Removal and Replacement

REMOVAL

1. Open the fuel filler door. Remove the 3 fuel filler neck attaching screws. Remove the fuel filler cap.
2. Raise vehicle on jackstands or centered on a frame contact type hoist. See Maintenance/Vehicle Lifting for the required lifting procedure to be used for this vehicle.
3. Remove both rear wheel and tire assemblies from the vehicle.

Fig. 19:

4. Remove the nut and bolt attaching each of the 4 lateral links to the crossmember (Fig. 19). The bolt for the left front lateral link may not be removed at this time. Remove the nut only. Once the crossmember is lowered, the bolt can be easily removed. (Fig. 19). Notice the forward attaching bolts face rearward.

CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig. 19) to prevent damage to the fuel tank and or fuel tubes in case of an accident. The bolt attaching the left rear lateral link must be installed with the bolt pointing forward to prevent damage to the fuel filler tube.

5. Remove the screw securing the brake tubes to the left stabilizer bar isolator bushing retainer.
6. Remove the 4 bolts attaching both stabilizer bar isolator bushing retainers to the frame rails (the 2 rearward attaching bolts also attach the front corners of the rear suspension crossmember in place). Allow the stabilizer bar to hang down.
7. Remove the parking brake cable tensioner from the intermediate parking brake cable.
8. Remove the parking brake cable tensioner from the left rear parking brake cable.
9. Remove the right rear parking brake cable from the intermediate parking brake cable.

Fig. 20:

10. Remove the retainer clips securing both rear parking brake cables assemblies to the rear suspension crossmember (Fig. 20).
11. Remove parking brake cables from crossmember.

Fig. 21:

12. Remove nuts attaching both brake proportioning valves to the rear corners of the crossmember (Fig. 21).
13. Position a transmission jack under the muffler.
14. Disconnect the hanger securing the exhaust resonator to the rear frame rail.
15. Disconnect the hangers securing the exhaust muffler to the rear suspension crossmember. There is one hanger on each side of the muffler.
16. Lower the transmission jack and muffler enough to allow for better access to the rear cross-member.
17. Remove the screw securing the fuel filler neck to the left frame rail.
18. Remove the final 2 bolts attaching the rear suspension crossmember to the frame rails. These are located at the rear corners of the crossmember (Fig. 21).
19. Lower rear suspension crossmember as low as possible to allow for removal of lateral link attaching bolt at left front corner of crossmember.

CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig. 19) to prevent damage to the fuel tank and or fuel tubes. Also, the bolt attaching the left rear lateral link must be installed with the bolt pointing forward to prevent damage to the fuel filler tube.

20. Remove the link attaching bolt and link from the left front corner of the crossmember.
21. Remove the rear suspension crossmember from the vehicle.

INSTALLATION

1. Install the rear suspension crossmember back into vehicle above muffler. Make sure that the brake tubes are properly routed above the crossmember as it is installed.
2. Install the rear proportioning valve mounting brackets into mounting position at the rear corners of the crossmember (Fig. 21). Install the attaching nuts.
3. Install Intermediate parking brake cable routing clip into place on left front of crossmember (Fig. 20).
4. Reattach left forward lateral link to crossmember. Install mounting bolt though the front of the crossmember mount towards the rear. Do not install and torque nut at this time.

CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig. 19) to prevent damage to the fuel tank and or fuel tubes. Also, when installing the bolt attaching the left rear lateral link, install the bolt pointing forward to prevent damage to the fuel filler tube.

5. Raise the crossmember up against the frame rails. Install, but do not fully tighten, the 2 bolts attaching the rear of the crossmember to the frame rails.
6. Raise the exhaust into place. Reattach the 3 exhaust hangers previously removed from the muffler and resonator.
7. Remove transmission jack supporting muffler and exhaust system.
8. Reinstall the fuel filler neck attaching screw and secure the fuel filler neck to the left frame rail.
9. Position the rear parking brake cables into crossmember alignment holes (Fig. 20).
10. Install the retainer clips securing both rear parking brake cables assemblies to the rear suspension crossmember (Fig. 20).
11. Reconnect the right rear parking brake cable to the intermediate parking brake cable.
12. Install the parking brake cable tensioner to the left rear parking brake cable.
13. Install the parking brake cable tensioner to the intermediate parking brake cable.
14. Install the 4 bolts attaching both stabilizer bar isolator bushing retainers to the frame rails (the 2 rearward attaching bolts attach the front corners of the rear suspension crossmember in place). Tighten the forward stabilizer bar isolator bushing retainer attaching bolts to 40 N.m (30 ft.lbs.). Tighten the 2 rearward stabilizer bar isolator bushing retainer attaching bolts (which also serve as the front cross-member attaching bolts) to 100 N.m (75 ft.lbs.).
15. Tighten the rear suspension crossmember rear attaching bolts to 100 N.m (75 ft.lbs.).
16. Install the screw securing the brake tubes to the left stabilizer bar isolator bushing retainer.
17. Install the remaining 3 lateral links to the rear suspension crossmember. The forward lateral arm mounting bolts must point rearward, and the rearward lateral arm mounting bolts must point forward.

CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig. 19) to prevent damage to the fuel tank and or fuel tubes. The bolt attaching the left rear lateral link must be installed with the bolt pointing forward to prevent damage to the fuel filler tube.

18. Install the lateral link attaching nuts, but DO NOT fully tighten at this time.

CAUTION: Tightening the lateral link attaching bolts at this time will cause the bushings contort at curb riding height, leading to premature failure of the bushings. Tighten bolts only when vehicle is at curb riding height.

19. Install wheel and tire assemblies on vehicle.
20. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 N.m (95 ft.lbs.).
21. Lower vehicle to the ground.
22. Install the 3 fuel filler neck attaching screws. Reinstall the fuel filler cap.
23. Tighten all 4 lateral arm to crossmember attaching bolt and nut assemblies to 95 N.m (70 ft.lbs.).
24. Check and reset rear wheel TOE to specifications if required.