Front Suspension - Crossmember

CROSSMEMBER

1. Install the appropriate bushing. Crossmember - Installation.
2. Place the crossmember centered on a transmission jack at working height. Secure the crossmember to the jack.

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

NOTE: Before installing the stabilizer bar, make sure the bar is not upsidedown. 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.





3. Install the stabilizer bar on the crossmember.
4. Install the two stabilizer bushing retainers (2) over the cushions on the bar.
5. Install the four screws (1) securing the stabilizer bushing retainers (2) to the crossmember. Tighten screws to 45 Nm (33 ft. lbs.).
6. Raise the front suspension crossmember using the transmission jack until the lower control arms can be easily installed on the crossmember.





7. Position each lower control arm (2) into brackets on the suspension crossmember (4).
8. Install the front mounting bolt (1) and the rear mounting bolt (3) 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.).





9. Continue to raise the front suspension crossmember into mounted position using the transmission jack lining up the mounting holes.
10. Place the front crossmember support brackets (1) over the crossmember rear bushings and frame rail (2). Install, but do not tighten mounting bolts (3).





11. Install all four crossmember mounting bolts (2), but do not tighten at this time.
12. 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.).





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





14. Remove the transmission jack from under front suspension crossmember.
15. Position the left front brake flex hose bracket on the frame rail and install the mounting screw.
16. 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 120 Nm (89 ft. lbs.).





17. Position the power steering pressure hose routing clamp(s) (4.0L engine only uses one) on the rear of the crossmember. Install and tighten the screw(s) to 8 Nm (71 in. lbs.).





18. 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.).





19. Install the rear engine mount. Engine Mount Insulator - Installation
20. 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.).





21. Position fore-aft 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.).





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





23. 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.).






NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.

24. Install the hub nut (1) on the end of each halfshaft stub shaft (2). With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to 160 Nm (118 ft. lbs.).





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





27. 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.).





28. Position the vehicle on alignment rack/drive-on hoist. Raise the hoist as necessary to access the lower control arm mounting bolts.
29. At curb height, tighten each lower control arm front mounting bolt (1) to 200 Nm (148 ft. lbs.).
30. Perform wheel alignment. Service and Repair