Malibu 2001-2005

Coil Springs

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the strut.
  4.  
  5. Mount the strut in a strut compressor.
    NOTE
    The strut compressor has strut mounting holes drilled for specific vehicle lines.

  6.  
  7. Compress the strut approximately 1 / 2 of its height after initial contact with the top cap.
    WARNING
    Never bottom the spring or damper rod.

  8.  
  9. Remove the strut damper shaft nut and place a guiding rod on top of the damper shaft. Use the rod to guide the damper shaft straight down through the spring cap while compressing the spring. Remove the components.

    Click image to see an enlarged view

    Fig. View of the strut mounted in the compressor



    Click image to see an enlarged view

    Fig. Use a socket and a wrench to remove the damper shaft nut spring cap while compressing the spring



    Click image to see an enlarged view

    Fig. Exploded view of the front strut



    Click image to see an enlarged view

    Fig. Exploded view of the rear strut

  10.  

To install:

  1. Install the bearing cap onto the strut compressor, if removed.
  2.  
  3. Mount the strut in the strut compressor using the bottom locking pin only.
  4.  
  5. Install the spring over the damper and swing the assembly up so the upper locking pin can be installed.
  6.  
  7. Install all shields, bumpers and insulators on the spring seat. Install the spring seat on top of the spring. Be sure the flat on the upper spring seat is facing in the proper direction. The spring seat flat should be facing the same direction as the centerline of the strut assembly spindle.
  8.  
  9. Install the guiding rod and turn the forcing screw while the guiding rod centers the assembly. When the threads on the damper shaft are visible, remove the guiding rod and install the nut. Torque the nut to 34 ft. lbs. (47 Nm).
  10.  
  11. Remove the assembly from the compressor.
  12.  
  13. Install the strut on the vehicle.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the strut assembly.
  4.  
  5. Place the strut assembly into the J 45400.
  6.  
  7. Adjust the compressing arms to contact the coils farthest away from the center of the spring.
  8.  
  9. Using the J 45400, compress the spring to remove the spring tension from the upper strut mount.
    NOTE
    Before removing the strut shaft nut, support the strut to prevent the strut from falling.

  10.  
  11. Remove the strut shaft nut, while holding the strut shaft.

    Click image to see an enlarged view

    Fig. Strut shaft nut removal with spring tension removed

  12.  
  13. Lower the strut from the spring and the J 45400.
  14.  
  15. Remove the upper strut mount assembly and mount bearing. Inspect for damage and replace as necessary.
  16.  
  17. Remove the upper spring seat and insulator from the spring and the J 45400. Inspect for damage and replace as necessary.
  18.  
  19. Using the J 45400, remove the spring tension in order to remove the spring. Inspect for damage and replace as necessary.
  20.  
  21. Remove the dust shield and jounce bumper assembly from the strut shaft. Inspect for damage and replace as necessary
  22.  
  23. Remove the lower spring seat insulator. Inspect for damage and replace as necessary.
  24.  

To install:

  1. Install the spring into the J 45400. Make sure the spring is level.
  2.  
  3. Use the J 45400 to compress the spring evenly.
  4.  
  5. Install the lower spring seat insulator.
  6.  
  7. Extend the strut shaft to the upper limit of its travel.
  8.  
  9. Insert the jounce bumper into the dust shield.
  10.  
  11. Slide the dust shield assembly onto the strut shaft.

    Click image to see an enlarged view

    Fig. Spring seat, jounce bumper and dust shield

  12.  
  13. Load the strut through the coil spring and the J 45400.
  14.  
  15. Firmly align the lower spring coil in the spring seat pocket.
  16.  
  17. Place the upper spring insulator and spring seat onto the top of the coil spring.
  18.  
  19. Place the bearing and strut mount on the top of the spring seat

    Click image to see an enlarged view

    Fig. Spring insulator, spring seat, bearing and strut mount

  20.  
  21. Install the upper strut shaft nut and tighten to 52 ft. lbs. (70 Nm).
  22.  
  23. Using the J 45400, remove the spring tension.
  24.  
  25. Remove the strut assembly from the J 45400.
  26.  
  27. Install the strut assembly.
  28.  

 
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