Frame and Underbody: Removal & Installation Pontiac Aztek I

Removal Procedure

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1. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
2. Remove the intermediate shaft from the steering gear stub shaft. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT in Power Steering.
3. Install a utility stand to the rear of the frame.
4. Remove the rear frame bolts.
5. Lower the rear of the frame.
6. Remove the upper and lower insulators from the rear of the frame as a set.

Scheme 10

1. Apply a thin coat of rubber lubricant GM P/N 1051717, Canadian P/N 5728223, to inside surface of lower insulator and to top surface of upper insulator.
2. Install the upper and lower insulators to the rear of the frame as a set.
3. Raise the rear of the frame. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
4. Install the rear frame bolts. Tighten Tighten the rear frame bolts to 165 N.m (122 lb ft).
5. Remove the utility stand.
6. Install the intermediate shaft to the steering gear stub shaft. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT in Power Steering.
7. Lower the vehicle.

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1. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
2. Remove the rear fascia. Refer to FASCIA REPLACEMENT - REAR BUMPER (AZTEK) or FASCIA REPLACEMENT - REAR BUMPER (RENDEZVOUS) in Bumpers.
3. Remove the rear energy absorber. Refer to ENERGY ABSORBER REPLACEMENT - REAR (AZTEK) or ENERGY ABSORBER REPLACEMENT - REAR (RENDEZVOUS) in Bumpers.
4. Remove the rear impact bar. Refer to IMPACT BAR REPLACEMENT - REAR BUMPER in Bumpers.
5. Remove the trailer hitch assembly.

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1. Install the trailer hitch to the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install bolts to frame rail. Tighten Tighten to 101 N.m (75 lb ft)
3. Install the rear impact bar. Refer to IMPACT BAR REPLACEMENT - REAR BUMPER in Bumpers.
4. Install the rear energy absorbers. Refer to ENERGY ABSORBER REPLACEMENT - REAR (AZTEK) or ENERGY ABSORBER REPLACEMENT - REAR (RENDEZVOUS) in Bumpers.
5. Install the rear fascia. Refer to FASCIA REPLACEMENT - REAR BUMPER (AZTEK) or FASCIA REPLACEMENT - REAR BUMPER (RENDEZVOUS) in Bumpers.
6. Lower the vehicle.

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1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-180875-S03801565212005073000000) in Battery.
2. Remove the carpet from the trunk area. Refer to CARPET REPLACEMENT in Interior Trim.
3. Remove the following components as needed: The sealers The sound deadening materials The corrosion materials
4. Remove the rear suspension support bolt.
5. Place a center punch through the damaged rear suspension support nut. Strike the center punch using a hammer. The punch will leave a dimple on the floor. Use the dimple in order to locate the area where the frame crossmember nut will be removed. IMPORTANT: Do not cut or damage the adjacent panels or the reinforcements.
6. Use a cutoff wheel in order to cut an access panel.
7. Lift the panel upward in order to gain access to the frame crossmember nut retainer. IMPORTANT: Reuse the frame crossmember nut retainer if the retainer is not damaged from the stripped out bolt.
8. Use an air chisel in order to break away the spot welds (1) on one side of the frame crossmember nut retainer (3).
9. Lift one side of the frame crossmember nut retainer enough in order to remove the frame crossmember nut.
10. Remove the rear suspension support nut (2).

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1. Install the rear suspension support nut (2).
2. Lower the frame crossmember nut retainer into place. Ensure that the following conditions exist: The frame crossmember nut is correctly positioned. The frame crossmember nut operates correctly.
3. Spot weld the frame crossmember nut retainer in the original location.
4. Clean and prepare the welded surfaces.
5. Apply corrosion protection. . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
6. Install the new rear suspension support bolt to the frame crossmember nut. Tighten Tighten the bolt to 105 N.m (77 lb ft).
7. Reposition the panel downward to the original position.
8. Stitch weld the panel back to the original position using 25 mm (0.98 in) welds along the seam. Leave 25 mm (0.98 in) gaps between the welds. A solid joint with minimal heat distortion will result. Continue to finish the stitch weld procedure.
9. Use a small grinder in order to remove the excess material from the floor panel until the following conditions exist: The floor panel is smooth. The floor panel is free from rough edges.
10. Clean and prepare the welded surfaces.
11. Apply corrosion protection.
12. Apply Primer and let the primer dry for approximately 30 minutes. Then apply Dominion Sure Seal P/N 110900 Sound Deadener or the equivalent to the repair area.
13. Install the carpet and the pad over the repair area. Refer to CARPET REPLACEMENT in Interior Trim.
14. Apply anti-corrosion compound GM P/N 12346225 or equivalent. Thoroughly coat the inside of the repair area through the access hole.
15. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-180875-S03801565212005073000000) in Battery.

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1. Disable the SIR system. Refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160365-S03580785242004021000000) in Air Bag Restraint Systems.
2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-180875-S03801565212005073000000) in Battery.
3. Remove all related panels and components. CAUTION: Refer to «FOAM SOUND DEADENERS CAUTION»(ref-175132-S37715434212005041500000) .
4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. .
5. Perform the necessary procedures to gain access to repair. Refer to CARPET REPLACEMENT in Interior Trim.
6. Mark cut the location for access to the cage nut. IMPORTANT: Do NOT damage any inner panels or reinforcements.
7. Cut the floor panel.
8. Remove the floor panel, accessing the cage nut.
9. Using a flat-bladed tool, pry open the cage nut retainer just enough to remove the gage nut.
10. Remove the damaged cage nut from the retainer.

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1. Install the new cage nut.
2. Close the cage nut retainer onto the new cage nut.
3. Grind both mating surfaces. IMPORTANT: The adhesive has s 40-50 minute working time. Do NOT allow the adhesive to totally cure off of the vehicle.
4. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5) or equivalent to both of the mating surfaces.
5. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces. This will ensure corrosion protection. IMPORTANT: DO NOT pull the panels apart after joining them together. Slide the panels against each other to realign the panels if necessary.
6. Install the floor panel to the body. IMPORTANT: The adhesive has s 40-50 minute working time. Do NOT allow the adhesive to totally cure off of the vehicle.
7. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5) or equivalent to both of the mating surfaces.
8. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces. This will ensure corrosion protection.
9. Using lacquer thinner, remove the excess adhesive from the lower quarter panel area.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. .
11. Paint the repair area. .
12. Complete the necessary procedures. Refer to CARPET REPLACEMENT in Interior Trim.
13. Enable the SIR system. Refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160365-S03580785242004021000000) in Air Bag Restraint Systems.
14. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-180875-S03801565212005073000000) in Battery.

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