Rear Cross-Member: Service and Repair
REAR CROSSMEMBERREMOVAL
1. Disconnect and isolate battery negative cable from battery post.
2. 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. Access and remove both rear hub and bearing assemblies.
8. 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:
9. Slide left rear parking brake cable button inboard and remove from equalizer (Fig. 56).
10. 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:
11. Remove screw mounting left rear brake hose routing bracket to front of rear crossmember (Fig. 57). Tie brake hose off to side, away from crossmember.
12. Remove screw mounting right rear brake hose routing bracket to front of rear crossmember (Fig. 57). Tie brake hose off to side, away from crossmember.
13. If equipped with AWD, remove rear driveline module and both rear half shafts.
Fig. 58:
14. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon (Fig. 58). Do not use a scratch awl to mark location.
15. Position under-hoist utility jack or transmission jack under center of rear suspension crossmember. Raise jack head to contact suspension crossmember and secure crossmember to jack.
Fig. 59:
16. Remove lower mounting bolt and nut at each rear shock absorber (Fig. 59).
Fig. 60:
17. 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.
18. 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:
19. Remove coil spring and isolator (Fig. 61), lower end first.
20. 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.
21. 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.
22. 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.
23. Remove coil spring and isolator (Fig. 61), lower end first.
24. Raise right side of crossmember back into mounted position. It is not necessary to install mounting bolts.
25. Remove both front and rear crossmember mounting bolts previously removed on left side of crossmember (Fig. 60).
26. 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.
27. Continue to lower jack until crossmember is at a comfortable working level.
Fig. 62:
28. Remove bolt and nut fastening stabilizer bar to each stabilizer link (Fig. 62).
29. Remove bolts fastening each stabilizer bar cushion retainer to crossmember (Fig. 62).
30. Remove stabilizer bar with cushions and retainers from crossmember.
NOTE: For installation purposes, when removing link fasteners, it important to note which bolt fastens what component and in what direction each fastener is installed in.
31. Perform following to each side of rear suspension:
Fig. 63:
a. Place a 13 mm 12-point box wrench over cable retainer on end of cable housing at crossmember and collapse retainer fingers (Fig. 63). Remove cable from crossmember.
Fig. 64:
b. Remove bolt and nut fastening spring link to crossmember (Fig. 64).
Fig. 65:
Fig. 66:
c. While holding toe adjustment cam bolt from rotating (Fig. 65), remove nut securing toe link at crossmember (Fig. 66). Remove link from cam bolt, then remove cam bolt and washer from crossmember.
Fig. 67:
d. Remove bolt and nut mounting compression link to crossmember (Fig. 67).
Fig. 68:
e. Remove nut and bolt mounting tension link to crossmember (Fig. 68).
f. Remove nut and bolt mounting camber link to crossmember (Fig. 68).
g. Carefully lift knuckle with links and parking brake cable attached as an assembly from rear suspension crossmember.
32. If necessary, remove ABS wheel speed sensor routing clips from crossmember.
33. Remove crossmember from jack head.
INSTALLATION
1. Install crossmember on jack head in the same position in which it was removed and secure in place.
2. If necessary, install ABS wheel speed sensor routing clips in crossmember.
3. Perform following to each side of rear suspension:
a. Carefully place knuckle with links and parking brake cable attached as an assembly into mounting position on rear suspension crossmember.
Fig. 69:
b. Install bolt and nut mounting camber link to crossmember (Fig. 69). Do not tighten at this time.
c. Install bolt and nut mounting tension link to crossmember (Fig. 69). Do not tighten at this time.
Fig. 70:
d. Install bolt and nut mounting compression link to crossmember (Fig. 70).
Fig. 71:
Fig. 72:
e. Slide toe adjustment cam bolt through rear crossmember from front and place cam washer over threads on rear. Place eccentric on head of bolt upward to 12 O'clock position. Install toe link over end of bolt and install nut. While holding cam bolt from rotating (Fig. 71), install nut securing toe link to crossmember (Fig. 72). Do not fully tighten at this time.
Fig. 73:
f. Install bolt and nut fastening spring link to crossmember (Fig. 73). Do not tighten at this time.
g. Set current-side of rear suspension to curb height using following tools:
Fig. 74:
I. Place Receiver, Special Tool 9031-3, cup-side-down over top of crossmember rear mount bushing (Fig. 74).
II. Place Curb Height Gage, Special Tool 9094, into shock absorber pocket in spring link and opposite end of tool over Receiver, Special Tool 9031-3 (Fig. 74).
III. Install bolt through crossmember rear mount bushing, Receiver, Special Tool 9031-3, and Curb Height Gage, Special Tool 9094. Install wing nut, hand tightening tools in place (Fig. 74).
IV. Move spring link up or down as necessary aligning lower shock bolt mounting hole with Curb Height Gage hole, then insert pin through both (Fig. 74).
h. Tighten link fasteners at crossmember to following specifications:
- Camber Link bolt - 68 N.m (50 ft.lbs.) torque (Fig. 69).
- Compression Link bolt - 68 N.m (50 ft.lbs.) torque (Fig. 70).
- Spring Link bolt - 129 N.m (95 ft.lbs.) torque (Fig. 73).
- Tension Link bolt - 68 N.m (50 ft.lbs.) torque (Fig. 69).
- Toe Link nut - 172 N.m (127 ft.lbs.) torque (Fig. 72).
i. Remove special tools.
j. Install end of parking brake cable into mounting hole in crossmember. Slide cable retainer on end of cable housing into hole until retainer fingers click into place.
4. Install stabilizer bar with cushions and retainers on crossmember.
Fig. 75:
5. Install cushion retainer mounting bolts (Fig. 75). Do not tighten at this time.
6. Install bolt and nut fastening stabilizer bar to each stabilizer link (Fig. 75). Do not tighten at this time.
7. Tighten cushion retainer mounting bolts to 61 N.m (45 ft.lbs.) torque.
8. Raise crossmember to body mounting points. As crossmember is raised, align shocks with pockets in spring links.
Fig. 76:
9. Continue to raise crossmember with jack until crossmember mounting bolts can be installed. Install left side crossmember mounting bolts, but not the right side bolts (Fig. 76). 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.
10. 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.
Fig. 77:
11. Install coil spring and isolator (Fig. 77), top end first.
NOTE: Verify that spring lower end coil is correctly placed against abutment built into spring link.
12. 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.
Fig. 78:
13. Install lower shock mounting bolt (Fig. 78). Do not tighten at this time.
14. Raise right side of crossmember into mounted position. Install right side crossmember mounting bolts (Fig. 76). Do not fully tighten bolts at this time.
15. Remove both front and rear crossmember mounting bolts on left side of vehicle (Fig. 76).
CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring.
16. 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.
17. Install coil spring and isolator (Fig. 77), top end first.
NOTE: Verify that spring lower end coil is correctly placed against abutment built into spring link.
18. 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.
19. Install lower shock mounting bolt (Fig. 78). Do not tighten at this time.
20. Raise left side of crossmember into mounted position and install previously removed mounting bolts (Fig. 76). Do not fully tighten bolts at this time.
Fig. 79:
21. Shift crossmember as necessary to line up mounts with location marks drawn in before removal (Fig. 79).
Fig. 80:
NOTE: If proper location marks are unavailable or as a check, the crossmember can be positioned utilizing the PLP points. Shift the crossmember as necessary to achieve the measured distances shown in the figure (Fig. 80).
22. Once mounts are lined up with location marks, tighten all four crossmember mounting bolts to 163 N.m (120 ft.lbs.) torque.
23. Tighten shock absorber lower mounting bolts to 102 N.m (75 ft.lbs.) torque.
24. Remove jack from under crossmember.
25. If equipped with AWD, install rear driveline module and both rear half shafts.
Fig. 81:
26. Install screw mounting right rear brake hose routing bracket to front of rear crossmember (Fig. 81).
27. Install screw mounting left rear brake hose routing bracket to front of rear crossmember (Fig. 81).
Fig. 82:
28. 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. 82). Release cables allowing button to seat. It may take some hand pressure to completely seat button.
29. Place left rear parking brake cable button into equalizer (Fig. 82). Release cables allowing button to seat. It may take some hand pressure to completely seat button.
30. Install rear half of exhaust system.
31. Install both hub and bearings with wheel speed sensors as well as all components necessary to access them.
32. Install tire and wheel assemblies. Tighten wheel mounting nuts to 135 N.m (100 ft.lbs.) torque.
33. Lower vehicle.
34. Unlock automatic adjuster in parking brake lever.
35. Connect battery negative cable to battery post.
36. Install spare tire under vehicle.
37. Position vehicle on alignment rack/drive-on hoist. Raise vehicle as necessary to access mounting bolts.
38. Tighten stabilizer link fasteners to 61 N.m (45 ft.lbs.) torque.
39. Perform wheel alignment.