REAR CROSSMEMBER REMOVAL/INSTALLATION [4WD]

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Warning
•  Always verify that the rear crossmember component is securely supported by a jack. If the rear crossmember component 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
•  Place alignment marks before removing the rear upper arm.
•  When installing, align the alignment marks of the rear crossmember and rear upper arm, and install.
•  Before installing the rear crossmember to the vehicle, completely tighten the rear upper arm inner bolts.

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 wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

6.  Disconnect the wiring harness clips and the wiring harness connector from 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 them aside so that they do 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 position allowing the rear lower arm installation bolts to be removed easily.

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10.  Place alignment marks on the rear crossmember and rear upper arm.

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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 fasteners in the order shown in the figure.

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13.  Remove the insulator.

14.  Remove the following parts. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

15.  Remove the following parts.

(1)  TWC (SKYACTIV-G 2.5) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)
(2)  Middle pipe (SKYACTIV-D 2.2) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(3)  Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
(4)  Rear lateral link (See REAR LATERAL LINK REMOVAL/INSTALLATION.)
(5)  Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)
(6)  Rear lower arm (See REAR LOWER ARM REMOVAL/INSTALLATION.)
(7)  Rear drive shaft (See REAR DRIVE SHAFT REMOVAL/INSTALLATION.)

16.  Disconnect the rear upper arm from the hub support. (See WHEEL HUB COMPONENT REMOVAL/INSTALLATION [4WD].)

17.  Remove in the order shown in the figure.

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

19.  Inspect the wheel alignment and adjust 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
6
Rear differential
(See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)
7
Rear crossmember


Rear Crossmember Component Removal Note

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

1.  Support the rear crossmember component with a jack and remove the rear crossmember installation nuts.

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2.  Remove the rear crossmember component.

3.  Disconnect the wiring harness clip from the rear crossmember and the wiring harness connector.

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Suspension Links Installation Note

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

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

1.  Install the wiring harness clips and the wiring harness connector to the rear crossmember.

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2.  Support the rear crossmember component using a jack and install.

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