Cross-Member: Service and Repair

CROSSMEMBER - NO.2

Special Tool(s):

Special Tool(s)

Removal

CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major repair expense. A new part with the same part number must be installed if installation is necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

1. Remove the LH and RH front wheel and tire assemblies.
2. Raise the vehicle.







3. Remove the engine mount nuts.
4. Lower the vehicle.
5. Using the special tool, support the engine.
6. Raise the vehicle.







7. Disconnect the LH and RH stabilizer bar links.
1. Remove the two nuts.
2. Separate the stabilizer bar links from the bar.







8. Remove the LH and RH outer tie rod end nuts.
1. Remove the two cotter pins.
2. Remove the two nuts.







9. Using the special tool, disconnect the LH and RH two tie-rod ends from the front wheel spindles.







10. Remove the bolt and disconnect the intermediate shaft from the steering gear.







11. Remove the nuts and position the steering gear aside.
- Support the steering gear away from the crossmember.







12. Remove the two bolts and position the LH and RH brake hose and brackets assemblies aside.







13. Remove the four bolts and position the LH and RH front brake calipers aside.
- Support the brake calipers away from the crossmember.







14. Position the front LH and RH anti-lock brake system (ABS) harness aside.
1. Release the two ABS harness from the support bracket
2. Remove the two bolts and the brackets.
3. Remove the two harness retainers from the frame.







15. Release the brake line from the retaining clips at the rear of the crossmember.







16. Remove the six LH and RH control lower arm rear mounting bolts.
17. Position a suitable support table under the crossmember.







18. Remove the four LH[ and RH crossmember reinforcement nuts and bolts and separate the reinforcement from the crossmember.







19. Remove the four crossmember bolts.
20. Lower and remove the crossmember assembly.
- Transfer components as necessary.

Installation

1. NOTE: Position the sway bar and the rear bushing plates into place as the crossmember is being raised.

Raise and position the crossmember assembly.







2. Position the LH and RH crossmember bracket.







3. Install the four crossmember bolts.
4. Remove the support table.







5. CAUTION: The bolts must be tightened in the sequence shown, or damage to the crossmember bracket may occur.

Install the LH and RH crossmember bracket nuts and bolts.
1. Tighten the rear bolt.
2. Tighten the front bolt.
3. Tighten the nuts.







6. Install the LH and RH control arm rear mounting bolts.







7. Position the brake line into the retaining clips at the rear of the crossmember.







8. Install the LH and RH ABS harness.
1. Install the two harness retainers into the frame.
2. Install the two brackets and bolts.
3. Install the two ABS harness into the support brackets.







9. Position the LH and RH brake caliper assemblies and install the four bolts.







10. Position the LH and RH brake hose and brackets and install the two bolts.







11. Position the steering gear and install the nuts.







12. Connect the intermediate shaft to the steering gear and install the bolt.







13. Connect the LH and RH front stabilizer bar links.
1. Position the front stabilizer bar.
2. Install the two nuts.







14. Install the LH and RH outer tie-rod ends, nuts and new cotter pins.
15. Lower the vehicle.
16. Remove the special tool from the engine.
17. Raise the vehicle.







18. Install the engine mount nuts.
19. Install the LH and RH front wheel and lire assemblies.