Front Cross-Member: Service and Repair

1. Remove splash shield(s).
2. Remove transverse member nuts and bolts, then transverse member.
3. Remove power steering return hose and pressure pipe.
4. Remove intermediate shaft bolt.
5. Support engine using suitable engine support, then remove No. 1 engine mount bolts.
6. Remove tie rod end ball joint, then suspend axle assembly with rope and remove lower arm bolt.
7. Remove gusset, then stabilizer control link nut.
8. Support crossmember with suitable jack, then remove protect bracket bolts and bracket, Fig. 22.
9. Remove nut, cam plate and adjusting cam bolt as follows:
a. Support crossmember using suitable jack, then remove crossmember nuts.
b. Lower crossmember to gain clearance, then mark cam plate and crossmember for installation reference.
c. Loosen and remove nut.

10. Remove steering gear and linkage.
11. Remove front stabilizer as described under Stabilizer Bar.
12. Remove crossmember undercover, then front crossmember. Inspect crossmember for damage and cracks.
13. Remove stopper, then crossmember bushing using rubber bushing replacer set tool Nos. 49 T034 0A0 and 49 T034 2A1, or equivalents, Fig. 23. Pull bushing into front crossmember using tools.
14. Reverse procedure to install, noting the following:
a. Apply soapy water to new front crossmember bushing, then install bushing by pulling into front crossmember using rubber bushing replacer set tool Nos. 49 T034 0A0 and 49 T034 2A1, or equivalents, Fig. 23.
b. Install cam plate so notch faces same direction as adjusting cam bolt, then align marks made during removal. Tighten cam plate nut to specifications.
c. Adjust front wheel alignment as described under Wheel Alignment.
d. Bleed air from power steering system as described under Power Steering System Bleed.

Fig. 22 Front Crossmember Replacement:

Fig. 23 Front Crossmember Bushing Replacement: