(D) Transmission Crossmember

NOTE:
USE WARRANTY DEALER CODING: 5060, AS BASIC PART NO.

This procedure should be done on flat ground or on a drive-on lift, with the wheels pointed straight and full weight resting on the wheels.

NOTE:
A SIMILAR NOISE CAN OCCUR AT THE TRANSFER CASE SKID PLATE ATTACHMENTS AND SHOULD BE INVESTIGATED IN CONJUNCTION WITH THIS REPAIR PROCEDURE.

1. Remove transmission weight:

a. Remove bolts attaching transmission mount to the crossmember.

b. Lift the transmission to remove any load to the crossmember. The crossmember should now be completely loose.

NOTE:
YOU MAY NOTICE THE FRAME RAILS TWIST SLIGHTLY AND "RELAX" AFTER THIS NEXT STEP.

2. Loosen crossmember:

a. Loosen all bolts attaching the crossmember to the frame siderails.

b. Loosen all bolts attaching the crossmember gusset(s) to the crossmember and to the frame siderails. The crossmember should now be completely loose.

3. Turn the steering wheel lock-to-lock and then straighten the wheels. This helps to remove any stress in the frame.

4. Install new crossmember fastening hardware one at a time and replace each nut and bolt with a new Nut (N800937-S427) and Bolt (N802114-52) and leave them loosely assembled until all crossmember and gusset fasteners have been replaced.

NOTE:
IT IS IMPERATIVE THAT THE FOLLOWING TIGHTENING SEQUENCE BE FOLLOWED.

5. Secure the crossmember attaching hardware. Determine which style of crossmember the vehicle is equipped with, and follow Step 6 or 7.





6. If the vehicle has a wraparound-style crossmember (Figure 7), torque each grouping of fasteners in the order listed in the following Substeps to 70 +/- 10.5 Nm (52 +/- 8 lb-ft).

a. Torque all three (3) bolts/nuts at the crossmember-to-frame siderail at the wraparound side (Figure 7, Number 1).

b. Torque the gusset-to-frame bolts (Figure 7, Number 2).

c. Torque the crossmember-to-frame bolts (Figure 7, Number 3).

d. Torque the gusset-to-crossmember bolts (Figure 7, Number 4).





7. If the vehicle has a double-gusseted crossmember (Figure 8), torque each grouping of fasteners in the order listed in the following Substeps to 70 +/- 10.5 Nm (52 +/- 8 lb-ft) and repeat for the other side.

a. Torque the gusset-to-frame bolts (Figure 8, Number 1).

b. Torque the crossmember-to-frame bolts (Figure 8, Number 2).

c. Torque the gusset-to-crossmember bolts (Figure 8, Number 3).

8. Reattach transmission:

a. Lower the transmission.

b. Reattach the transmission using new Nuts (N621945-S2) and torque to 95 +/- 15 N.m (70 +/- 11 lb-ft).

9. Inspect gusset/crossmember joint:

a. Visually inspect the joint between the gusset and crossmember. If all fasteners have been torqued properly and any gap exists between the two, shim joint with washers.

b. Reattach the gusset with new Bolts (N802114-S2) and Nuts (N800937-S427) torqued to 70 +/- 10.5 Nm (52 +/- 7 lb-ft).

NOTE:
ON HEAVY DUTY VEHICLES, IT MAY BE NECESSARY TO UPGRADE THE REPLACEMENT FASTENER TO A 9/16" GRADE 8 TORQUE PREVAILING NUT (34990-S2) AND BOLT (58698-S2) TORQUED TO 190 +/- 4 Nm (140 +/- 3 LB-FT).