Front Cross-Member: Service and Repair

CROSSMEMBER

REMOVAL AND INSTALLATION

CAUTION:
^ Before removing the steering wheel and air bag module assembly, always refer to Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this, the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious injury.
^ *1: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.
^ *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.

Pre-removal & Post-installation Operation:

Removal Steps 1-16:

Removal Steps 17-20 & Required Special Tool:

REMOVAL SERVICE POINTS
[[A]] STEERING COLUMN ASSEMBLY AND STEERING GEAR DISCONNECTION





Pinch the steering column shaft clip with pliers, and pull up the shaft in the direction shown to disengage the steering column assembly.





NOTE: If the steering column shaft is removed accidentally, remove the steering column assembly and be sure to insert the steering column shaft into the steering column as shown in the figure.

[[B]] JAM NUTS (CONNECTION FOR TIE ROD END AND LOWER ARM BALL JOINT) REMOVAL

CAUTION:
^ Do not remove the nut from ball joint. Loosen it and use special tool MB991897 to avoid possible damage to ball joint threads.
^ Hang special tool MB991897 with a cord to prevent it from falling.





1. Replace the jam nut for lower arm ball joint with a regular nut, because the original one is a little bit large to install special tool MB991897. Install special tool MB991897 as shown in the figure.





2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.

3. Tighten the bolt with a wrench to disconnect the lower arm ball joint, tie rod end and remove the jam nut.

[[C]] FRONT AXLE CROSSMEMBER STOPPER REMOVAL





The crossmember mounting bolts need not be unscrewed when the front axle crossmember stopper is replaced. However, the bolts may become loosened when the front axle crossmember stopper is removed. Retighten the bolts to 180 ± 20 Nm (133 ± 15 ft. lbs.).

[[D]] FRONT AXLE CROSSMEMBER STAY REMOVAL





The crossmember mounting bolts need not be unscrewed when the front axle crossmember stay is replaced. However, the bolts may become loosened when the front axle crossmember stay is removed. Retighten the bolts to 180 ± 20 Nm (133 ± 15 ft. lbs.).

[[E]] ENGINE REAR ROLL STOPPER BRACKET, POWER STEERING GEAR AND LINKAGE, STABILIZER BAR AND FRONT AXLE NO.1 CROSSMEMBER ASSEMBLY REMOVAL





Support the front axle number 1 crossmember with a transmission jack, and then remove the crossmember mounting nuts and bolts.

INSTALLATION SERVICE POINTS
]]A[[ STABILIZER BAR INSTALLATION





Align the stabilizer bar identification mark with the right end of the bushing (LH).

]]B[[ POWER STEERING GEAR BRACKET/ENGINE REAR ROLL STOPPER BRACKET INSTALLATION





Tighten the bolts in the following sequence:
1. Tighten bolt A and then tighten bolt B.
2. Tighten bolts E finger tight.
3. Tighten bolt C and then tighten bolts D.
4. Tighten bolts E and then tighten bolt F.

]]C[[ ENGINE REAR ROLL STOPPER BRACKET, POWER STEERING GEAR AND LINKAGE, STABILIZER BAR AND FRONT AXLE NO.1 CROSSMEMBER ASSEMBLY INSTALLATION





Align the steering column dash panel cover notch (arrow A) with the steering gear lug (arrow B), and install the engine rear roll stopper bracket, power steering gear and linkage, stabilizer bar and front axle number 1 crossmember assembly.

]]D[[ FRONT AXLE CROSSMEMBER STAY/JAM NUTS INSTALLATION





Ensure that the crossmember mounting bolts have been tightened to 180 ± 20 Nm (133 ± 15 ft. lbs.), and then install the front crossmember stay with the jam nut.

]]E[[ FRONT AXLE CROSSMEMBER STOPPER/JAM NUTS INSTALLATION





Ensure that the crossmember mounting bolts have been tightened to 180 ± 20 Nm (133 ± 15 ft. lbs.), and then install the front crossmember stopper with the jam nut.

INSPECTION
^ Check the crossmembers for cracks or damage.