Crossmember - Front

CROSSMEMBER - FRONT

Removal

All vehicles
1. Remove the upper radiator sight shield.
2. Support the radiator to the upper radiator support.
3. Install the three-bar engine support.
4. Remove the front wheel and tire assemblies.







5. Remove the eight bolts and the two front I-braces.
- Discard the bolts.







6. Remove the two clips and position the front anti-lock brake sensors aside.







7. Remove the four bolts, support and position the front brake calipers aside.







8. CAUTION: Hold the external hex of the tie rods when removing the nuts.

Remove and discard the two nuts and separate the tie rod ends from the front spindles.







9. CAUTION: Hold the external hex of the stabilizer bar links when removing the nuts.

Remove and discard the two nuts and separate the stabilizer bar links from the lower control arm and position aside.







10. CAUTION: Hold the external hex of the ball joints when removing the nuts.

Remove and discard the nuts and separate the upper ball joint from the spindle.

11. Remove the underbody splash shields.







12. Remove the A/C and power steering line bracket bolts.







13. NOTE: The nut is most easily accessed from above the front of the radiator support crossmember.

Loosen the nut two turns, remove the bolt and position the water control valve aside.

3.9L only
14. Remove the block heater harness retainer.

All vehicles







15. Remove the bolts, position and support the power steering gear aside.
- Discard the nuts.







16. Remove the engine mount nuts.







17. Remove and discard the lower front strut mount bolts.







18. WARNING: Make sure the front crossmembers are secured to the lift table. Failure to follow these instructions may result in personal injury.

NOTE: Mark the right and left crossmember locations to the body:

Position the lifting table under the two crossmembers and remove the four engine crossmember bolts and the four radiator support crossmember bolts.

19. Lower the radiator support and engine crossmembers as an assembly.







20. NOTE: Discard the control arm nuts and bolts.

Remove the control arm nuts and bolts.

Radiator support crossmember removal







21. Remove the bolts and the water control valve bracket.







22. Remove and discard the bolts and position the stabilizer bar aside.

Installation

Radiator support crossmember







1. NOTE: The front I-brace shoulder bolt will have 1.5 mm (0.059 in) of clearance between the front I-brace bracket and the bolt. This is normal and the bolt should not be tightened any further.

Position the stabilizer bar and install the new bolts.







2. Position the water control valve bracket and install the bolts.

All vehicles







3. Loosely install the new control arm cam bolts and nuts.
4. Position the radiator support and engine crossmembers as an assembly.







5. NOTE:
- Align the crossmember markings.
- Make sure the weight of the engine is not contacting the crossmember and make sure the crossmember assembly is in contact with the body before tightening the bolts.

Install the four engine crossmember bolts and the four radiator support crossmember bolts.







6. Install the engine mount nuts.







7. Install the new lower front strut mount bolts.







8. CAUTION: Hold the external hex of the ball joints when installing the nuts.

Position the upper ball joints into the spindles and install the new nuts.







9. CAUTION: Hold the external hex of the stabilizer bar links when installing the nuts.

Position the two stabilizer bar links into the lower control arm and install the new nuts.







10. Position the power steering gear and install the bolts.







11. CAUTION: Hold the external hex of the tie rods when installing the nuts.

Position the two tie rod ends into the spindles and install the new nuts.







12. Position the two front brake calipers and install the bolts.







13. Position the two front anti-lock brake sensors and install the clips.

3.9L only
14. Install the block heater harness.

All vehicles







15. Position the water control valve and tighten the nut.







16. Position the A/C and power steering brackets and install the bolts.







17. Position the two front I-braces and loosely install the four bolts.
1 Loosely install the front bolts.
2 Position the I-braces.
3 Loosely install the rear bolts.







18. Make sure that the four front I-brace insulators are correctly positioned.







19. Install the four front I-brace bolts.







20. Tighten the four front I-brace bolts.
21. Install the underbody splash shields.
22. Install the front wheel and tire assemblies.
23. Remove the three-bar engine support.
24. Remove the support from the radiator.
25. Install the upper radiator sight shield.
26. Align the front suspension.