2002 Pontiac Aztek AWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the lower control arm.
  2. Install the control arm bolts and nuts.

    Important:  Align the ball stud cotter pin hole parallel to the knuckle in order to ease the cotter pin installation.

  3. Install the ball stud to the knuckle.
    NOTE: Refer to FASTENER NOTICE .
  4. Install the ball stud castle nut.

    Tighten 

    Tighten the ball stud castle nut to 55 N.m (40 lb ft).

    Fig 1: Installing Lower Control Arm, Bolts & Nuts
    G01746873Courtesy of GENERAL MOTORS CORP.

    Important:  Do not loosen the ball stud nut in order to align the ball stud nut slots to the ball stud cotter pin hole.

  5. If necessary, tighten the ball stud castle nut in order to align the ball stud castle nut slot (1) to the ball stud cotter pin hole (2) as shown.
    Fig 2: Aligning Ball Stud Castle Nut Slot To Ball Stud Cotter Pin Hole
    G01746874Courtesy of GENERAL MOTORS CORP.

    Important:  Ensure that the cotter pin ends do not contact the ABS sensor connector or the drive axle.

  6. Install a new cotter pin and bend the ends as shown in either example.
  7. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement .
    Fig 3: Bending Ends Of Cotter Pin
    G01746875Courtesy of GENERAL MOTORS CORP.
  8. Install the wheel speed sensor harness to the lower control arm.

    Important:  This is a prevailing torque type fastener. This fastener may be reused only if:

    • The fastener and its counterpart are clean and free from rust.
    • The fastener develops 3 N.m (27 lb in) of torque (drag) against its counterpart prior to the fastener seating.

    If the fastener does not meet these criteria, REPLACE the fastener.

  9. Install the lower control arm nuts.

    Tighten 

    Tighten the lower control am nuts to 113 N.m (83 lb ft).

  10. Install the tire and wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
  11. Lower the vehicles.
    Fig 4: Installing Wheel Speed Sensor Harness To Lower Control Arm
    G01746876Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.