Front Mount

INSTALLATION

Special Tools:











CAUTION: Prior to bushing installation, inspect the bushing to make sure it is the correct side bushing for the job. Left side bushings have the travel limiter (1) tipped to the right in relationship to the bushing (4) can flange as shown. Right side bushings have the travel limiter (2) tipped to the left in relationship to the bushing (3) can flange as shown. Once installed, the travel limiters with face slightly outward from straight-ahead position.


CAUTION: It is very important that bushing be installed in same position as original to maintain vehicle ride quality and bushing longevity. That is why bushing, once installed, needs to closely match reference marks applied upon removal of original bushing.

1. Position bushing on crossmember bushing bore aligning bushing can flange with reference marks applied during removal.





2. Assemble tools (See following list) over bushing and crossmember as shown.
- (2) Receiver
- (3) Press
- (4) Installer





NOTE: Ensure Installer (3), Special Tool , is positioned that it will clear compression link bracket (1) while bushing is being installed.

3. Tighten Press (2) screw-drive, pressing bushing into crossmember. Install bushing until bushing can flange contacts surface of crossmember.
4. Remove tools.
5. Verify bushing closely lines up with reference marks applied during removal.





6. Install bolt and nut as shown (1) fastening compression link (3) to crossmember. Do not tighten bolt at this time.

NOTE: Do not reinstall coil springs on spring links at this time. Install as directed in later steps.





7. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft (1) onto rear axle differential flange (2) and align shock absorbers with pockets in spring links.






NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.

8. Continue to raise crossmember (1) with jack until crossmember mounting bolts (2 and 3) can be installed. Install left side crossmember mounting bolts, but not the right side bolts. It is not necessary to tighten bolts at this point.






CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).

9. Slowly lower jack allowing right side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring (2) Installation. Do not lower jack any further than necessary.

NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.

10. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.





11. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
12. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.





13. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place.






NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.

14. Raise right side of crossmember (1) into mounted position. Install right side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time.
15. Remove both front and rear crossmember mounting bolts (2 and 3) on left side of vehicle.






CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).

16. Slowly lower jack allowing left side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring (2) Installation. Do not lower jack any further than necessary.

NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.

17. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.





18. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
19. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.





20. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place.






NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.

21. Raise left side of crossmember (1) into mounted position. Install left side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time.










22. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.





23. Once mounts are lined up with location marks, on both sides of vehicle, measure distance (1) between the tension link (2) and weld flange (3) on body directly in front of it, just outboard of the front mount bushing (4). This distance must be at least 12 mm to allow proper clearance for suspension movement. If distance is less than 12 mm on either side of vehicle, shift that side of rear crossmember directly rearward until distance is 12 mm or greater. To do so, loosen 3 mounting bolts slightly, leaving one on opposite side of shift snugged to pivot off of. Shift crossmember rearward and snug loosened bolts. Remeasure opposite side to be sure it still maintains minimum 12 mm distance.





24. Tighten all four crossmember mounting bolts (2 and 3) to 180 Nm (133 ft. lbs.).





25. Remove jack (3) from under rear axle differential.





26. Remove bungee cord (1) supporting propeller shaft (2).





27. Align propeller shaft index marks placed upon removal. Install propeller shaft rear coupler-to-axle flange bolts and nuts by hand. Tighten propeller shaft rear coupler-to-axle flange bolts to 81 Nm (60 ft. lbs.).





28. Install fuel filler tube.





29. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.





30. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
31. Insert speed sensor connectors (3 and 4) into body wiring harness connector (1) located in luggage compartment floor pan (2). When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.





32. If equipped with standard or premium disc brakes, on each rear disc brake:
a. Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing.
b. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3).
c. CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed.
Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 31 Nm (23 ft. lbs.) torque.
d. Make sure brake hose is properly routed and will not come in contact with suspension components.

33. If equipped with SRT8 disc brakes, at each rear disc brake, support spring link using a transmission jack or other appropriate jack as indicated in removal procedure. Rear Crossmember Isolator - Removal





34. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
35. If equipped with SRT8 disc brakes, on each rear disc brake, install caliper mounting bolts (1). Tighten bolts to 130 Nm (96 ft. lbs.) torque.
36. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.





37. Route parking brake cable above rear crossmember, then slide cable (1, 3) through equalizer (2) above rear axle differential (once installed).






NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.

38. Connect front parking brake cable (5) at connector (3) to right rear parking brake cable (4).





39. Insert front parking brake cable routing bracket locating pin into front flange of crossmember (3), then install screw (2) fastening cable (1) routing bracket to rear crossmember.





40. Install rear exhaust system (2) (dual-outlet exhaust shown in figure).





41. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 Nm (110 ft. lbs.). Tires And Wheels - Installation
42. Lower vehicle until rear wheels are just above floor level.
43. Apply parking brake lever. Release lever, then reapply.
44. Check to make sure rear wheels will not rotate with lever applied.
45. Lower vehicle.





46. Connect the battery negative cable (2) to the battery post.
47. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
48. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.





49. Tighten shock absorber lower mounting bolt nuts (4) to 72 Nm (53 ft. lbs.).





50. Tighten compression link bolt and nut (1) at crossmember to 85 Nm (63 ft. lbs.).
51. Perform wheel alignment, paying special attention to thrust angle. If rear crossmember needs to be shifted to align thrust angle, try to avoid compromising tension link clearance (Refer to 23 ). Wheel Alignment Procedures