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Frame & Underbody: Other Pontiac G6 I

Frames, Subframes & Crossmembers 21 illustrations ~1959 words

Tools Required

J 39580 Engine Support Stand. See Special Tools .

Scheme 3

Scheme 3: Removal Procedure
Scheme 3: Removal Procedure

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Scheme 5

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Scheme 7

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Scheme 8

Scheme 9

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Scheme 9

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Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Install the engine support fixture. Refer to «Engine Mount Bracket Replacement»(ref-243010-S38830058712006082100000) for the 2.4L engine.
  2. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
  3. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
  4. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
  5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
  6. Remove the lower ball joints from the steering knuckles. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
  7. Remove the tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
  8. Remove both stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
  9. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to «Power Steering Gear Replacement (Hydraulic)»(ref-243012-S23289827622006082100000) or «Power Steering Gear Replacement (Electronic)»(ref-243012-S26775079452006082100000) .
  10. Remove the front transmission mount bolt from the frame. Refer to «Transmission Mount Replacement - Front»(ref-243013-S31720374962006082100000) for the 4T40-E/4T45-E transmission.
  11. Remove the left transmission mount nuts from the frame. Refer to «Transmission Mount Replacement - Left»(ref-243013-S39382940872006082100000) for the 4T40-E/4T45-E transmission.
  12. Remove the rear transmission mount bracket nuts from the frame. Refer to «Transmission Mount Replacement - Rear»(ref-243013-S33404342302006082100000) for the 4T40-E/4T45-E transmission.
  13. Remove the brake lines from the retainers on the frame.
  14. Lower the vehicle until the frame contacts the J 39580 . See «Special Tools»(ref-243009-S37499958092006082100000) .
  15. Remove the reinforcement bolts (1).
  16. Remove the front frame bolts (1).
  17. Remove the rear frame bolts (4).
  18. Remove the frame reinforcements (3).
  19. Raise the vehicle off of the frame.
  20. Remove the following components if replacing the frame: The lower control arms-Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) . The stabilizer shaft-Refer to «Stabilizer Shaft Replacement»(ref-243011-S38768234662006082100000) .

J 39580 Engine Support Stand. See Special Tools .

Scheme 13

Scheme 13
Scheme 13
  1. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-243014-S15424971832006082100000) for the 3.5L engine.
  2. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
  3. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
  4. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
  5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
  6. Remove the lower ball joints from the steering knuckles. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
  7. Remove the tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
  8. Remove both stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
  9. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to «Power Steering Gear Replacement (Hydraulic)»(ref-243012-S23289827622006082100000) or «Power Steering Gear Replacement (Electronic)»(ref-243012-S26775079452006082100000) .
  10. Remove the engine mount nuts from the frame. Refer to «Engine Mount Replacement»(ref-243014-S39558207372006082100000) for the 3.5L engine.
  11. Remove the front transmission mount bolt from the frame. Refer to «Transmission Mount Replacement - Front»(ref-243013-S31720374962006082100000) for the 4T40-E/4T45-E transmission.
  12. Remove the left transmission mount nuts from the frame. Refer to «Transmission Mount Replacement - Left»(ref-243013-S39382940872006082100000) for the 4T40-E/4T45-E transmission.
  13. Remove the rear transmission mount bracket nuts from the frame. Refer to «Transmission Mount Replacement - Rear»(ref-243013-S33404342302006082100000) for the 4T40-E/4T45-E transmission.
  14. Remove the brake lines from the retainers on the frame.
  15. Lower the vehicle until the frame contacts the J 39580 . See «Special Tools»(ref-243009-S37499958092006082100000) .
  16. Remove the reinforcement bolts (1).
  17. Remove the front frame bolts (1).
  18. Remove the rear frame bolts (4).
  19. Remove the frame reinforcements (3).
  20. Raise the vehicle off of the frame.
  21. Remove the following components if replacing the frame: The lower control arms-Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) . The stabilizer shaft-Refer to «Stabilizer Shaft Replacement»(ref-243011-S38768234662006082100000) .

J 39580 Engine Support Stand. See Special Tools .

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Scheme 15

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Scheme 17

Scheme 17
Scheme 17
  1. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-243015-S30052994002006082100000) for the 3.9L engine.
  2. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
  3. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
  4. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
  5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
  6. Remove the lower ball joints from the steering knuckles. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
  7. Remove the tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
  8. Remove both stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
  9. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to «Power Steering Gear Replacement (Hydraulic)»(ref-243012-S23289827622006082100000) or «Power Steering Gear Replacement (Electronic)»(ref-243012-S26775079452006082100000) .
  10. Remove the engine mount nuts from the frame. Refer to «Engine Mount Replacement»(ref-243015-S32973693972006082100000) for the 3.9L engine.
  11. Remove the front transmission mount nut (1) and bolt (2) from the frame. Refer to «Transmission Mount Replacement - Front»(ref-243016-S04664041942006082100000) for the 4T65-E transmission.
  12. Remove the left transmission mount nuts from the frame. Refer to «Transmission Mount Replacement - Left»(ref-243016-S13914929782006082100000) for the 4T65-E transmission.
  13. Remove the rear transmission mount bracket nuts (1) from the frame. Refer to «Transmission Mount Bracket Replacement - Rear»(ref-243016-S19146824922006082100000) for the 4T65-E transmission.
  14. Remove the brake lines from the retainers on the frame.
  15. Lower the vehicle until the frame contacts the J 39580 . See «Special Tools»(ref-243009-S37499958092006082100000) .
  16. Remove the reinforcement bolts (1).
  17. Remove the front frame bolts (1).
  18. Remove the rear frame bolts (4).
  19. Remove the frame reinforcements (3).
  20. Raise the vehicle off of the frame.
  21. Remove the following components if replacing the frame: The lower control arms-Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) . The stabilizer shaft-Refer to «Stabilizer Shaft Replacement»(ref-243011-S38768234662006082100000) .

J 39580 Engine Support Stand. See Special Tools .

Scheme 18

Scheme 18
Scheme 18
  1. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-243015-S30052994002006082100000) for the 3.9L engine.
  2. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
  3. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
  4. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
  5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
  6. Remove the lower ball joints from the steering knuckles. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
  7. Remove the tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
  8. Remove both stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
  9. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire, or equivalent, being sure not to overextend the intermediate shaft. Refer to «Power Steering Gear Replacement (Hydraulic)»(ref-243012-S23289827622006082100000) or «Power Steering Gear Replacement (Electronic)»(ref-243012-S26775079452006082100000) .
  10. Remove the engine mount nuts from the frame. Refer to «Engine Mount Replacement»(ref-243015-S32973693972006082100000) for the 3.9L engine.
  11. Remove the front transmission mount nut (1) and bolt (2) from the frame. Refer to «Transmission Mount Replacement - Front»(ref-243017-S01392633482006082100000) for the F40 transmission.
  12. Remove the left transmission mount nuts (1) from the frame. Refer to «Transmission Mount Replacement - Left»(ref-243017-S15809851872006082100000) for the F40 transmission.
  13. Remove the rear transmission mount bracket nuts (1) from the frame. Refer to «Transmission Mount Bracket Replacement - Rear»(ref-243017-S33208648852006082100000) for the F40 transmission.
  14. Remove the brake lines from the retainers on the frame.
  15. Lower the vehicle until the frame contacts the J 39580 . See «Special Tools»(ref-243009-S37499958092006082100000) .
  16. Remove the reinforcement bolts (1).
  17. Remove the front frame bolts (1).
  18. Remove the rear frame bolts (4).
  19. Remove the frame reinforcements (3).
  20. Raise the vehicle off of the frame.
  21. Remove the following components if replacing the frame: The lower control arms-Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) . The stabilizer shaft-Refer to «Stabilizer Shaft Replacement»(ref-243011-S38768234662006082100000) .

J 39580 Engine Support Stand. See Special Tools .

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-243014-S15424971832006082100000) for the 3.5L engine.
  2. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
  3. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation»(ref-243005-S07348510082006082100000) .
  4. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
  5. Disconnect the Antilock Brake System (ABS) sensor from the wheel speed sensor and frame.
  6. Remove the lower ball joints from the steering knuckles. Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) .
  7. Remove the tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-243012-S12025436212006082100000) .
  8. Remove both stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(ref-243011-S00724327522006082100000) .
  9. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to «Power Steering Gear Replacement (Hydraulic)»(ref-243012-S23289827622006082100000) or «Power Steering Gear Replacement (Electronic)»(ref-243012-S26775079452006082100000) .
  10. Remove the engine mount nuts from the frame. Refer to «Engine Mount Replacement»(ref-243014-S39558207372006082100000) for the 3.5L engine.
  11. Remove the front transmission mount bolt from the frame. Refer to «Transmission Mount Replacement - Front»(ref-243013-S31720374962006082100000) for the 4T40-E/4T45-E transmission.
  12. Remove the left transmission mount nuts from the frame. Refer to «Transmission Mount Replacement - Left»(ref-243013-S39382940872006082100000) for the 4T40-E/4T45-E transmission.
  13. Remove the rear transmission mount bracket nuts from the frame. Refer to «Transmission Mount Replacement - Rear»(ref-243013-S33404342302006082100000) for the 4T40-E/4T45-E transmission.
  14. Remove the brake lines from the retainers on the frame.
  15. Lower the vehicle until the frame contacts the J 39580 . See «Special Tools»(ref-243009-S37499958092006082100000) .
  16. Remove the frame reinforcement bolts (2) and frame brace bolts (1).
  17. Remove the front frame bolts (1).
  18. Remove the rear frame bolts (5).
  19. Remove the frame reinforcements (2).
  20. Raise the vehicle off of the frame.
  21. Remove the following components if replacing the frame: The lower control arms-Refer to «Lower Control Arm Replacement»(ref-243011-S19974582932006082100000) . The stabilizer shaft-Refer to «Stabilizer Shaft Replacement»(ref-243011-S38768234662006082100000) .

J 39580 Engine Support Stand. See Special Tools .

J 39580 Engine Support Stand. See Special Tools .

CH-47672 Frame Insulator Remover/Installer. See Special Tools .

Scheme 21

Scheme 21: Removal Procedure
Scheme 21: Removal Procedure
  1. Remove the frame from the vehicle. Refer to «Frame Replacement (Coupe 2.4L/4T40-E/4T45-E)»(ref-243009-S28939599432006082100000) or «Frame Replacement (Coupe 3.5L/4T40-E/4T45-E)»(ref-243009-S03643259772006082100000) or «Frame Replacement (Coupe 3.9L/4T65-E)»(ref-243009-S34360641872006082100000) or «Frame Replacement (Coupe 3.9L/F40)»(ref-243009-S10160843132006082100000) or «Frame Replacement (Convertible 3.5L/4T40-E/4T45-E)»(ref-243009-S24938334332006082100000) or «Frame Replacement (Convertible 3.9L/4T65-E)»(ref-243009-S38980325342006082100000) or «Frame Replacement (Convertible 3.9L/F40)»(ref-243009-S21460857982006082100000) .
  2. Install the CH-47672 to the frame insulator that you are removing as shown. See «Special Tools»(ref-243009-S37499958092006082100000) .
  3. Use the CH-47672 to remove the frame insulator from the frame. See «Special Tools»(ref-243009-S37499958092006082100000) .

Scheme 22

Scheme 22: Installation Procedure
Scheme 22: Installation Procedure

Scheme 23

Scheme 23
Scheme 23
  1. Clean the frame insulator opening.
  2. Apply thin coat of rubber lubricant GM P/N 1051717 (Canadian P/N 5728223), or equivalent to the inside of the frame insulator opening.
  3. Apply thin coat of rubber lubricant GM P/N 1051717 (Canadian P/N 5728223), or equivalent to the inside of the frame insulator.
  4. Install the frame insulator to the front frame opening with the alignment tabs facing up. IMPORTANT: The frame insulator tabs should be aligned horizontally or left to right on the vehicle and the recessed area should be aligned vertically or front to back on the vehicle.
  5. Use the CH-47672 to install the frame insulator to the frame. See «Special Tools»(ref-243009-S37499958092006082100000) .
  6. Remove the CH-47672 from the frame. See «Special Tools»(ref-243009-S37499958092006082100000) .
  7. Install the frame to the vehicle. Refer to «Frame Replacement (Coupe 2.4L/4T40-E/4T45-E)»(ref-243009-S28939599432006082100000) or «Frame Replacement (Coupe 3.5L/4T40-E/4T45-E)»(ref-243009-S03643259772006082100000) or «Frame Replacement (Coupe 3.9L/4T65-E)»(ref-243009-S34360641872006082100000) or «Frame Replacement (Coupe 3.9L/F40)»(ref-243009-S10160843132006082100000) or «Frame Replacement (Convertible 3.5L/4T40-E/4T45-E)»(ref-243009-S24938334332006082100000) or «Frame Replacement (Convertible 3.9L/4T65-E)»(ref-243009-S38980325342006082100000) or «Frame Replacement (Convertible 3.9L/F40)»(ref-243009-S21460857982006082100000) .

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