A. Inspect For Frame Cracking
Service Procedure1. Place vehicle over a hoist.
2. Disconnect and remove battery, and the battery tray.
3. Disconnect the Powertrain Control Module (PCM) connector.
4. Either remove the cap on the overflow reservoir (sealed system) or loosen the radiator cap to depressurize the cooling system. Disconnect the overflow tube from the radiator if required.
WARNING:
Do not remove the radiator cap with the system hot and pressurized. Serious burns from the coolant can occur.
NOTE:
If radiator cap is removed to depressurize system, retighten cap or loss of coolant will occur.
5. Remove the upper radiator support cross member (Fig 1). Scribe prior to removal to keep clearance between the hood and the Grill Opening Panel (GOP) the same during reassembly (Do not remove torx screws from upper support bracket). Remove nuts on GOP to upper support bracket to maintain clearance (Fig. 2).
6. Remove the fan assembly. It is not necessary to remove the left (passenger side) fan shroud at this time. Unbolt the power steering reservoir on models equipped with the 2.5L engine.
7. Remove the front marker lamps, parking lamps, headlamp bezels and disconnect temperature sensor wire (if equipped).
8. Remove the fog lamps (if equipped).
9. Remove the air cleaner cover, filter, and air cleaner housing. This is necessary in order to gain access to release the wiring harness connector behind the left (passenger side) headlamp when removing the GOP.
10. Remove the front GOP and the attached wiring harness. Remove the 7 mm bolt on the bottom center of the GOP from the bottom.
11. Disconnect the transmission oil cooler lines on the right (Drivers side) of the radiator and plug (if equipped). Carefully position the radiator on top of the engine to allow access to the area above the steering gear (Fig. 3). Remove the mechanical fan shroud (if equipped).
NOTE:
Use care to protect the radiator from damage when positioning it on top of the engine.
12. Remove the auxiliary transmission oil cooler (if equipped), and set aside.
13. Examine the frame area at the steering gear attachment points for any signs (visual or audible) of cracking or deformation while the steering wheel is being turned from full lock left to full lock right, on dry pavement (Fig. 4).
NOTE:
THE FULL WEIGHT OF THE VEHICLE MUST BE ON THE WHEELS FOR THIS STEP.
14. Center steering wheel.
15. Raise vehicle on hoist.
16. Remove the front lower splash shield and front axle skid plate (if equipped).
17. Loosen the right (drivers side) front fender splash shield and move aside.
18. Lower vehicle.
19. Disarm mechanical air bag (if equipped).
A. Move the tilt steering column to its lowest position (if equipped).
B. Remove the arming screw cap from the steering wheel back cover using a small flat blade screwdriver (Fig. 5).
C. From outside the vehicle, reach through the driver's window and rotate the arming screw counter-clockwise. Do NOT use power driven tools! Back the screw off until the head is about one inch above the surface of the steering wheel back cover (Figs. 6 and 7).
NOTE:
The arming screw has a built in stop that prevents the bolt from backing all the way out.
20. Remove the steering gear attaching bolts (Fig. 8), push the steering gear away from the frame and remove the steering gear spacer. Inspect the frame area again for any signs of cracking or deformation (Fig. 9).
IF NO CRACKS ARE FOUND, CONTINUE WITH SECTION B.
IF ANY CRACKS ARE FOUND, SKIP TO SECTION C.