GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Suspension 🢒 Rear Suspension 🢒 Rear Axle Replacement

Removal Procedure

    Important: If the rear axle is being replaced due to a wheel alignment issue and is not physically damaged, refer to Thrust Angle Description for additional information.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Disconnect the left and right rear brake pipes from the rear brake hoses at the axle.
  4. Disconnect the brake hoses from the axle brake hose bracket.
  5. Plug the brake pipes and hoses in order to prevent additional brake fluid loss.
  6. Disconnect both rear parking brake cables at the rear brake. Refer to Parking Brake Rear Cable Replacement in Park Brake.
  7. If applicable, disconnect the ABS harness connectors and disconnect from the axle.
  8. Support the rear axle with a hydraulic lift table.

    9. Object Number: 855039 Size: SH
  9. Remove the lower shock bolts. Refer to Shock Absorber Replacement .

    10. Object Number: 855051 Size: SH
  10. Lower the hydraulic lift table and remove the rear coil springs. Refer to Coil Spring Replacement .
  11. Disconnect the park brake cables from the cable brackets.

    12. Object Number: 888335 Size: SH
  12. Remove the wheel bearing/hub retaining nuts from both sides.
  13. Remove the wheel bearing/hubs, with the brakes and backing plate as an assembly.

    14. Object Number: 855059 Size: SH
  14. Remove all rear axle bushing bracket bolts.
  15. Use the hydraulic lift table to lower the rear axle from the vehicle.
  16. Remove the rear axle bushing through bolts and the park brake cable brackets.
  17. Remove the rear coil spring lower seat from the axle.

Installation Procedure
  1. Install the rear coil spring lower insulators to the axle.
  2. Install the axle brackets to the axle bushings, with the alignment slot on the outboard side.

    3. Important: The axle bushing through bolts must be installed with the bolt head facing inboard.

  3. Loosely install the bushing bolts and nuts .
  4. Place the axle on the hydraulic lift table.
  5. Raise the axle into position.

    6. Object Number: 855059 Size: SH
  6. Hand tighten the axle bracket to body bolts just enough to hold the brackets flush to the body.

    7. Important: The axle through bolts must be tightened with the axle at the correct trim height and prior to torquing the axle bracket to body bolts.

  7. 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. Refer to Trim Height Inspection in Suspension General Diagnosis for D height measurement.

    8. Notice: Refer to Fastener Notice in the Preface section.

  8. Tighten the axle bushing through bolts.

    9. Tighten
    Tighten the bolts to 90 N·m (66 lb ft) +60 degrees.

  9. Insert two 12 mm diameter pins through the axle brackets into the underbody.

    10. Object Number: 855056 Size: SH
  10. Align the left side axle bracket and snug down the bolts.

    11. Object Number: 855058 Size: SH
  11. Align the right side axle bracket and snug down the bolts.

    12. Object Number: 1662835 Size: SH
  12. To identify a one piece jounce bumper, the end of the bumper (1) will be molded as one piece with the bumper body.

    13. Object Number: 1662842 Size: SH
  13. To identify a two piece jounce bumper, the end of the bumper (1) will be separate from the bumper body (2).

    14. Notice: To avoid axle bolt weld nut damage, you must identify the jounce bumper and use the correct torque specification.

  14. Tighten all the bracket to body bolts.

    15. Tighten

    1. If the vehicle has a one piece jounce bumper, tighten the nut to 90 N·m (66 lb ft) +30 degrees.
    2. If the vehicle has a two piece jounce bumper, tighten the nut to 90 N·m (66 lb ft) +45 degrees.
  15. Install the wheel bearing/hubs, with the brakes and backing plate assemblies.

    16. Object Number: 888335 Size: SH
  16. Install the bearing/hub nuts.

    17. Tighten
    Tighten the nuts to 50 N·m (37 lb ft) + 30 degrees.

  17. Connect the brake hoses to the rear axle brackets.
  18. Connect the brake pipes to the brake hoses at the axle.

    19. Tighten
    Tighten the brake pipe fittings to 19 N·m (14 lb ft).


    Object Number: 855051 Size: SH
  19. Install the rear coil springs. Refer to Coil Spring Replacement .

    20. Object Number: 855039 Size: SH
  20. Install the lower shock bolts. Refer to Shock Absorber Replacement .
  21. Lower and remove the hydraulic lift table.
  22. If applicable, connect the ABS sensor harness connector and harness to axle retainer.
  23. Connect the park brake cables to the axle brackets and rear brakes. Refer to Parking Brake Rear Cable Replacement in Park Brake.
  24. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
  25. Install the rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  26. Lower the vehicle.