Front Suspension Crossmember

Front Suspension Crossmember

Removing






- Open the hood and remove the screws (2) securing the ABS ICU mounting bracket (1) to the crossmember left forward support arm.

- Raise and support the vehicle.






- On each side of the vehicle, remove the wheel mounting nuts (3), then the tire and wheel assembly (1).





- With aid of a technician, apply the brakes to keep the front hub from turning, on each side of the vehicle, remove the hub nut (1) from the drive axle stub shaft (2).

- Push in on the end of each axle shaft stub shaft (2), disengaging its splines from the hub splines.






- At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary (wrench placed on machined flats on stud), remove the nut (2) securing the link to the stabilizer bar (3).






- Remove the front engine mount thru-bolt (4).






- Remove the crossmember front mounting bolt (6).

- Remove the crossmember four rear mounting bolts (3, 4).

- Remove the crossmember.






- Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2). Remove the heat shield.

- Remove the rear engine mount.






- Remove the screw (1) securing the power steering return hose routing clamp to the rear of ABS ICU mounting bracket.






- Remove the screws (3) securing the power steering pressure hose routing clamps to the rear of crossmember.






- Remove the bolts (1) securing the steering gear (2) to the crossmember.

- Support the steering gear (2) using a bungee cord or equivalent to maintain the location of the steering gear in the vehicle once the crossmember is lowered.

- Remove the screw securing the left front brake flex hose bracket to the frame rail.


When drawing the location of the crossmember on the underbody in the following step, do not use a sharp object that can damage the surface of the underbody.

- Using an appropriate marker, draw an outline (1) as necessary marking the location of the front suspension crossmember on the underbody. This will aide alignment upon installation.

- Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember. Secure the crossmember to the jack.






- Remove the bolts (3) securing both front crossmember support brackets (1) to the frame rails (2) of the vehicle.






- Remove all four bolts (2) attaching the front suspension crossmember to the underbody of the vehicle. Remove front crossmember support brackets after removal of rear mounting bolts.


Lower the power steering gear slowly, paying special attention to the steering gear and fluid hoses. Do not strain or overextend the hoses because damage to the hoses or connecting hardware may occur.

- Slowly lower the front suspension crossmember using the transmission jack just enough to allow easy removal of the lower control arm mounting bolts.






- Remove the front bolt (1) attaching each lower control arm (2) to the crossmember (4).

- Remove the rear bolt (3) and nut attaching each lower control arm (2) to the crossmember (4).

- Separate the lower control arms from the crossmember, then support each lower control arm using a bungee cord or equivalent to keep undue stress off the ball joints.

- Lower the front suspension crossmember to working height using the transmission jack.






- Remove the screws (1) securing the stabilizer bushing retainers (2) to the crossmember.

- Remove the two stabilizer bushing retainers (2).

- Remove the stabilizer bar from the crossmember.

Installing

- Place the crossmember centered on a transmission jack at working height. Secure the crossmember to the jack.

• Before stabilizer bar installation, inspect the cushions for excessive wear, cracks, damage and distortion. Replace any pieces failing inspection.

• Before installing the stabilizer bar, make sure the bar is not upside down. The stabilizer bar must be installed so that when in mounted position, the ends of the bar curve under the steering gear tie rods, up to the links.

- Install the stabilizer bar on the crossmember.






- Install the two stabilizer bushing retainers (2) over the cushions on the bar.

- Install the four screws (1) securing the stabilizer bushing retainers (2) to the crossmember. Tighten screws to 45 Nm (33 ft lbs).

- Raise the front suspension crossmember using the transmission jack until the lower control arms can be easily installed on the crossmember.






- Position each lower control arm (2) into brackets on the suspension crossmember (4).

- Install the front mounting bolt (1) and the rear mounting bolt (2) and nut attaching each lower control arm to crossmember.

• Do not tighten the front bolt (1) at this time.

- Tighten the rear mounting bolt nut to 155 Nm (114 ft lbs).

- Continue to raise the front suspension crossmember into mounted position using the transmission jack lining up the mounting holes.






- Place the front crossmember support brackets (1) over the crossmember rear bushings and frame rail (2). Install, but do not tighten mounting bolts (3).






- Install all four crossmember mounting bolts (2), but do not tighten at this time.

- Using a soft face hammer, tap the front suspension crossmember (1) back-and-forth or side-to-side until it is aligned with the previously made location marks on the vehicle underbody. Once the front suspension crossmember is correctly positioned, tighten all four crossmember mounting bolts (2) to 163 Nm (120 ft lbs).






- Tighten the mounting bolts (3) for each front crossmember support bracket (1) to 54 Nm (40 ft lbs).

- Remove the transmission jack from under front suspension crossmember.

- Position the left front brake flex hose bracket on the frame rail and install the mounting screw.






- Center the steering gear (2) mounting bosses over the mounting holes in the crossmember and install two steering gear mounting bolts (1). Tighten the mounting bolts to 75 Nm (55 ft lbs).






- Position the power steering pressure hose routing clamps on the rear of the crossmember. Install and tighten the screws to 8 Nm (71 in lbs).






- Position the power steering return hose routing clamp on the rear of the ABS ICU mounting bracket. Install and tighten the screw (1) to 8 Nm (71 in lbs).

- Install the rear engine mount.






- Position the heat shield (1) over the steering gear (2). Install the mounting screws and push-pins. Tighten the screws to 8 Nm (71 in lbs).






- Position crossmember in engine compartment and install mounting bolts (3, 4, 6). Tighten forward mounting bolt (6) to 113 Nm (83 ft lbs). Tighten rearward mounting bolts (3, 4) at suspension crossmember (2) to 55 Nm (41 ft lbs).






- Install front engine mount thru-bolt (4). Tighten bolt to 57 Nm (42 ft lbs).






- Attach the stabilizer bar link (1) at each end of the stabilizer bar (3). At each link, install and tighten the nut (2) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 88 Nm (65 ft lbs).






- Install the hub nut (1) on the end of each axle shaft stub shaft (2). With aid of a technician, apply the brakes to keep the front hub from turning, tighten the hub nut to 160 Nm (118 ft lbs).






- On each side of vehicle, install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) in proper sequence to 135 Nm (100 ft lbs).

- Lower vehicle.






- Install the screws (2) securing the ABS ICU mounting bracket (1) to the crossmember left forward support arm. Tighten the screws to 50 Nm (37 ft lbs).

- Position the vehicle on alignment rack/drive-on hoist. Raise the hoist as necessary to access the lower control arm mounting bolts.






- At curb height, tighten each lower control arm front mounting bolt (1) to 155 Nm (114 ft lbs).

- Perform wheel alignment.