2005 Saturn Relay AWDFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the rear tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Support rear differential carrier using a utility stand.
    4. Fig 1: View Of Rear Differential Carrier Mounting Bolts
    GM690531Courtesy of GENERAL MOTORS CORP.
  4. Remove the rear differential carrier mounting bolts (5) from the rear crossmember. Refer to Differential Replacement in Rear Drive Axle.
  5. Remove the rear suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  6. Disconnect the wheel speed sensor harness from the lower control arm and from the rear cross member.
  7. Remove the rivets that attach the park brake cable to the rear crossmember.
  8. Remove the automatic level control (ALC) height sensor and link from the crossmember bar and lower control arm. Refer to Automatic Level Control Sensor Replacement in Automatic Level Control.
  9. Secure the ALC wiring harness out of the way.
  10. Using a utility jack, support the rear crossmember.
  11. Remove the rear crossmember mounting bolts.
    12. Fig 2: View Of Rear Crossmember
    GM771995Courtesy of GENERAL MOTORS CORP.
  12. Lower the rear crossmember.
  13. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement in Rear Suspension.
  14. Remove the rear axle upper control arms from the rear crossmember. Refer to Rear Axle Upper Control Arm Replacement in Rear Suspension.
  15. Remove the rear axle lower control arms from the rear crossmember. Refer to Rear Axle Lower Control Arm Replacement in Rear Suspension.
  16. Remove the tie rods from the rear crossmember. Refer to Tie Rod Replacement (Front Wheel Drive) or Tie Rod Replacement (All Wheel Drive) in Rear Suspension.
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.

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