In this study, we present a sustainable, sensor-assisted method for relieving residual stress in interference-fitted metal components, integrating press-fitting and vibratory stress relief at the component’s natural frequency. The process is structured into four stages: (1) initial residual stress and geometric alignment assessment via X-ray diffraction (XRD) and alignment sensors, (2) the identification of the workpiece’s resonant frequency using a vibration analyzer, (3) the application of controlled resonant excitation to induce stress relaxation, and (4) the re-evaluation of residual stress and perpendicularity after treatment. Experimental results demonstrated effective stress redistribution, resulting in a significant reduction in residual stress and improved dimensional stability, particularly at higher interference strains. The integrated use of vibration sensing and XRD confirmed microstructural recovery through reduced full width at half maximum values of diffraction peaks, which means the reduction in dislocation density. This nondestructive, energy-efficient approach supports sustainable manufacturing by enhancing product reliability without material removal.