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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

2007 Accessories & Equipment Frame and Underbody - Corvette

SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications Specification Metric English 110 N.m 81 lb ft 2 N.m 18 lb in 2 N.m 18 lb in 100 N.m 74 lb ft 5 N.m 44 lb in 5 N.m 44 lb in 2 N.m 18 lb in 28 N.m 21 lb ft 50 N.m 36 lb ft

Application Crossmember Bolt Nut Fuel Door Pocket Screws Fuel Door Screws Power Steering Gear Mounting Bolts Quarter Panel Screws Quarter Panel to Brace Screws Rear Bumper Fascia Bolts Shock Absorber Lower Mounting Nuts Skid Bar to Frame Bolts

REPAIR INSTRUCTIONS FRONT TOW HOOK REPLACEMENT Removal Procedure

1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) or Battery Negative Cable Disconnection and Connection (7.0L) . 3. Remove all related panels and components. 4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

MY Wednesday, April 01, 2009 1:14:26 1:14:19 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 1: Identifying Welds - Front Courtesy of GENERAL MOTORS CORP. 5. Remove the welds (1) attaching the tow hook to the impact bar.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 2: View Of Tow Hook - Front Courtesy of GENERAL MOTORS CORP. 6. Remove the tow hook (1) from the impact bar. Installation Procedure

1. Clean and prepare all of the welded surface and apply 3M weld-thru coating P/N 05916 or equivalent as necessary.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 3: View Of Tow Hook - Front Courtesy of GENERAL MOTORS CORP. 2. Position the tow hook (1) to the passenger side of the impact bar.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 4: View Of Tow Hook & Impact Bar - Front Courtesy of GENERAL MOTORS CORP. 3. From the right outer edge of the impact bar (2) measure 269 mm (10 5/8 in) to the center of the tow hook (1).

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 5: View Of Welds - Front Courtesy of GENERAL MOTORS CORP. 4. Using a metal inert gas (MIG) welder, weld a 51 mm (2 in) stitch along the tow hook to the impact bar in 4 places (1).  Front  Rear  Inboard side  Outboard side 5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to MY Wednesday, April 01, 2009 1:14:19 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

6. 7. 8. 9.

Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) or Battery Negative Cable Disconnection and Connection (7.0L) . Enable the SIR system. Refer to SIR Disabling and Enabling .

REAR TOW HOOK REPLACEMENT Removal Procedure

1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) or Battery Negative Cable Disconnection and Connection (7.0L) . 3. Remove all related panels and components. 4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 6: View Of Welds - Rear Courtesy of GENERAL MOTORS CORP. 5. Remove the welds (1) attaching the tow hook to the impact bar.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 7: View Of Tow Hook - Rear Courtesy of GENERAL MOTORS CORP. 6. Remove the tow hook (1) from the impact bar. Installation Procedure

1. Clean and prepare all of the welded surface and apply 3M weld-thru coating P/N 05916 or equivalent as necessary.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 8: Positioning Tow Hook - Rear Courtesy of GENERAL MOTORS CORP. 2. Position the tow hook (1) to the center of the impact bar.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 9: View Of Welds - Rear Courtesy of GENERAL MOTORS CORP. 3. Using a metal inert gas (MIG) welder, weld a 51 mm (2 in) stitch along the tow hook to the impact bar in 4 places (1).  Front  Rear  Inboard side  Outboard side 4. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

5. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . 6. Install all related panels and components. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (6.0L) or Battery Negative Cable Disconnection and Connection (7.0L) . 8. Enable the SIR system. Refer to SIR Disabling and Enabling . SKID BAR REPLACEMENT Removal Procedure

1. 2. 3. 4. 5.

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front fascia. Refer to Front Bumper Fascia Replacement . Remove all related panels and components. Support the radiator assembly. Support the skid bar.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 10: View Of Skid Bar Bolts Courtesy of GENERAL MOTORS CORP. 6. Remove the 4 bolts (1) attaching the skid bar to the frame rails. 7. Remove the skid bar. 8. Save all of the brackets, mounting studs, and accessories for transfer to the new skid bar. Installation Procedure

1. Transfer all of the brackets, mounting studs, and accessories to the new skid bar. 2. Position the skid bar to the frame rails.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 11: View Of Skid Bar Bolts Courtesy of GENERAL MOTORS CORP. NOTE:

Refer to Fastener Notice .

3. Install the 4 bolts (1) attaching the skid bar to the frame rails. Tighten: Tighten the bolts to 50 N.m (36 lb ft). 4. Install all related panels and components. 5. Install the front fascia. Refer to Front Bumper Fascia Replacement . 6. Lower the vehicle. MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

FRONT CROSSMEMBER BOLT REPLACEMENT Removal Procedure

Fig. 12: View of Crossmember Nut & Bolt - Front Courtesy of GENERAL MOTORS CORP. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Use hand tools to remove the nut from the bolt that you are replacing. 3. Lower the vehicle. MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

4. Open the hood. 5. Remove the battery heat shield, if removing the right rear bolt only. Refer to Battery Heat Shield Replacement in Engine Electrical.

Fig. 13: View Of Crossmember Bolt & Spring Clip - Front Courtesy of GENERAL MOTORS CORP. MY Wednesday, April 01, 2009 1:14:20 PM

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6. Use snap ring pliers to remove the spring clip. 7. Remove the bolt. Installation Procedure

Fig. 14: View Of Crossmember Bolt & Spring Clip - Front MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Courtesy of GENERAL MOTORS CORP. IMPORTANT: Verify that you have selected a bolt of the proper length. 1. Install the crossmember bolt. 2. Use snap ring pliers to install the spring clip.

Fig. 15: View of Crossmember Nut & Bolt - Front Courtesy of GENERAL MOTORS CORP. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

General Information. NOTE:

Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install a new nut to the crossmember bolt and tighten the nut with hand tools. Tighten: Tighten the nut to 110 N.m (81 lb ft). 5. Lower the vehicle. 6. Install the battery heat shield, if necessary. Refer to Battery Heat Shield Replacement in Engine Electrical. REAR CROSSMEMBER BOLT REPLACEMENT Removal Procedure

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Fig. 16: View Of Crossmember Bolt & Spring Clip - Front Courtesy of GENERAL MOTORS CORP. 1. Use hand tools to remove the nut from the forward bolt that you are replacing. 2. Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement (Convertible) or Rear Compartment Floor Panel Carpet MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Replacement (Coupe) .

Fig. 17: Scribed Marks Labeled XMBR BOLT In The Floor Courtesy of GENERAL MOTORS CORP. 3. Locate the scribed marks labeled XMBR BOLT in the floor which identifies the area directly over the front bolt to be replaced. The scribed marks are located approximately 230 mm (9 in) inward from the rear compartment side panel and 255 mm (10 in) rearward of the intermediate panel.

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Fig. 18: Access Hole Over Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Fuel system components lie under the cargo compartment floor. When drilling the access hole restrict the drilling depth to 6 mm (3/16 in). 4. Drill an access hole with a 50-mm (2-in) hole saw directly over the bolt.

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Fig. 19: Snap Ring & Rear Crossmember Bolt Courtesy of GENERAL MOTORS CORP. 5. Use snap ring pliers to remove the spring clip. 6. Remove the bolt. Installation Procedure

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Fig. 20: Snap Ring & Rear Crossmember Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Verify that you have selected a bolt of the proper length. 1. Install the crossmember bolt. 2. Use snap ring pliers to install the spring clip.

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Fig. 21: View Of Crossmember Bolt & Spring Clip - Front Courtesy of GENERAL MOTORS CORP. NOTE:

Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install a new nut to the crossmember bolt and tighten the nut with hand tools. Tighten: Tighten the nut to 110 N.m (81 lb in).

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Fig. 22: Galvanized Steel Or Fiber Reinforced Plastic Courtesy of GENERAL MOTORS CORP. 4. Cut a suitable piece of galvanized steel or fiber reinforced plastic sized to cover the hole in the floor with at least a 25-mm (1-in) overlap on all sides. IMPORTANT: Fuel system components lie under the cargo compartment floor. Do not use rivets or screws to attach the cover over the hole. 5. Lightly scuff sand the bonding surfaces of both the panel and the cover. 6. Wipe each bonding surface with alcohol. 7. Apply a 3-6 mm (1/8 -1/4 in) bead of adhesive around the perimeter of the cover.

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Fig. 23: Leak Proof Seal Courtesy of GENERAL MOTORS CORP. 8. Install the cover over the hole in the floor. Apply pressure to the cover to squeeze out the adhesive and form a consistent leak-proof seal. IMPORTANT: A leak proof seal is essential so that exhaust and fuel fumes cannot enter the vehicle. 9. Smooth out the adhesive around the cover. Verify that no skips or gaps occur. 10. Allow the bonding adhesive to cure. MY Wednesday, April 01, 2009 1:14:20 PM

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Fig. 24: Rear Compartment Carpet Courtesy of GENERAL MOTORS CORP. 11. Install the rear compartment carpet. Refer to Rear Compartment Floor Panel Carpet Replacement (Convertible) or Rear Compartment Floor Panel Carpet Replacement (Coupe) . FRONT SUSPENSION CROSSMEMBER REPLACEMENT (WITH ZO6)

Tools Required   

J 28467-B Universal Engine Support Fixture J 33432-A Transverse Spring Compressor J 41803 Engine Support Fixture

Removal Procedure

1. Remove the generator from the accessory mounting bracket. Refer to Generator Replacement (6.0L) or Generator Replacement (7.0L) . 2. Install J 41803 and J 28467-B and support the engine. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and MY Wednesday, April 01, 2009 1:14:20 PM

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Installation .

Fig. 25: Inner Tie Rod Assembly, Jam Nut, Outer Tie Rod End Stud Nut, Steering Knuckle & Outer Tie Rod End Courtesy of GENERAL MOTORS CORP. 5. Remove the steering linkage outer tie rod end stud nuts (3). Refer to Rack and Pinion Outer Tie Rod End Replacement . 6. Remove the stabilizer shaft from the vehicle. Refer to Stabilizer Shaft Replacement . 7. Disconnect the intermediate shaft lower coupling from the steering gear. Refer to Intermediate Steering Shaft Replacement . 8. Remove the bolts from the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement . MY Wednesday, April 01, 2009 1:14:20 PM

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9. Support and reposition the EBCM/BPMV and bracket away from the crossmember.

Fig. 26: Power Steering Gear & Crossmember Courtesy of GENERAL MOTORS CORP. 10. 11. 12. 13.

Remove the power steering gear mounting bolts. Remove the power steering fluid cooler from the crossmember. Lift the power steering gear off of the crossmember and support. Remove the engine oil line hose bracket from the crossmember.

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Fig. 27: Leaf Spring Fixture (J 33432-A) Courtesy of GENERAL MOTORS CORP. 14. Using the J 33432-A , remove the transverse spring from the vehicle. Refer to Front Transverse Spring Replacement .

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Fig. 28: Lower Shock Absorber & Bolts Courtesy of GENERAL MOTORS CORP. 15. Disconnect the lower shock absorber bolts from the lower control arms.

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Fig. 29: View Of Lower Control Arms & Bolts Courtesy of GENERAL MOTORS CORP. 16. Remove the lower control arm bolts from the crossmember. 17. Place a transmission jack under the crossmember. 18. Remove the engine mount lower nuts. Refer to the following procedures:  Engine Mount Replacement - Left Side for the 7.0L engine  Engine Mount Replacement - Right Side for the 7.0L engine

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Fig. 30: Locating Wheel Speed Sensor Wiring Harness Courtesy of GENERAL MOTORS CORP. 19. Disconnect the wheel speed sensor wiring harness (1) from the crossmember.

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Fig. 31: Electrical Harness, Brake Pipe & Crossmember Courtesy of GENERAL MOTORS CORP. 20. Disconnect the electrical harness from the clips on the crossmember. 21. Disconnect the brake pipe from the clips on the crossmember.

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Fig. 32: View Of Front & Rear Crossmember Nuts Courtesy of GENERAL MOTORS CORP. 22. Remove the crossmember mounting nuts. 23. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember. Installation Procedure

NOTE:

The magnesium crossmember requires aluminum spacers at all metal contact points. Failure to reinstall these spacers will result in severe corrosion damage.

1. Carefully inspect the magnesium crossmember. Replace any damaged or missing spacers prior to installation. MY Wednesday, April 01, 2009 1:14:20 PM

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 33: View Of Front & Rear Crossmember Nuts Courtesy of GENERAL MOTORS CORP. 2. Raise the crossmember to the vehicle. 1. Align the crossmember dowel pins to the frame rails. 2. Align the engine mount studs. NOTE:

Refer to Fastener Notice .

3. Install new crossmember mounting nuts. Tighten: Tighten the new crossmember mounting nuts to 110 N.m (81 lb ft). 4. Install the engine mount lower nuts. Refer to one of the following procedures: MY Wednesday, April 01, 2009 1:14:20 PM

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Engine Mount Replacement - Left Side for the 7.0L engine Engine Mount Replacement - Right Side for the 7.0L engine

Fig. 34: View Of Wheel Speed Sensor Wiring Harness Retaining Clips Courtesy of GENERAL MOTORS CORP. 5. Fasten the wheel speed sensor wiring harness retaining clips (1) to the crossmember. 6. Fasten the brake pipe to the retaining clips on the crossmember.

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Fig. 35: Electrical Harness, Brake Pipe & Crossmember Courtesy of GENERAL MOTORS CORP. 7. Connect the electrical harness to the clips on the crossmember. 8. Connect the brake pipe to the clips on the crossmember.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 36: Leaf Spring Fixture (J 33432-A) Courtesy of GENERAL MOTORS CORP. 9. Install the transverse spring with the J 33432-A connected, to the crossmember. Refer to Front Transverse Spring Replacement . 10. Install the engine oil line hose bracket to the crossmember.

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2007 Chevrolet Corvette 2007 Accessories & Equipment Frame and Underbody - Corvette

Fig. 37: View Of Lower Control Arm & Bolts Courtesy of GENERAL MOTORS CORP. NOTE:

The magnesium crossmember requires the use of unique lower control arm cam bolts, washers, and aluminum bushing ferrules. Failure to use these specific components during assembly will result in severe corrosion damage.

11. Install the lower control arm to the crossmember. Refer to Lower Control Arm Replacement .

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2007 CHEVROLET CORVETTE Service Repair Manual  
2007 CHEVROLET CORVETTE Service Repair Manual  
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