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Home arrow Technical arrow Install Instructions arrow Installation Instructions for the SPS 1991+ S-Series Suspension Bushings
Installation Instructions for the SPS 1991+ S-Series Suspension Bushings PDF Print E-mail
Installation Instructions

 

Please take a few minutes to read through these instructions in their entirety BEFORE you start to modify your Saturn. Remember: careful planning and preparation will make your install experience educational and painless.

 

Suspension Bushing Kit Preparation

 

1. Make sure that you have all the parts listed below before you attempt this installation! Contact SPS immediately if you have questions or concerns regarding part quantities or part numbers.

 

PART DESCRIPTIONPART #QTY
Front Suspension Bushings:
Front LCA Inner Bushing 3398
2463
3397
2
2
2
Front Stabilizer Bar to LCA Bushing 7110
7109
2
2
Front Stabilizer Bar to Frame Bushing 5620 2
Rear Suspension Bushings:
Rear Trailing Link to Body Bushing 3390 2
Rear Trailing Link to Knuckle Bushing 8256 4
Lateral Link Bushing 3389 16
Inner Sleeves for Lateral Link Bushing 8
Rear Stabilizer Bar to Crossmember Bushing for 15mm bar 5575 2
Bushing Lubricant 1

 

Vehicle Preparation and Support

 

1. Loosen the lug nuts of the road wheels using a 19mm socket and place the entire vehicle on jackstands. Be sure that the car is firmly supported before going ANY further with this installation!

2. Remove tires and wheels.

 

Front Suspension Link Removal

 

1. Remove front lower control arm as below:

 

  • If your vehicle has ABS, be careful not to damage ABS speed sensor ring on halfshaft.
  • Remove and discard lower control arm ball stud cotter pin (at connection to knuckle).
  • Loosen lower control arm ball stud castle nut, until top of castle nut is level with top of ball stud.
  • Separate lower control arm from knuckle. (Do NOT use wedge type ball joint removal tool as boot may be damaged.)
  • Remove lower front inner fender splash shield (2 push pins and 3 molded clips, remove front section first on left side and rear section first on right side).
  • Remove the lower control arm to cradle fastener.
  • Remove the tension strut (front stabilizer bar) nut at lower control arm.
  • Remove lower control arm from vehicle
  •  

    2. Remove front stabilizer bar to cradle mounting bracket fasteners and remove stabilizer bar assembly from vehicle.

     

  • Be sure to mark left/right sides of stabilizer bar for proper re-installation later.
  •  

    Rear Suspension Link Removal

     

    1. Remove trailing link assembly:

     

  • Remove trailing arm to knuckle fastening nut.
  • Remove two trailing arm to body fasteners.
  • Slide trailing arm from knuckle and remove from vehicle
  •  

    2. Remove lateral links:

     

  • Remove the long bolt holding the two lateral links to knuckle.
  • Before proceeding, be sure to note the locating holes on both the left and right side of the crossmember. There is a slot in the crossmember over a hole in the body rail. Using a paint pen or similar implement, mark the location of the body holes within the crossmember slot to insure proper alignment of your rear suspension/crossmember after installation.
  • Loosen and remove the two forward bolts holding the crossmember to the chassis. DO NOT DISCARD!
  • Loosen, but DO NOT remove the two rear crossmember bolts. Loosen only enough to allow the crossmember to swing down to gain access to the forward lateral link pivot bolt. Be sure that the brake lines do not bind or stretch during this procedure.
  • Remove the lateral link inboard bolts holding the lateral links to the crossmember.
  • Remove the lateral links from vehicle.
  •  

    Replace Bushings in Front Suspension Links

     

    Some things to keep in mind before you start this section:

     

  • Pressing bushings in or out takes a significant amount of force and completing these steps successfully will require access to a shop or arbor press. At SPS, we use a 20-ton hydraulic shop press.
  • Whether pressing a bushing in or out, always make sure that the part is properly supported on the bottom. Always fully support the rubber or the suspension link around the entire circumference. If you see the parts slipping as you press down, or if you feel the parts binding up, stop and check your setup before continuing. 
  •  

    1 Replace bushings in front lower control arm:

     

  • Remove the stabilizer bar end bushings and discard. (You may need to cut out one side of the bushing and then you can easily remove the other side.)
  • ***Do not damage (or discard) the inner sleeve from the inner bushing as you must reuse it!
  • ***Do not remove or destroy the outer can (metal shell) that contains the inner bushing!
  • Remove the inner bushing from the control arm, leaving the outer can in place and saving the inner sleeve. (Support the control arm inner bushing outer shell from the bottom side, then first press the inner sleeve out, then press the rubber out.)
  • Clean inside of outer can thoroughly to remove any old bushing material.
  • Clean inner sleeve of any rubber residue.
  • Apply the supplied grease to all surfaces of bushing that contact metal and insert pivot bushings part numbers 3397, 2463, & 3398 as shown in diagram. Then, support bushing pieces from the bottom and press in inner sleeve.
  • Lubricate end of stabilizer bar strut rod and control arm at stabilizer bar mount, Install bushing part number 7109 & 7110 and loosely assemble.
  • Lubricate the outside flange of the inner pivot bushings.
  • Lubricate inner diameter of bushings before installing on stabilizer bar.
  • Install new bushings with slits facing toward the front of the vehicle.
  • Locate new bushings in same location as old bushings.  
  •  

    Replace Bushings in Rear Suspension Links

     

    Please see comments in the previous section regarding pressing bushings in or out.

     

    1. Replace bushings in trailing link:

     

  • Remove the rubber strut rod bushings from the knuckle and discard.
  • Press out the pivot pin from the bushing by fully supporting the bushing and link on the bottom side and pressing the pin through from the top. DO NOT DISCARD the pivot pin. Modify one end with rounded taper as shown in picture. Smooth off sharp edges and save for re-assembly.
  • Remove rubber bushing from link by supporting link on the bottom end and pressing rubber through from the top. Clean all surfaces of rust and rubber.
  • Lubricate new bushing and press into strut rod using the tapered end as the leading edge. Support the link on the bottom and press new bushing in from the top.
  • Lubricate inside diameter of bushing and insert pin, the end with the new modified rounded taper with smooth edges first.
  •  

    2. Replace bushings in lateral links:

     

  • Press lateral link bushings out of lateral links. Support link on the bottom and press out rubber and inner bushings sleeves from above.
  • Clean all surfaces free from rust and rubber.
  • Apply the supplied grease to the inner diameter of the lateral link, install bushing part number 3389 (four pieces total per link), lubricate inside diameter of bushing and install sleeve. Note: there are two different sleeves for these links; each link will receive one each of these sleeves. The differences are in the inside diameter of the sleeve, .563" I.D. for the outer bushings to knuckle, versus .500” I.D. for the inner bushings to crossmember. 
  •  

    Front Suspension Link Installation

     

    1. You should now have a loose assembly of the stabilizer bar with lower control arms.

    2. Position lower control arm inner attachments to cradle (do not install fasteners yet).

    3. Install stabilizer bar brackets to cradle. Use Loctite 242 (Blue Medium Strength) and loosely assemble.

    4. Loosely assemble lower control arm inner bushing fasteners on both sides.

    5. Tighten the following to the specified torque on BOTH sides of the vehicle:

    Stabilizer bar to cradle 140N-m (103ft-lbs)
    Lower control control arm to cradle 125N-m (92ft-lbs) if tightening bolt
    100N-m (74ft-lbs) if tightening nut
    Stabilizer bar to lower control arm 144N-m (106ft-lbs)

    6. Install ball stud into steering knuckle.

     

  • Torque castle nut, 75 N-m (55 ft-lbs)
  • If it is necessary to rotate the castle nut after tightening to orient it to the hole in the stud, always tighten the nut to align it, NEVER loosen it.
  • Install cotter pin and bend.
  •  

    7. Install body shields.

     

    Rear Suspension Link Installation

     

    1. Install lateral links into vehicle:

     

  • Lubricate the outside faces of the bolts and loosely assemble lateral links into the crossmember.
  • Lifting the crossmember back into position, loosely assemble the bolts that hold it to the body but DO NOT tighten.
  • Referring to the crossmember alignment holes, re align to the marks previously made and hand tighten.
  • Install the lateral links to the knuckle and tighten all hardware at knuckle and crossmember. This includes one bolt at the lateral links to knuckle, and two bolts at the lateral links to crossmember on each side.
  • Torque the following fasteners to specification:
  • Rear Crossmember to Body 120 N-m (89 ft-lbs)
    Lateral Link Inner Bolt to Crossmember 120 N-m (89 ft-lbs)
    Lateral Link Outer Bolt to Knuckle 165 N-m (122 ft-lbs)

    2. Install trailing links into vehicle:

  • Lubricate inside diameter of trailing link to knuckle bushing and insert link through knuckle.
  • Assemble second bushing, washer and nut. The cupped end of the washer should face outward.
  • Assemble front of rod to body and tighten all hardware
  • Torque the following fasteners to specification:
  • Trailing Link to Body 120N-m (89 ft-lbs)
    Trailing Link to Rear Knuckle 100 N-m (74 ft-lbs)

     

    Replace rear stabilizer to crossmember bushings:

     

    1. Remove stabilizer bar to crossmember fasteners.

    2. Remove and discard rubber bushings.

    3. Lubricate and install new poly bushings. Simply open bushing at slit and slide over the stabilizer bar at its intended location on the bar.

    4. Install stabilizer bar to crossmember, torque to 55 N-m (41 ft-lbs).

     

    Vehicle Wrap-Up and Road Test

     

    1. Re-install all tires and wheels.

    2. Raise the entire vehicle and remove jackstands. Torque the lug nuts to 140 Nm (103 ft-lb) using a 19mm socket. Re-install any hubcaps or wheel covers also using a 19mm socket.

    3. The suspension may require alignment for toe and camber. Please have the vehicle aligned to your specifications to maintain handling characteristics and to prevent uneven tire wear.

    4. Road test the vehicle to confirm proper function of the brakes. USE CAUTION THE FIRST TIME YOU DRIVE YOUR CAR AFTER MODIFICATION TO ENSURE THE PROPER FUNCTION OF ALL VEHICLE SYSTEMS!

     

     
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