Chevrolet Cobalt Service & Repair Manual: Frame

Removal

With wheels of vehicle facing straight ahead, secure steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of steering column will prevent damage and a possible fault of SIR system. Steering wheel must be secured in position before disconnecting following components: Steering column, Intermediate shaft(s), Steering gear. After disconnecting these components, do not rotate steering wheel or move front tires and wheels. Failure to follow this procedure may cause SIR coil assembly to become un-centered and cause possible damage to SIR coil. If you think SIR coil has became un-centered, refer to your specific SIR coil’s centering procedure to re-center SIR Coil.
Special tool: J 24319-B Steering Linkage and Tie Rod Puller.
Special tool: J 43631 Ball Joint Remover.
1. With wheels in straight ahead position, remove key from ignition switch.
2. Secure cooling module to upper body structure, Fig. 1.
3. Raise and support vehicle.
4. Remove front wheels from vehicle.
5. Remove left and right splash shields and three screws in inner fenders.
6. Remove lower radiator air deflector from frame.
7. Remove front transaxle mount to frame through bolt, Fig. 2.
8. Remove rear transaxle mount to frame bolts, Fig. 3.
9. Remove both stabilizer link to stabilizer shaft nuts, Fig. 4.
10. Remove both tie rod to steering knuckle nuts, Fig. 5.
11. Use J 24319-B or equivalent to separate outer tie rods from steering knuckles, Fig. 6.
12. Remove intermediate steering shaft to steering gear pinch bolt and discard, Fig. 7.Note: DO NOT rotate intermediate shaft once separated from gear. Possible damage could occur.
13. Disconnect intermediate steering shaft from steering gear.
14. Remove both lower control arm ball stud to steering knuckle pinch bolts, Fig. 8. Do not free ball stud by using a pickle fork or a wedge-type tool. Damage to seal or bushing may result.
15. Lower both lower control arms in order to disengage steering knuckle. If required, use J 43631 or equivalent. Do not free ball stud by using a pickle fork or a wedge-type tool. Damage to seal or bushing may result.
16. Mark frame to body position with a paint pen or permanent marker.
17. Lower vehicle to approximately three feet off ground in order to place a hydraulic lift table under frame.
18. Use two 2 x 4's between lift table and frame and lift table to frame.
19. Slowly remove frame bolts using following sequence:
  a. Remove front frame bolts.
  b. Remove rear frame bolts, Fig. 9.
20. Slowly lower lift table and frame to floor.
21. Continue with following steps when replacing frame:
  a. Remove steering gear from frame, as required.
  b. Remove stabilizer bar from frame, as required.
  c. Remove lower control arms from frame, as required.
  d. Remove radiator brackets from frame.

Installation

1. If replacing frame, perform following steps:
  a. Install radiator brackets to frame.
  b. Install lower control arms to frame, as required.
  c. Install stabilizer bar to frame, as required.
  d. Install steering gear to frame, as required.
2. With frame on lift table, raise frame to vehicle.
3. Hand start all frame bolts while aligning frame to paint marks, Fig. 9.Torque frame bolts to 74 ft. lbs., plus 180°.
4. Lower and remove hydraulic table.
5. Connect lower control arm to steering knuckle, Fig. 8.
6. Install ball joint pinch bolt and nut. Note: Torque sequence must be followed in order that is listed:
  a. First Pass: Torque nut to 37 ft. lbs.
  b. Reverse nut 3/4 turn.
  c. Second Pass: Torque nut to 37 ft. lbs., plus 30°.
7. Hand start front transaxle mount through bolt, Fig. 2.
8. Loosen rear transmission mount through bolt. Note: Front and rear transmission mounts must be allowed to settle with through bolts loosened.
9. Torque rear transaxle mount to frame bolts to 37 ft. lbs., Fig. 3.
10. Front and rear transaxle mount through bolts in following order:
  a. Torque rear bolt to 74 ft. lbs.
  b. Torque front bolt to 74 ft. lbs.
11. Install outer tie rods to steering knuckles.
12. Install new outer tie rod to knuckle nuts, Fig. 5.Torque to 18 ft. lbs., plus 90 degrees.
13. Connect stabilizer links to stabilizer shaft, Fig. 4.
14. Connect intermediate shaft to steering gear.
15. Install a new intermediate shaft pinch bolt, Fig. 7.Torque to 25 ft. lbs.
16. Install left and right splash shields and three inner fender screws, as required.
17. Install lower radiator air deflector to frame.
18. Install front wheels, as required.
19. Lower vehicle.
20. Road test vehicle in order to test for following conditions:
  a. Steering leads or pulls. Inspect wheel alignment measurement, as required.
  b. Abnormal powertrain noise or vibration at idle. Inspect and adjust, as required.

Fig. 1 Radiator upper core support

Fig. 2 Front transaxle mount

Fig. 3 Rear transaxle mount

Fig. 4 Stabilizer link

Fig. 5 Outer tie rod end to steering knuckle

Fig. 6 Tie rod separation tool

Fig. 7 Intermediate steering shaft

Fig. 8 Lower control arm stud to steering knuckle

Fig. 9 Front frame bolts

    Door Striker
    Sedan Removal 1. Open door. 2. Remove front side door lock striker screws, Fig. 1. 3. Remove front side do ...

    Front Bumper Fascia
    Removal 1. Remove headlamp assemblies, as required. 2. Remove front fender liners as outlined in Front Fender Liner. ...

    See also:

    Chevrolet Cobalt Owners Manual. Driving at Night
    Night driving is more dangerous than day driving because some drivers are likely to be impaired — by alcohol or drugs, with night vision problems, or by fatigue. Night driving tips include: - Drive defensively. - Do not drink and drive. - Reduce headlamp glare by adjusting the inside rearv ...

    Chevrolet Cobalt Owners Manual

    Chevrolet Cobalt Service Manual


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