Front Suspension Crossmember Replacement

Front Suspension Crossmember Replacement

- Tools Required
- J 28467-B Universal Engine Support Fixture
- J 41803 Engine Support Fixture
- J 33432-A Transverse Spring Compressor

Removal Procedure





1. Remove the generator from the accessory mounting bracket.
2. Remove the washer pump/reservoir.
3. Remove the engine coolant temperature switch electrical connector and reposition.
4. Remove the front headlamp electrical connector and reposition.
5. Install J 41803 and J 28467-B and support the engine.
6. Raise and support the vehicle. Refer to Vehicle Lifting.
7. Remove the tire and wheel assemblies.





8. Remove the steering linkage outer tie rod end stud nuts (3).





9. Disconnect the shock absorber solenoid electrical connector, if equipped.





10. Disconnect the real time damping (RTD) sensor links.
11. Remove the stabilizer shaft from the vehicle.
12. Disconnect the intermediate shaft lower coupling from the steering gear.
13. Remove the bolts from the electronic brake control module/brake pressure modulator valve (EBCM/BPMV) bracket.
14. Support and reposition the EBCM/BPMV and bracket away from the crossmember.





15. Remove the power steering gear mounting bolts.
16. Remove the power steering fluid cooler from the crossmember.
17. Lift the power steering gear off of the crossmember and support.





18. Using the J 33432-A, remove the transverse spring from the vehicle.





19. Disconnect the lower shock absorber bolts from the lower control arms.
20. Remove the lower control arm bolts from the crossmember.





21. Place a transmission jack under the crossmember.
22. Remove the engine mount lower nuts. Refer to the following procedures:
- Engine Mount Replacement - Left.
- Engine Mount Replacement - Right.





23. Disconnect the wheel speed sensor wiring harness from the crossmember.





24. Disconnect the electrical harness from the clips on the crossmember.
25. Disconnect the brake pipe from the clips on the crossmember.





26. Remove the crossmember mounting nuts.
27. Lower the crossmember out of the vehicle by removing the transmission jack from under the crossmember.

Installation Procedure





1. Raise the crossmember to the vehicle.
1.1. Align the crossmember dowel pins to the frame rails.
1.2. Align the engine mount studs.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install new crossmember mounting nuts.
- Tighten the new crossmember mounting nuts to 110 Nm (81 ft. lbs.).
3. Install the engine mount lower nuts. Refer to one of the following procedures:
- Engine Mount Replacement - Left
- Engine Mount Replacement - Right





4. Fasten the wheel speed sensor wiring harness retaining clips to the crossmember.
5. Fasten the brake pipe to the retaining clips on the crossmember.





6. Connect the electrical harness to the clips on the crossmember.
7. Connect the brake pipe to the clips on the crossmember.





8. Install the transverse spring with the J 33432-A connected, to the crossmember.





9. Install the lower control arm to the crossmember.





10. Install the shock absorbers to the lower control arms.
- Tighten the shock absorber lower mounting nuts to 28 Nm (21 ft. lbs.).





11. Install the power steering gear to the crossmember.
- Tighten the power steering gear mounting bolts to 100 Nm (74 ft. lbs.).
12. Install the bolts to the brake pressure modulator valve bracket.
13. Connect the intermediate shaft to the steering gear.





14. Install the steering linkage outer tie rod ends to the steering knuckles.
15. Connect the RTD sensor links to the upper control arm, if equipped.





16. Connect the shock absorber solenoid electrical connector, if equipped.
17. Install the stabilizer shaft to the vehicle.
18. Install the tire and wheel assemblies.
19. Lower the vehicle.
20. Remove J 41803 and J 28467-B from the engine.
21. Install the generator.
22. Install the washer pump/reservoir.





23. Install the engine coolant temperature switch electrical connector.
24. Install the front headlamp electrical connector.
25. Connect the negative battery cable.
- Tighten the negative battery cable to 15 Nm (11 ft. lbs.).
26. Perform a vehicle front end alignment.