Rear Crossmember Bushing - Rear Mount

REAR CROSSMEMBER BUSHING - REAR MOUNT

REMOVAL

1. Disconnect and isolate battery negative cable from battery post.
2. If vehicle is not equipped with All Wheel Drive (AWD), remove spare tire.
3. Lock out automatic adjuster in parking brake lever.
4. Raise and support vehicle. Refer to Vehicle Lifting.
5. Position an extra pair of jack stands under and support forward end of engine cradle to help stabilize vehicle during rear suspension removal/installation.
6. Remove both rear wheel and tire assemblies.
7. Remove rear half of exhaust system.

NOTE: It may be necessary to back off parking brake shoe adjustment to allow sufficient slack to disengage cable buttons from connectors in following two steps.

Fig. 56:

8. Slide left rear parking brake cable button inboard and remove from equalizer (Fig. 56).
9. While holding parking brake cable connector on end of front cable secure with a pair of pliers at the front cable button, slide right rear parking brake cable button inboard and remove from cable connector (Fig. 56).

Fig. 57:

10. Remove screw mounting left rear brake hose routing bracket to front of rear crossmember (Fig. 57).
11. Remove screw mounting right rear brake hose routing bracket to front of rear crossmember (Fig. 57).

NOTE: In some cases, it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle. This can usually be accomplished before guide pin bolts are removed, by grasping rear of caliper and pulling outward working with guide pins, thus retracting piston. Never push on piston directly as it may get damaged.

12. Remove each rear caliper from its mount and support as follows:

Fig. 83:

a. Remove two caliper guide pin bolts (Fig. 83).

Fig. 84:

b. Remove caliper assembly from brake adapter by first rotating bottom of caliper away from rotor, then lifting caliper (with shoes) away from upper adapter abutment (Fig. 84).

Fig. 85:

c. To prevent weight of caliper from overextending and damaging brake hose and tubing while caliper is off mount, hang brake caliper from vehicle using wire or cord (Fig. 85). Be sure to hang caliper and brake hose far enough forward on body, away from crossmember, to allow sufficient room to lower crossmember without interference.

Fig. 86:

13. Disconnect vehicle wiring harness from each rear wheel speed sensor connector (Fig. 86).
14. Unclip each rear wheel speed sensor connector from spare tire mounting support (Fig. 86).
15. If equipped with AWD:

a. Reference mark propeller shaft-to-rear driveline module input flange connection.
b. Remove three propeller shaft-to-rear driveline module mounting bolts. Do not attempt removal of shaft from module at this time due to alignment pin interference. Removal happens as crossmember is lowered in a later step.

Fig. 93:

16. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon (Fig. 93). Do not use a scratch awl to mark location.

Fig. 87:

17. Position under-hoist utility jack or transmission jack under center of rear suspension crossmember (without AWD) or rear driveline module (with AWD) (Fig. 87). Raise jack head to contact driveline module/suspension crossmember and secure in place.

Fig. 59:

18. Remove lower mounting bolt and nut at each rear shock absorber (Fig. 59).

Fig. 60:

19. Remove both front and rear crossmember mounting bolts on left side of vehicle (Fig. 60).

CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to remove coil spring.

20. Slowly lower jack allowing left side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring removal. Do not lower jack any further than necessary.

Fig. 61:

21. Remove coil spring and isolator (Fig. 61), lower end first.
22. Raise left side of crossmember back into mounted position and install previously removed mounting bolts. It is not necessary to tighten bolts at this point.
23. Remove both front and rear crossmember mounting bolts on right side of vehicle (Fig. 60).

CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to remove coil spring.

24. Slowly lower jack allowing right side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring removal. Do not lower jack any further than necessary.
25. Remove coil spring and isolator (Fig. 61), lower end first.
26. Raise right side of crossmember back into mounted position. It is not necessary to install mounting bolts.
27. Remove both front and rear crossmember mounting bolts previously removed on left side of crossmember (Fig. 60).
28. Slowly lower jack. Do not lower jack at a fast rate. As jack is lowered, remove propeller shaft from alignment pin on end of rear driveline module input flange and support it with a bungee or cord, keeping it at its normal height. Do not allow propeller shaft to hang on its own.
29. Continue to lower jack until rear suspension module is at a comfortable working level.
30. Remove rear suspension module from jack.
31. Turn rear suspension module upside down and place on appropriate working surface.
32. As an installation reference, carefully mark location of bushing requiring removal on crossmember using a marker or crayon (Fig. 93). Do not use a scratch awl to mark location.

Fig. 94:

33. Assemble tools over bushing as shown (remember crossmember is upside-down) (Fig. 94). Ensure Receiver straddles can flange on bushing.
34. Tighten Press screw-drive, pressing bushing out of crossmember.

INSTALLATION

CAUTION: It is very important that bushing be installed in same position as original to maintain vehicle ride quality and bushing longevity. That is why bushing, once installed, needs closely match reference marks applied upon removal of original bushing.

1. Position bushing over crossmember bushing bore aligning bushing can flange with reference marks applied during removal.

Fig. 95:

Fig. 96:

2. Assemble tools over bushing and crossmember as shown (remember crossmember is upside-down)(Fig. 95). Ensure Installer, Special Tool 9031-4, is positioned to match cutout with can flange on bushing (Fig. 96).
3. Using hand tools, tighten Press screw-drive, pressing bushing into crossmember. Install bushing until bushing can flange contacts surface of crossmember.
4. Remove tools.
5. Verify bushing closely lines up with reference marks applied during removal.
6. Turn rear suspension module right-side-up and center it on jack in same position as upon removal. Secure crossmember to jack.
7. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft onto alignment pin on end of rear driveline module input flange and align shocks with pockets in spring links.
8. Continue to raise crossmember with jack until two crossmember mounting bolts can be installed (Fig. 60). Install left side crossmember mounting bolts, but not the right side bolts (Fig. 60). It is not necessary to tighten bolts at this point.

CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring.

9. Slowly lower jack allowing right side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring Installation. Do not lower jack any further than necessary.
10. Install coil spring and isolator (Fig. 61), top end first.

NOTE: Verify spring lower end coil is correctly placed against abutment built into spring link.

11. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
12. Install lower shock mounting bolt (Fig. 59). Do not tighten at this time.
13. Raise right side of crossmember into mounted position. Install right side crossmember mounting bolts (Fig. 60). Snug, but do not fully tighten bolts at this time.
14. Remove both front and rear crossmember mounting bolts on left side of vehicle (Fig. 60).

CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring.

15. Slowly lower jack allowing left side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring installation. Do not lower jack any further than necessary.
16. Install coil spring and isolator (Fig. 61), top end first.

NOTE: Verify spring lower end coil is correctly placed against abutment built into spring link.

17. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
18. Install lower shock mounting bolt (Fig. 59). Do not tighten at this time.
19. Raise left side of crossmember into mounted position and install previously removed mounting bolts (Fig. 60). Snug, but do not fully tighten bolts at this time.
20. Shift crossmember as necessary to line up mounts with location marks drawn in before removal (Fig. 93).
21. Once mounts are lined up with location marks, tighten all four crossmember mounting bolts to 163 N.m (120 ft.lbs.) torque.
22. Tighten shock absorber lower mounting bolts to 102 N.m (75 ft.lbs.) torque.
23. Remove jack from under rear driveline module/crossmember.
24. If equipped with AWD, line up location reference marks and install propeller shaft-to-rear driveline module mounting bolts. Tighten mounting bolts to 54 N.m (40 ft.lbs.) torque.
25. Clip each wheel speed sensor connector to spare tire mounting support (Fig. 86).
26. Connect vehicle wiring harness to each wheel speed sensor connector (Fig. 86).
27. Install each rear brake caliper on its mount as follows:

a. Make sure abutment shims are in place on both slide abutments of caliper adapter.

CAUTION: Use care when installing brake caliper onto adapter so guide pin bushings and sleeves do not get damaged by mounting bosses on adapter.

b. Retract caliper guide pins to clear mounting bosses on caliper adapter when installing caliper.
c. Install brake caliper in opposite way it was removed. Starting with upper end, carefully position caliper and brake shoes over brake rotor and align outboard shoe's upper edge with caliper slide abutment. Rotate lower end of caliper into mounting position on adapter.

CAUTION: Extreme caution should be taken not to cross thread caliper guide pin bolts when they are installed.

d. Carefully install caliper guide pin bolts (Fig. 83). Tighten bolts to 22 N.m (192 in.lbs.) torque.

28. Install screw mounting right rear brake hose routing bracket to front of rear crossmember (Fig. 57).
29. Install screw mounting left rear brake hose routing bracket to front of rear crossmember (Fig. 57).
30. While holding cable connector on end of front cable secure with a pair of pliers at the front cable button, Place right rear cable button into cable connector (Fig. 56). Release cables allowing button to seat. It may take some hand pressure to completely seat button.
31. Place left rear parking brake cable button into equalizer (Fig. 56). Release cables allowing button to seat. It may take some hand pressure to completely seat button.
32. Install rear half of exhaust system.
33. Install tire and wheel assemblies. Tighten wheel mounting nuts to 135 N.m (100 ft.lbs.) torque.
34. Lower vehicle.
35. Unlock automatic adjuster in parking brake lever.
36. Connect battery negative cable to battery post.
37. If vehicle is not equipped with All Wheel Drive (AWD), Install spare tire under vehicle.
38. Perform wheel alignment.