Rear Crossmember Bushing - Front Mount
BUSHING-REAR CROSSMEMBER FRONT 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. Remove rear exhaust system (2) (dual-outlet exhaust shown in figure).
5. Apply alignment index marks (3) to the propeller shaft rubber coupler (1) and axle flange (2).
6. Remove three (four if equipped with 215 MM axle) propeller shaft coupler-to-axle flange bolts and nuts.
7. Support propeller shaft (2) using a bungee cord (1). Attach ends of cord to fuel tank straps as shown.
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 (3) under center of rear axle differential (1). Raise jack head to contact differential and secure in place. When securing crossmember to jack, be sure not to secure stabilizer bar.
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. Do not lower jack at a fast rate. Lower just enough to allow propeller shaft removal from rear axle differential. Do not lower jack any further than necessary. Slide propeller shaft out of rear axle differential and allow bungee cord previously installed to support.
27. Lower crossmember until crossmember is at a comfortable working level to access bushings. Support rear suspension assembly using jack stands to help stabilize assembly during bushing service.
28. Remove coil springs (2) with isolators (1 and 5) from spring links (4).
29. As an installation reference, carefully mark location of bushing requiring removal on crossmember (around bushing can flange) using a marker or crayon. Do not use a scratch awl to mark location.
30. Remove nut and bolt (1) fastening compression link (3) to crossmember.
31. Remove travel limiter (2) from bushing inner metal sleeve (1). To do so, use an appropriate grinding tool to remove inner metal sleeve material until limiter can be safely removed.
32. Slide Support (2), Special Tool 9031-9, into end of crossmember (3) surrounding bushing bore as shown.
33. Snug set-screws (1) securing Support (2) to crossmember.
34. Insert Brace (1), Special Tool 9031-10, between Support 9031-9 (3) and bushing bore flange (2) matching step in Brace to bore flange.
35. Snug set-screws (2) against Brace 9031-10. Do not overtighten set-screws as they will distort and bend bushing bore flange.
NOTE: Prior to using Press (1), Special Tool C-4212F, lubricate screw-drive threads to provide ease of use and promote tool longevity.
36. Assemble tools (See following list) over bushing as shown. Ensure Remover lies between ridges (3) on bushing to properly contact bushing can.
- (1) Press C-4212F
- (2) Remover 9031-5A
- (4) Receiver 9031-8A
37. Tighten Press (1) screw-drive, pressing bushing out of crossmember.
38. Remove all tools.
INSTALLATION
CAUTION:
- Prior to bushing installation, inspect the bushing to make sure it is the correct side bushing for the job. Left side bushings have the travel limiter (1) tipped to the right in relationship to the bushing (4) can flange as shown. Right side bushings have the travel limiter (2) tipped to the left in relationship to the bushing (3) can flange as shown. Once installed, the travel limiters with face slightly outward from straight-ahead position.
- It is very important that bushing be installed in same position as original to maintain vehicle ride quality and bushing longevity. That is why bushing, once installed, needs to closely match reference marks applied upon removal of original bushing.
1. Position bushing on crossmember bushing bore aligning bushing can flange with reference marks applied during removal.
2. Assemble tools (See following list) over bushing and crossmember as shown.
- (2) Receiver 9031-6
- (3) Press C-4212F
- (4) Installer 9031-7A
NOTE: Ensure Installer (3), Special Tool 9031-7, is positioned that it will clear compression link bracket (1) while bushing is being installed.
3. Tighten Press (2) screw-drive, pressing bushing into crossmember. Install bushing until bushing can flange contacts surface of crossmember.
4. Remove tools.
5. Verify bushing closely lines up with reference marks applied during removal.
6. Install bolt and nut as shown (1) fastening compression link (3) to crossmember. Do not tighten bolt at this time.
NOTE: Do not reinstall coil springs on spring links at this time. Install as directed in later steps.
7. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft (1) onto rear axle differential flange (2) and align shock absorbers with pockets in spring links.
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 axle differential.
26. Remove bungee cord (1) supporting propeller shaft (2).
27. Align propeller shaft index marks (3) placed upon removal. Install propeller shaft rear coupler-to-axle flange bolts and nuts by hand. Tighten propeller shaft rear coupler-to-axle flange bolts to 81 N.m (60 ft.lbs.).
28. Install fuel filler tube.
29. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
30. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
31. 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.
32. 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).
CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed.
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.
33. 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.
34. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
35. 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.
36. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.
37. 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.
38. Connect front parking brake cable (5) at connector (3) to right rear parking brake cable (4).
39. 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.
40. Install rear exhaust system (2) (dual-outlet exhaust shown in figure).
41. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft.lbs.).
42. Lower vehicle until rear wheels are just above floor level.
43. Apply parking brake lever. Release lever, then reapply.
44. Check to make sure rear wheels will not rotate with lever applied.
45. Lower vehicle.
46. Connect battery negative cable (2) to battery post. It is important that this is performed properly.
47. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
48. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
49. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft.lbs.).
50. Tighten compression link bolt and nut (1) at cross-member to 85 N.m (63 ft.lbs.).
51. 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).