Cross-Member: Service and Repair

*** UPDATED BY TSB #13-01-90

Figure 1.:

SYMPTOM/CONDITION

In the event a steering gear-to-crossmember (K-frame) attaching bolt/nut is cross-threaded or broken during steering gear installation or removal, it is no longer necessary to replace the crossmember (K-frame). Only the damaged bolt/nut need be replaced as described in the following procedure.

PARTS REQUIRED

1 Bolt (35 mm [1 3/8 in. long]) PN 4636780
1 Bolt (45 mm [1 3/4 in. long]) PN 4636781
1 Nut, Flange Head PN 6100518
1 Nut, Washer Assembly PN 6100054

REPAIR PROCEDURE

1. Remove the front crossmember (K-member) and steering gear assembly as described in the Steering or Frame sections.


2. Remove the sway eliminator shaft from the crossmember.


3. Remove the steering gear from the crossmember.



4. Using a 7/16 inch drill bit, enlarge the mounting hole in the crossmember at the location of the cross threaded or broken bolt.

CAUTION:
ATTEMPTS TO LEAVE THE STEERING GEAR ON THE CROSSMEMBER AND DRILLING BOTH PARTS
AT THE SAME TIME, MAY RESULT IN DAMAGE TO THE STEERING GEAR.

5. Using a 7/16 inch drill bit, enlarge the mounting hole in the steering gear at the location of the cross threaded or broken bolt.

Figure 2.:

6. To provide access for installing the new retaining nut at either or both of the two front locations of the crossmember, use a 1 1/2 inch hole saw to cut a hole at the lower center of the crossmember as shown.
Use the template provided to locate the center of the access hole.

If the cross threaded or broken bolt is at either of the rear location it is not necessary to cut an access hole. The replacement nut can be installed through the sway eliminator bar pocket opening.


NOTE:
ACCESS HOLES ARE REQUIRED AT THE FORWARD HOLE LOCATIONS AND ONLY AT THE PROBLEM LOCATION REQUIRING REPAIR.

Access Hole center, Template:

7. Position the steering gear on the crossmember and install new bolts in the positions NOT requiring repairs. Tighten the bolts to 29 N-m (21 ft. lb.) torque. This will locate the steering gear on the crossmember and make the installation of the 10 mm replacement bolt(s) easier.

8. Select and install the proper length replacement bolt(s) as follows:
* If the replacement bolt is on the right (passenger) side, use PN 4636780 (35 mm [ 1 3/8 in.] long).
* If the replacement bolt is on the left (driver's) side, use PN 4636781 (45 mm [ 1 3/4 in.] long).

9. Select and install the proper replacement nut as follows:
* If the original nut is still in the crossmember, use the flange head nut PN 610O518.
* If the original nut is not in the crossmember, use nut/washer assembly PN 6100054.

10. Tighten the replacement bolt to 75 N-m (55 ft. lbs.) torque.

11. Install the sway eliminator shaft as described in the applicable Service Manual.

12. Install the front suspension crossmember assembly as described in the applicable Service Manual Frame and Steering sections.