembly. The strut assembly then connects to the vehicle body by way of an upper bearing. The steering knuckle is allowed to travel up and down independent of the vehicle body structure and frame.

This up and down motion of the steering knuckle as the vehicle travels over bumps is absorbed predominantly by the coil spring. This spring is retained under tension over the strut assembly. A strut is used in conjunction with this system in order to dampen out the oscillations of the coil spring. A strut is a basic hydraulic cylinder. The strut is filled with oil and has a moveable shaft that connects to a piston inside the strut. Valves inside the shock absorber offer resistance to oil flow and consequently inhibit rapid movement of the piston and shaft. Each end of the shock absorber is connected in such a fashion to utilize this recoil action of a spring alone. Each end of the strut is designed as the connection point of the suspension system to the vehicle and acts as the coil spring seat. This allows the strut to utilize the dampening action to reduce the recoil of a spring alone. The lower control arm is allowed to pivot at the vehicle frame in a vertical fashion. The ball joint allows the steering knuckle to maintain the perpendicular relationship to the road surface.

Front suspensions systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right lower control arm assemblies through the stabilizer link and stabilizer shaft insulators. This bar controls the amount of independent movement of the suspension when the vehicle turns. Limiting the independent movement defines the vehicles handling characteristics on turns.

Special Tools

Special Tools Illustration Tool Number/ Description J 24319-B Universal Steering Linkage Puller J 42129 Wheel Hub Removal J 43631 Ball Joint Remover J 45400 Strut Spring Compressor

Scheme 1

Scheme 2

Scheme 3

Scheme 4

See also:
• Lifting and Jacking the Vehicle
• Tire and Wheel Removal and Installation
• Fastener Notice
• Brake Rotor Replacement - Front
• Measuring Wheel Alignment
• Transmission Mount Replacement - Side (W/L61)
• Engine Mount Replacement
• Trim Height Inspection Procedure
• Stabilizer Shaft Link Replacement