B. Replace Steering Gear Crossmember
NOTE:Steering gear crossmember replacement requires the use of P/N CAAM9983.
1. Remove both rear tire and wheel assemblies.
2. Remove the fasteners that attach the battery access panel (Figure 2) and remove the panel.
3. Disconnect and isolate the negative battery cable at the battery.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
4. Disconnect and isolate the positive battery cable at the battery.
CAUTION:
Failure to isolate both the positive and negative battery cables from the battery may cause Powertrain Control Module PCM) and/or battery damage during welding.
5. Using a 6-inch steel ruler, measure the distance from the inside rear edge of the steering gear crossmember to the lower edge of the frame crossmember. Perform this measurement procedure on the right and left side of the steering crossmember (Figure 3). Record these measurements for future reference.
6. Using Special Tool # 6632, remove the two steering gear mounting bolts (Figure 4).
CAUTION:
There are selective toe pattern shims located between the steering gear mounting bushings and the steering gear crossmember (Figure 5). Using a grease pencil, mark the shims (right or left side) so that they can be reinstalled into their original position.
NOTE:
The right side steering gear mounting bolt has a taping plate nut located on the bottom side of the steering gear crossmember (Figure 5). The taping plate nut must be saved.
7. Using plastic fie straps or equivalent, temporarily secure the steering gear tie rod arms to the stabilizer bar. This will keep the steering gear suspended above the steering gear crossmember.
8. Using a cut off wheel, grind off all of the welds that hold the steering gear crossmember to the frame.
CAUTION:
Do not use plasma arc cutting equipment or cutting torch to remove the steering gear crossmember.
9. Once the steering gear crossmember has been removed, grind all areas where the new steering crossmember is to be welded. All old weld material and paint must be removed.
10. Using two "C" clamps, carefully clamp the new steering gear crossmember into position. Center the steering gear crossmember between the frame rails and use the measurements recorded in Step 5 to set new steering gear crossmember to the correct height (Figure 6).
NOTE:
Place the "C" clamps at the bottom edge of the crossmember mounting tab.
11. Shield the surrounding area and components from exposure to welding heat and spatter.
12. Tack weld the rear crossmember mounting tabs into position. Remove the "C" clamps and check the position of the crossmember. Adjust the location if necessary.
WARNING:
Only use the specified welding wire (Lincoln Electric Co. NR-211 MP). Do not substitute with other types or thickness welding wire.
IMPORTANT:
All welding must be performed by a qualified welder.
NOTE:
Refer to the Welding Procedure Specifications Chart in this document for all welder set-up information.
CAUTION:
Attach the welder ground lead directly to the frame as close to the weld area as possible.
13. Weld the rear crossmember tabs into position (Figure 8). Do not weld the front tabs at this time.
14. Using "C" clamps, clamp the right and left side steering crossmember front tabs to the frame rails (Figure 7).
NOTE:
Both front tabs must be clamped into place before welding.
15. Tack weld the front steering gear crossmember mounting tabs to the side of the frame rails and then remove the "C" clamps (Figure 8).
16. Recheck the steering gear crossmember positioning and adjust if required.
17. Weld the steering gear crossmember mounting tabs to the side of the frame rails (Figure 8).
18. Remove the weld splatter shielding installed in Step 11.
19. Remove the tie straps and position the steering gear onto the steering gear crossmember.
20. Lift the left side of the steering gear slightly and place the left side selective toe pattern shim(s) under the steering gear mounting bushing (Figure 5). Then install the mounting bolt. Do not tighten the mounting bolt at this time.
21. Lift the right side of the steering gear slightly and place the right side selective toe pattern shim(s) under the steering gear mounting bushing (Figure 5). Then install the mounting bolt and tapping plate nut.
22. Using Special Tool # 6632 and a torque wrench, tighten both mounting bolts to 150 ft. lbs. (203 N.m).
23. Continue with Step 5 of Section "C - Install Steering Gear Crossmember Reinforcement Bracket."