Front Cross-Member: Service and Repair

ENGINE CRADLE CROSSMEMBER

REMOVAL

Fig. 30:

1. Disconnect and isolate battery negative cable. (Fig. 30)

Fig. 31:

2. Install overhead powertrain support fixture (Tool 8534B and adapter kit 8534-12) (Fig. 31):

Fig. 32:

a. Remove engine oil dipstick tube-to-cylinder head fastener (Fig. 32). Install lift/support bracket 8534-8 and secure with dipstick tube bolt.

Fig. 33:

b. Disconnect coolant temperature sensor (at thermostat housing). Remove engine harness-to-cylinder head bolt. Position harness out of the way. Install and secure lift/support bracket and bolt 8534-7 as shown in (Fig. 33).

Fig. 34:

c. Assemble 8534-2 mounting bracket/sleeve assemblies to support tube 8534-1 and install to vehicle, allowing brackets to rest on inner fender ledges (Fig. 34).

Fig. 35:

d. Assemble cross-bar 8534-3, clamp 8534-5 and support leg 8534-4 to support tube, allowing support leg to rest on radiator upper support (Fig. 35).

Fig. 36:

Fig. 37:

e. Tighten cross-bar-to-support tube clamp 8534-5 (Fig. 36), as well as mounting bracket/ sleeve 8534-2 thumb screw and hex nut to secure fixture (Fig. 37).

Fig. 38:

Fig. 39:

Fig. 40:

f. Install lift bracket/hook assemblies as shown in (Fig. 38) (Fig. 39) (Fig. 40). Tighten T-handles just enough to build tension between the fixture and drivetrain.

3. Raise vehicle on hoist. Refer to Vehicle Lifting.
4. Remove both front tire/wheel assemblies.
5. If necessary, disconnect the wheel speed sensor harness from the support brackets to gain slack in harness.

Fig. 41:

6. Disconnect sway bar links from struts (Fig. 41).
7. Remove lower control arm bolts to engine cradle and swing control arms out of the way.
8. Remove fascia. Refer to Front Bumper.
9. Remove engine front and rear mount-to-cradle nuts.
10. Disconnect brake hydraulic line and brackets from frame rails.
11. Remove the bolts and separate the brake line support bracket from cradle.

Fig. 42:

12. Remove screw mounting power steering hydraulic hose clamps to cradle on right side (Fig. 42).

Fig. 43:

13. Remove tie-strap clip securing power steering hydraulic pressure hose to engine cradle (Fig. 43).
14. Remove screw securing power steering hydraulic return hose clamp to engine cradle at cooling loop (Fig. 43).

Fig. 44:

15. Remove screw securing power steering hydraulic return hose clamp to left side of engine cradle (Fig. 44).
16. Remove power steering rack and pinion mounting bolts.

Fig. 45:

Fig. 46:

17. Set Driveline Support Table, Tool 8874 into position (Fig. 45) (Fig. 46).

Fig. 47:

18. Lower vehicle until cradle and fixture engage as shown in (Fig. 47).
19. Remove four (4) cradle-to-body bolts.
20. Slowly raise vehicle on hoist to separate cradle from vehicle. Verify that overhead fixture is secure to inner fenders and radiator upper support. Have helper guide brake and power steering hydraulic lines through, as they will remain attached to cradle assembly.
21. Remove stabilizer bar.

Fig. 48:

22. If equipped with 3.8L engine, remove both tuned mass dampers as necessary (Fig. 48).

INSTALLATION

Fig. 49:

1. If equipped with 3.8L engine, install both tuned mass dampers (Fig. 49). Tighten mounting bolts to 68 N.m (50 ft.lbs.).
2. Install stabilizer bar onto engine cradle.
3. Install cradle and fixture into position under vehicle.

Fig. 50:

4. Slowly lower vehicle (Fig. 50). While lowering vehicle, align engine front and rear mount studs to their respective thru-holes in cradle.
5. Aligning index/scribe mark placed upon disassembly, Install four (4) cradle-to-body bolts and tighten to 162 N.m (120 ft.lbs.).
6. Remove overhead powertrain support fixture from engine compartment:
a. Remove rear support/lift bracket and connect coolant temperature sensor.
b. Remove front support/lift bracket. Install and tighten engine oil dipstick fastener.

7. Raise vehicle on hoist and remove driveline support table.
8. Install and tighten engine front and rear mount-to-cradle nuts to 54 N.m (40 ft.lbs.).
9. Install power steering rack and pinion mounting bolts.

Fig. 51:

10. Install screw securing power steering hydraulic return hose clamp to left side of engine cradle (Fig. 51).

Fig. 52:

11. Install hose clamp screw securing power steering hydraulic return hose to engine cradle at cooling loop (Fig. 52).
12. Install tie-strap clip into engine cradle securing power steering hydraulic pressure hose in place (Fig. 52).

Fig. 53:

13. Overlap power steering hydraulic hose clamps and install mounting screw fastening hydraulic hoses to cradle on right side (Fig. 53).
14. Position brake line support brackets onto cradle and install the bolts.
15. Position brake lines into the plastic support brackets and fasten the brackets.
16. Install the fascia.
17. Position the lower control arms in place and install the control arm to cradle bolts.

Fig. 54:

18. Install sway bar links to strut attaching points (Fig. 54). Tighten link-to-strut nuts to 88 N.m (65 ft.lbs.).
19. If necessary, position wheel speed sensor harness back onto support bracket.
20. Install both front tire/wheel assemblies.

Fig. 55:

21. Connect solenoid/pressure switch connector (Fig. 55). Tighten screw to 4 N.m (35 in.lbs.).
22. Connect battery negative cable.
23. Align front end.