Differential Mount Bushing
BUSHING-DIFFERENTIAL MOUNTREMOVAL
1. Disconnect and isolate battery negative cable (2) from battery post.
2. Raise and support vehicle.
3. On each side of vehicle rear, remove wheel mounting nuts (3), then tire and wheel assembly (1).
4. On each side of vehicle rear, while a helper applies brakes to keep hub from rotating, remove hub nut (1) from half shaft (2).
5. Remove rear exhaust system (2) (dual-outlet exhaust shown in figure).
6. Remove rear axle differential.
7. Slide each axle half shaft from hub and bearing and remove from vehicle.
NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
8. Disconnect front parking brake cable (5) at connector (3) to right rear parking brake cable (4) above axle differential.
9. Remove front parking brake cable (3) from equalizer (2).
10. Remove screw (2) fastening front parking brake cable (1) routing bracket to rear crossmember front flange (3).
11. If equipped with standard or premium disc brakes, on each rear disc brake:
a. While holding guide pins from turning, remove disc brake caliper guide pin bolts (2).
b. Remove brake caliper (1) from brake adapter (3) and pads.
c. Guide brake caliper up through suspension, following brake hose path. Support caliper above rear suspension using with bungee cord or wire to keep caliper from overextending brake hose when crossmember is lowered.
CAUTION: When pushing pistons back into caliper bores, use only a trim stick as shown or other suitable soft tool. Never use a screwdriver or other metal pry bar due to potential damage to braking surface of rotor, caliper, pistons or dust boots.
12. If equipped with SRT8 disc brakes, on each rear disc brake, place trim stick (4) between brake pad (2) and outer edge of rotor (3).
13. If equipped with SRT8 disc brakes, on each rear disc brake, using trim stick, slowly apply pressure against brake pad (2) until both pistons (on that side of caliper) are completely bottomed in bores of caliper half.
NOTE: Repeat above procedure to opposite brake pad (1) and pistons as necessary.
14. If equipped with SRT8 disc brakes, on each rear disc brake, support spring link (1) using a transmission jack (5) or other appropriate jack. Raise spring link just enough to access brake caliper lower mounting bolt (4) from above compression link (2).
15. If equipped with SRT8 disc brakes, on each rear disc brake, remove the lower and upper caliper mounting bolts (1).
16. If equipped with SRT8 disc brakes, on each rear disc brake, remove brake caliper (2) with pads from knuckle and brake rotor. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.
17. If equipped with SRT8 disc brakes, remove jack from under spring link.
NOTE: To remove wheel speed sensor connector from body wiring harness connector, move retaining clip (2) and pull sensor connector outward.
18. Remove wheel speed sensor connectors (3 and 4) from body wiring harness connector (1) located in luggage compartment floor pan (2).
19. Unclip left wheel speed sensor cable (3) from routing clip (1) near body connector.
20. On each side of vehicle, remove shock absorber (1) lower mounting bolt (2) and nut (4).
21. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon. Do not use a scratch awl to mark location.
22. Position an extra pair of jack stands under and support forward end of engine cradle to help stabilize vehicle during rear suspension removal/installation.
23. Position under-hoist utility jack or transmission jack (2) under center of rear crossmember (1). Raise jack head to contact crossmember and secure in place.
WARNING: Before opening fuel system, review all Warnings and Cautions.
24. Remove fuel filler tube.
NOTE: If equipped with AWD, when removing crossmember mounting bolts in following step, be sure to not to misplace spacers (1) between cross-member mounts (2) and body.
25. Remove both front (3) and both rear (2) mounting bolts fastening crossmember (1) in place.
26. Slowly lower crossmember using jack until crossmember is at a comfortable working level.
27. Remove coil springs and isolators (1, 2 and 5) from spring links.
28. Remove bolt (1) from bushing prior to removal.
NOTE:
- Prior to using Special Tool 9520, lubricate Bolt (1) threads to provide ease of use and promote tool longevity.
- When installing Thrust Bearing (6), be sure to place hardened side toward Bolt head.
29. Assemble tools (See following list) over bushing as shown.
- (1) Bolt
- (2) Nut
- (3) Washer
- (4) Receiver 9520-4
- (5) Remover 9520-3
- (6) Thrust Bearing
30. While holding Nut (2) from rotating, using hand tools, tighten Bolt (1) until Remover (5) comes in contact with bushing and Receiver (4) sets squarely against crossmember.
31. Continue to tighten Bolt (1), pressing bushing out of crossmember.
32. Remove tools with bushing.
INSTALLATION
NOTE:
- It is important that tapered end (3) of bushing be installed first into forward end of cross-member to ease installation.
- When installing Thrust Bearing (7), be sure to place hardened side toward Bolt head.
1. Insert tapered end of NEW bushing (3) into forward end of crossmember bushing bore.
2. Assemble tools (See following list) through cross-member and bushing as shown.
- (1) Bolt
- (2) Disc 9520-1
- (3) Bushing
- (4) Nut
- (5) Washer
- (6) Installer 9520-2
- (7) Thrust Bearing
3. Insert Installer (6) into end of bushing and Disc (2) into opposite end of crossmember bushing bore.
4. While holding Nut (4) from rotating, tighten Bolt (1) using hand tools, pressing bushing into crossmember. Stop when Installer (6) bottoms against bushing bore.
5. Remove tools.
CAUTION: Differential mounting bolts (1) must be installed through bushings prior to crossmember installation in vehicle. Bolts cannot be inserted through bushings once crossmember is installed.
6. Insert differential mounting bolt (1) through mount bushing from rear (198 mm axle differential shown in figure. Other axles differ, but similar).
NOTE: Do not install coil springs on spring links at this time.
7. Raise crossmember to body mounting points. As crossmember is raised, align shocks (3) with pockets in spring links. Do not install bolts at this time.
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 N.m (133 ft.lbs.).
25. Remove jack (3) from under rear crossmember.
26. Install fuel filler tube.
27. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
28. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
29. 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.
CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed.
30. 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. Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 31 N.m (23 ft.lbs.) torque.
d. Make sure brake hose is properly routed and will not come in contact with suspension components.
31. 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.
32. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
33. If equipped with SRT8 disc brakes, on each rear disc brake, install caliper mounting bolts (1). Tighten bolts to 130 N.m (96 ft.lbs.) torque.
34. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.
35. 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.
36. Connect front parking brake cable (5) at connector (3) to right rear parking brake cable (4).
37. 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.
38. On each side of vehicle, slide an axle half shaft (2) through hub and bearing and install hub nut (1). Do not tighten hub nuts at this time.
39. Install rear axle differential.
40. While a helper applies brakes to keep hub from turning, tighten hub nut to 213 N.m (157 ft.lbs.).
41. Install rear exhaust system (2) (dual-outlet exhaust shown in figure).
42. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft.lbs.).
43. Lower vehicle.
44. Connect battery negative cable (2) to battery post. It is important that this is performed properly.
45. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
46. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
47. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft.lbs.).
48. 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 Step 23).