REAR CROSSMEMBER REMOVAL/INSTALLATION [4WD]

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Warning
•  Verify that the crossmember is securely supported by a jack. If the rear crossmember falls off, it can cause serious injury or death, and damage to the vehicle.
Caution
•  Performing the following procedures could cause an open circuit in the rear ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the rear ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.
Note
•  Mark the position before removing the rear upper arm.
•  Align the rear crossmember and rear upper arm markings when installing the rear upper arm.
•  Tighten the rear upper arm inner bolt completely before installing the rear crossmember component to the vehicle.

1.  Switch the ignition ON (engine off).

2.  Release the electric parking brake.

3.  Switch the ignition off.

4.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

5.  Remove the wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

6.  Disconnect the wiring harness clips and connector installed to the rear crossmember.

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7.  Disconnect the rear differential breather hose and set it aside so that it does not interfere with the servicing. (See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)

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8.  Disconnect the rear ABS wheel-speed sensor wiring harness and the electric parking brake motor gear unit connector and set it aside so that it does not interfere with the servicing. (See REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4WD].)

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9.  Jack up the vehicle to the unloaded condition, and support the rear lower arm using a jack.

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10.  Align the rear crossmember component and rear upper arm and mark them.

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11.  Remove the following parts: (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

(1)  Floor under cover No.2
(2)  Floor under cover No.1

12.  Remove the following parts: (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(1)  Insulator
(2)  Brace bar
(3)  Tunnel member

13.  For SKYACTIV-G (Without cylinder deactivation) or SKYACTIV-G 2.5T vehicles, perform the following procedure:

(1)  Disconnect the HO2S connector and the wiring harness clip.
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(2)  Remove the TWC. (See EXHAUST SYSTEM INSPECTION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

14.  For SKYACTIV-G (With cylinder deactivation) vehicles, perform the following procedure:

(1)  Disconnect the exhaust shutter valve connector.
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(2)  Disconnect the wiring harness clips.
(3)  Disconnect the HO2S connector and the wiring harness clip.
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(4)  Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

15.  For SKYACTIV-D 2.2 (Without SCR system) vehicles, perform the following procedure:

(1)  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

16.  For SKYACTIV-D 2.2 (With SCR system) vehicles, perform the following procedure:

(1)  Disconnect the quick release connector from the urea injector. (See UREA INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(2)  Remove the clips.
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(3)  Remove the bolts.
(4)  Disconnect the connector.
(5)  Set the NOx sensor No.1 side bracket aside.
(6)  Remove the bolts.
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(7)  Set the NOx sensor No.2 side bracket aside.
(8)  Remove the following parts as a single unit.
•  NOx sensor No.1 side bracket
•  NOx sensor No.2 side bracket
•  SCR converter (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

17.  Remove the following parts:

(1)  Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
(2)  Rear lateral link (See REAR LATERAL LINK REMOVAL/INSTALLATION.)
(3)  Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)
(4)  Rear lower arm (See REAR LOWER ARM REMOVAL/INSTALLATION.)
(5)  Rear drive shaft (See REAR DRIVE SHAFT REMOVAL/INSTALLATION.)

18.  Remove in the order indicated in the table.

19.  Install in the reverse order of removal. (See Suspension Links Installation Note.)

20.  Inspect the wheel alignment and adjust it if necessary. (See REAR WHEEL ALIGNMENT.)

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1
Rear crossmember component
(See Rear Crossmember Component Removal Note.)
(See Rear Crossmember Component Installation Note.)
2
Rear stabilizer component
3
Rear upper arm
(See REAR UPPER ARM REMOVAL/INSTALLATION [4WD].)
4
Rear crossmember mudguard
5
Rear differential mount rubber
(See REAR DIFFERENTIAL MOUNT RUBBER REMOVAL/INSTALLATION.)
6
Rear differential
(See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)
7
Rear crossmember


Rear Crossmember Component Removal Note

Warning
•  Verify that the rear crossmember is securely supported by a jack. If the rear crossmember falls off, it can cause serious injury or death, and damage to the vehicle.

1.  Support the rear crossmember with the jack and remove the nuts.

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2.  Remove the rear crossmember component.

3.  Disconnect the wiring harness clips and connector shown in the figure.

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Suspension Links Installation Note

1.  When installing the joint sections with rubber bushings, perform the following procedures:

(1)  Temporarily tighten the bolts and nuts with the vehicle lifted up.
(2)  Lower the vehicle to the ground and tighten the bolts and nuts to the specified torque.


Rear Crossmember Component Installation Note

Warning
•  Verify that the rear crossmember is securely supported by a jack. If the rear crossmember falls off, it can cause serious injury or death, and damage to the vehicle.

1.  Assemble the wiring harness clips and connector shown in the figure.

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2.  Support the rear crossmember component and install the rear crossmember.

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