Rear Cross-Member: Service and Repair

Rear Suspension Support Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the rear wheels. Refer to Tire and Wheel Removal and Installation (Service and Repair).
3. Remove the exhaust system. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement).
4. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).




5. Remove the top strut assembly to body retaining bolts (1).




6. Disconnect the wheel speed sensor jumper harness electrical connector (1).





Note: Detach the rear park brake cable and clevis (1) from the park brake actuator (2) by pivoting the rear park brake cable and clevis (1) rearward using pliers.

7. Detach the rear park brake cable and clevis (1) from the park brake actuator (2).

Note: Remove the outer cable (4) from the rear knuckle (3) by pulling the outer cable (4) forward.

8. Remove the outer cable (4) from the rear knuckle (3).





Note: Bolts with thread sealant must be discarded after removal.

9. Remove the brake caliper anchor plate to knuckle retaining bolts (2).
Discard the bolts.

Note: DO NOT disconnect the hydraulic brake flexible hose from the brake caliper otherwise complete bleeding of the braking system will be necessary.

10. Remove the brake caliper from the knuckle.




Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).

11. Support the brake caliper (4) with heavy mechanic's wire, or equivalent (3).
12. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.




13. Detach the brake hose (1) from the upper control arm mounted brake hose retaining bracket (5).
14. Position the suitable frame support table under the vehicle.
15. Using suitable frame support table, lower the vehicle to the frame support table.
16. Remove the rear sub frame to rear chassis rail retaining fasteners.
17. Carefully raise the vehicle from the rear frame assembly.
18. Remove the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (Rear Suspension).
19. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement (Rear Suspension).
20. Remove the rear wheel hub and knuckle assembly. Refer to Knuckle Replacement (Rear Suspension).




21. Remove the rear strut assembly to lower control arm retaining bolt (2) and nut (1).
Discard the nut.





Note: The lower control arm to subframe retaining bolt (1) and nut (2) eccentric washers (3) that are used to adjust the rear suspension camber. One eccentric washer (3) is mounted directly to the head of the lower control arm to subframe retaining bolt (1).

22. Mark the eccentric washers (3) with reference to their seating position relative to the subframe.




23. Remove the lower control arm to subframe retaining bolt (1) and nut (5).
Discard the nut.
24. Remove the lower control arm (4) from the subframe (3).
25. Remove the upper control arm pivot bushing. Refer to Rear Suspension Upper Control Arm Bushing Replacement (Service and Repair).





Note: Fasteners with thread sealant must be replaced after removal.

26. Remove the upper control arm ball joint to subframe retaining bolt (1) and nut (5).
Discard the nut.




27. Remove the trailing arm to subframe retaining bolt (2) and nut (1).
Discard the nut.
28. Remove the drive shafts. Refer to Rear Wheel Drive Shaft Replacement (Service and Repair).
29. Remove the trailing arm.
30. Remove the differential. Refer to Differential Replacement ().





Note: The adjust link to subframe retaining bolt (2), nut (5) and eccentric washers (1) are used to adjust the rear suspension toe. One eccentric washer (1) is mounted directly to the head of the adjust link to subframe retaining bolt (2).

31. Mark the eccentric washers (1) with reference to their seating position relative to the subframe (4).
Note: Fasteners with thread sealant must be discarded after removal.

Discard the nut.

Remove the adjust link to subframe retaining bolt (2) and nut (5).
32. Remove the adjust link (3) from the subframe (4).




33. Disconnect the rear frame wiring harness to rear frame center retaining clips (1).




34. Disconnect the rear frame wiring harness to rear frame side retaining clips (1).

Installation Procedure




1. Connect the rear frame wiring harness to rear subframe side retaining clips (1).




2. Connect the rear frame wiring harness to rear subframe center retaining clips (1).




3. Install the adjust link (3) into the rear subframe (4).

Note:
* The eccentric washers (1) must be fitted correctly in terms of their orientation and alignment marks.
* The adjust link to rear subframe retaining bolt (2) and NEW nut (5) must not to be fully tightened at this stage.

4. Install the adjust link to rear subframe retaining bolt (2).
5. Install the eccentric washer (1) and the NEW nut (5).
Do not fully tighten at this stage.




6. Install the trailing arm (5) to the rear subframe.

Note: The upper control arm to subframe retaining bolt (3) and nut (4) must not to be fully tightened at this stage.

7. Install the trailing arm to rear subframe retaining bolt (3) and NEW nut (4).
Do not fully tighten at this stage.

Note: The trailing arm to knuckle retaining bolt (1) and nut (2) must not to be fully tightened at this stage.

8. Install the trailing arm to knuckle retaining bolt (1) and NEW nut (2).
Do not fully tighten at this stage.
9. Install the upper control arm into the rear subframe.

Caution: Refer to Fastener Caution (Fastener Caution).

10. Install the upper control arm ball joint to rear subframe retaining bolt (1) and NEW nut and tighten a first pass to 80 Nm (59 lb ft) and a final pass 120 degrees.
11. Install the upper control arm to knuckle retaining bolt (3) and NEW nut (4) and tighten the bolt first pass to 60 Nm (44 lb ft) and an additional 90 degrees.
12. Install the upper control arm pivot bushing. Refer to Upper Control Arm Replacement (Upper Control Arm Replacement).




13. Install the lower control arm (4) into the rear subframe (3).

Note:
* The eccentric washers (2) must be fitted correctly in terms of their orientation and alignment marks.
* Do not fully tighten the lower control arm to rear subframe retaining bolt (1) and nut (5) at this stage.

14. Install the lower control arm to rear subframe retaining bolt (1).
15. Install the eccentric washer (2) and the NEW nut (5).
Do not fully tighten at this stage.




16. Connect the rear strut assembly (4) to the lower control arm (3).

Note: Do not fully tighten the lower control arm to strut assembly retaining bolt (2) and nut (1) at this stage.

17. Install the lower control arm to strut assembly retaining bolt (2) and NEW nut (1).
Do not fully tighten at this stage.
18. Install the rear wheel hub and knuckle assembly. Refer to Knuckle Replacement (Rear Suspension) in rear Suspension.
19. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement (Rear Suspension).
20. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (Rear Suspension).

Note: Make sure the intermediate brake cable is clear of the rear frame to body mount prior to securing the frame retaining bolts.

21. Lower the vehicle to the frame.
22. Index the rear side frame mounts to the rear locator sleeves located on the body.
23. Lower the vehicle until the frame mounts contact the body rail.
24. Install the rear sub frame to rear chassis rail retaining bolts and tighten to 100 Nm (74 lb ft) and a final pass of 110 degrees.
25. Raise the vehicle.
26. Remove the frame support table from under the vehicle.




27. Attach the brake hose (1) from the upper control arm mounted brake hose retaining bracket (5).




28. Remove the heavy mechanic's wire, or equivalent support (2) from the brake caliper (1).





Caution: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

29. Install the brake caliper assembly (2) to the knuckle (3).
30. Install the NEW brake caliper anchor plate to knuckle retaining bolts (1) and tighten to 110 Nm (81 lb ft).




31. Install the rear park brake cable (4) into the rear knuckle (3).
Make sure that the rear park brake cables (4) are properly seated.

Note: Attach the rear park brake cable and clevis (1) to the park brake actuator (2) by pivoting the rear park brake cable and clevis (1) rearward using pliers.

32. Attach the rear park brake cable and clevis (1) to the park brake actuator (2).




33. Connect the wheel speed sensor jumper harness electrical connector (1).




34. Install the top strut assembly to body retaining bolts (1) and tighten to 58 Nm (43 lb ft).
35. Attach the electrical connector to the right hand rail.




36. Install the outer cable (4) to the vehicle underbody bracket (3).
Make sure that the outer cables (4) are properly seated in the vehicle underbody bracket (3).

Note: Wrap a workshop cloth around the rear inner cable (1) to protect it from damage. Using pliers, pull the rear inner cable (1) forward and downwards to install the ball nipple to the front park brake cable and equalizer bracket assembly (2).

37. Install the rear inner cables (1) to the front park brake cable and equalizer bracket assembly (2).
38. Install the differential. Refer to Differential Replacement ().
39. Install the drive shafts. Refer to Rear Wheel Drive Shaft Replacement (Service and Repair).
40. Install the rear strut assembly. Refer to Shock Absorber Replacement (Rear Suspension Shock Absorber).
41. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
42. Install the exhaust system. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement).
43. Install the rear wheel. Refer to Tire and Wheel Removal and Installation (Service and Repair).
44. Lower the vehicle to the ground.
45. Bounce the vehicle several times to settle the suspension.





Note: The lower control arm to the subframe retaining bolt (1) and nut (2) eccentric washers (3) are used to adjust rear suspension camber.

46. Align the marks on the eccentric washers (3) with the marks on the subframe.

Note: Make sure that the vehicle is positioned on a suitable hoist to load the rear suspension bushes to the correct position.

47. Tighten the lower control arm to subframe retaining bolt (1) and nut (2) and tighten to 115 Nm (85 lb ft).




48. Tighten the lower control arm to knuckle retaining bolt (2) and nut (1) a first pass to 40 Nm (30 lb ft) and a final pass 120 degrees.





Note: Make sure that the vehicle is positioned on a suitable hoist to load the rear suspension bushes to the correct position.

49. Tighten the trailing arm to subframe retaining bolt (2) and NEW nut (1) to 100 Nm (74 lb ft).




50. Tighten the trailing arm to knuckle retaining bolt (2) and NEW nut (1) to 40 Nm (30 lb ft) and final pass 120 degrees.





Note: Make sure that the vehicle is positioned on a suitable hoist to load the rear suspension bushes to the correct position.

51. Align the marks on the eccentric washers (1) with the marks on the subframe (3).
52. Tighten the adjust link to subframe retaining bolt (2) and NEW nut (4) to 115 Nm (85 lb ft).
53. Correct the wheel alignment of the vehicle, if necessary. Refer to Wheel Alignment Specifications (Wheel Alignment Specifications).