Subframe: Service and Repair

Sub-frame - V8

Service Repair No - 60.35.78

Remove
1. Position the vehicle on a lift.
2. Disconnect the battery earth lead.
3. Raise the front of the vehicle and support on axle stands.
4. Remove the front road wheels.
5. Remove the viscous fan.
6. Remove the air intake plenum.





7. Position a suitable container below the PAS rack to collect fluid spillage.





8. Loosen the union nut, disconnect the PAS outlet hose from the pump and discard the O-ring.





9. Remove the two nuts securing the engine brackets to the mountings.
10. Fit LRT-12-216 to the engine lifting eyes.
11. Connect a suitable chain to the lifting bracket and take the weight of the engine.
12. Drain the oil from the differential.
13. Remove the RH drive shaft seal.





14. Remove the differential oil seal.
15. Remove the Torx bolt from the steering column lower clamp.
16. Rotate the steering wheel to the straight-ahead position, align the pinion marks and remove the ignition key.





17. Disconnect the steering column from the pinion.
18. Note the fitted position for refit, then remove the cable ties securing the height sensor harness to the sub-frame and sensors.





19. Disconnect the height sensor multiplugs.





20. Disconnect the multiplug from the PAS rack pinion sensor.
21. If fitted: Remove the two speed nuts securing each anti-roll bar heat shield to the body, and the two bolts securing each heat shield to the sub-frame.





22. Use a transmission jack to support the sub-frame.
23. Remove the six bolts securing the sub-frame.





24. Remove and discard the two bolts securing the sub-frame to the cross-member.
25. With assistance, lower and remove the sub-frame assembly.
26. Release the two straps securing the PAS fluid return hose to the sub-frame.
27. Note the orientation. Remove the banjo bolts securing the fluid feed and return hoses to the PAS rack.
28. Remove the hoses. Discard the sealing washers.
29. Release the five clips securing the vacuum hose to the PAS rack.
30. Remove and discard the two bolts and nuts securing the PAS rack, remove rack.
31. Remove the four bolts securing the engine mountings and remove the mountings.
32. Remove the four nuts securing the anti-roll bar, remove the clamps and the anti-roll bar.
33. Remove the four bolts securing the height sensors and remove the sensors.
34. Remove the nuts and bolts securing the lower arms and remove the arms.
35. Remove the nuts and bolts securing the tie rods and remove the rods.
36. Remove the two PAS hose clips from the sub-frame.
37. Remove the two speed nuts from the sub-frame.

Refit
1. Fit the speed nuts to the sub-frame.
2. Fit the PAS hose clips to the sub-frame.
3. Fit the tie rods, fit the nuts and bolts but do not tighten at this stage.
4. Fit the lower arms, fit the nuts and bolts but do not tighten at this stage.
5. Position the height sensor assemblies to the sub-frame, fit and tighten the bolts to 2.5 Nm (1.8 ft. lbs.).
6. Clean the anti-roll bar bush locations on the sub-frame.
7. Fit the anti-roll bar, fit the clamps and nuts but do not tighten fully at this stage.
8. Clean the engine mounting mating faces.
9. Fit the engine mountings and tighten the bolts to 56 Nm (40 ft. lbs.).
10. Fit the PAS rack. Fit new bolts and nuts, and tighten to 100 Nm (74 ft. lbs.), then tighten a further 90 degrees.
11. Clean the fluid hoses and mating faces.
12. Align and fit the hoses.
13. Using new sealing washers, fit the PAS hoses and tighten the M16 banjo bolt to 40 Nm (30 ft. lbs.). and the M14 banjo bolt to 36 Nm (26 ft. lbs.).
14. Position the return hose and secure with the clips.
15. Clean the sub-frame and body mating faces.
16. With assistance, fit the sub-frame assembly.
17. Using new bolts, tighten the six bolts securing the sub-frame to the body to 165 Nm (122 ft. lbs.). then tighten the two most rearward bolts a further 90 degrees. Tighten the bolts securing the sub-frame to the front cross-member to 132 Nm (97 ft. lbs.).
18. Fit the anti-roll bar heat shields and tighten the fixings.
19. Lower the engine onto its mountings.
20. Tighten the nuts securing the engine brackets to the mountings to 100 Nm (74 ft. lbs.).
21. Connect the multiplug to the PAS rack pinion sensor.
22. Connect the height sensor multiplugs.
23. Correctly position the height sensor harness and secure with cable ties.
24. Clean the PAS pump and pipe union mating faces.
25. Fit a new O-ring to the high pressure pipe, align the pipe to the PAS pump, and tighten the union to 25 Nm (18 ft. lbs.).
26. Check the alignment and connect the column to the PAS rack. Fit a new clamp bolt and tighten to 24 Nm (18 ft. lbs.).
27. Fit a new differential oil seal.
28. Fit a new RH drive shaft seal.
29. Fill the differential to the correct level with oil.
30. Fit the viscous fan.
31. Fit the air intake plenum.
32. Connect the battery earth lead.
33. Fit the front wheels.
34. Lower the vehicle onto its wheels.
35. Bleed the PAS system.
36. Check and if necessary adjust wheel alignment.