Cobalt 2006-2008, G5 2007

Axle Beam

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the rear wheels.
  6.  
  7. Disconnect the left and right rear brake pipes from the rear brake hoses at the axle.
  8.  
  9. Disconnect the brake hoses from the axle brake hose bracket.
  10.  
  11. Plug the brake pipes and hoses in order to prevent additional brake fluid loss.
  12.  
  13. Disconnect both rear parking brake cables at the rear brake.
  14.  
  15. If applicable, disconnect the Antilock Brake System (ABS) harness connectors and disconnect from the axle.
  16.  
  17. Support the rear axle with a hydraulic lift table.
  18.  
  19. Remove the lower shock bolts.
  20.  
  21. Lower the hydraulic lift table and remove the rear coil springs.
  22.  
  23. Disconnect the park brake cables from the cable brackets.
  24.  
  25. Remove the wheel bearing/hub retaining nuts from both sides.
  26.  
  27. Remove the wheel bearing/hubs, with the brakes and backing plate as an assembly.

    Click image to see an enlarged view

    Fig. Rear axle beam removal

  28.  
  29. Remove all rear axle bushing bracket bolts.
  30.  
  31. Use the hydraulic lift table to lower the rear axle from the vehicle.
  32.  
  33. Remove the rear axle bushing through bolts and the park brake cable brackets.
  34.  
  35. Remove the rear coil spring lower seat from the axle.
  36.  

To install:

  1. Install the rear coil spring lower insulators to the axle.
  2.  
  3. Install the axle brackets to the axle bushings, with the alignment slot on the outboard side.
    NOTE
    The axle bushing through bolts must be installed with the bolt head facing inboard.

  4.  
  5. Loosely install the bushing bolts and nuts.
  6.  
  7. Place the axle on the hydraulic lift table.
  8.  
  9. Raise the axle into position.
  10.  
  11. Hand tighten the axle bracket to body bolts just enough to hold the brackets flush to the body.
    NOTE
    The axle through bolts must be tightened with the axle at the correct trim height and prior to tightening the axle bracket to body bolts.

  12.  
  13. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance between the bottom edge of the upper spring seat and the bottom of the notch in the lower spring seat.

    Click image to see an enlarged view

    Fig. D height measurement

  14.  
  15. Before setting the D height measurement:
    1. Set the tire pressure to the specifications shown on the certification label.
    2.  
    3. Check the fuel level. Add additional weight if necessary to simulate a full tank.
    4.  
    5. Make sure the passenger and rear compartments are empty, except for the spare tire.
    6.  
    7. Make sure the vehicle is on a flat and level surface, such as an alignment rack.
    8.  
    9. Check that all the vehicle doors are securely closed.
    10.  
    11. Check that the vehicle hood and rear deck lids are securely closed.
    12.  
    13. Check for installed after market accessories or modifications that could affect trim height measurement.
      NOTE
      All dimensions are measured vertical to the ground. Trim height should be within plus or minus 0.39 inch (10mm) to be considered correct.

    14.  

  16.  

The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components.

  1. Use the following procedure to check the D dimension:
    1. With the vehicle on a flat level surface, lift upward on the rear bumper 1 1 / 2  inches (38mm).
    2.  
    3. Gently remove your hands and allow the vehicle to settle.
    4.  
    5. Repeat the jouncing operation 2 more times.
    6.  
    7. Measure the D height for the left and right side of the vehicle. Measure the vertical distance between the bottom edge of the upper spring seat to the bottom of the notch in the lower spring seat.
    8.  
    9. Using your hands, jounce the front of the vehicle downward approximately 1 1 / 2  inches (38mm).
    10.  
    11. Gently remove your hands and allow the vehicle to settle .
    12.  
    13. Repeat the jouncing operation 2 more times.
    14.  
    15. Measure the D height dimension.
    16.  
    17. The true D height dimension number is the average of the high and the low measurements:

      2.0L engine: 8.4 inches (213mm)
       
      2.2L engine with P195/60R15 tires: 9.4 inches (238mm)
       
      2.2L engine with P205/50R16 tires: 9 inches (228mm) If these measurements are out of specifications, inspect for worn or damaged suspension components and/or collision damage.
       

    18.  

  2.  
  3. Tighten the axle bushing through bolts. Tighten the bolts to 66 ft. lbs. (90 Nm) plus 60°.
  4.  
  5. Insert two 12mm diameter pins through the axle brackets into the underbody.

    Click image to see an enlarged view

    Fig. Aligning the left side axle bracket



    Click image to see an enlarged view

    Fig. Aligning the right side axle bracket

  6.  
  7. Align the left side axle bracket and snug down the bolts.
  8.  
  9. Align the right side axle bracket and snug down the bolts.
  10.  
  11. Tighten all the bracket to body bolts. Tighten the bolts to 66 ft. lbs. (90 Nm) plus 45°.
  12.  
  13. Install the wheel bearing/hubs, with the brakes and backing plate assemblies.
  14.  
  15. Install the bearing/hub nuts. Tighten the nuts to 33 ft. lbs. (45 Nm) plus 30°.
  16.  
  17. Connect the brake hoses to the rear axle brackets.
  18.  
  19. Connect the brake pipes to the brake hoses at the axle. Tighten the brake pipe fittings to 14 ft. lbs. (19 Nm).
  20.  
  21. Install the rear coil springs.
  22.  
  23. Install the lower shock bolts.
  24.  
  25. Lower and remove the hydraulic lift table.
  26.  
  27. If applicable, connect the ABS sensor harness connector and harness to axle retainer.
  28.  
  29. Connect the park brake cables to the axle brackets and rear brakes.
  30.  
  31. Bleed the brake system.
  32.  
  33. Install the rear wheels.
  34.  
  35. Lower the vehicle.
  36.  

 
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