Front Cross-Member: Service and Repair

RENEW

- Disconnect vehicle battery earth.

- Open bonnet and fit fender protectors.

- Attach 18G 1465 lifting eye to front of inlet manifold and MS 53C support bracket across engine bay and take the weight of the engine.

- Raise the front of the vehicle and position suitable supports.

- Note wheel to stud relationship, remove front wheels.

- Remove road spring RH / LH. Service and Repair

- Remove front shock absorber upper fixings and buffers RH / LH.

- Remove RH and LH front brake caliper/assemblies.

- Position steering to the straight ahead.

- Remove universal joint to steering rack pinion fixing and disengage joint from pinion.

Note: The universal joint cannot be completely disconnected from the pinion.

- Remove the power steering pipe to crossmember fixings and spacers.

- Disconnect the steering rack feed and return pipes, drain fluid into a suitable container.

- Fit blanking plugs to the pipes and rack.

- Reposition the pipes away from the suspension area.

- Dispose of drained fluid safely.

- Remove engine mounting upper securing nuts.

WARNING: ENSURE THAT THE ENGINE IS FULLY SUPPORTED BY THE SPECIAL TOOLS 18G 1465 AND MS 53.

- From below, support the crossmember assembly.





- Remove crossmember forward fixings (Fig. 1).

- Lower the crossmember assembly from the vehicle ensuring that the brake calipers, pipes and steering column joint are clear.

- Position the crossmember assembly onto a suitable work surface.

- Using special tool JD 100 to release track rod end tapers, remove and place aside steering rack assembly.

- Remove anti roll bar and mountings.

- Remove lower wishbone fulcrum tie bar.

- Remove lower wishbone fulcrum shaft RH / LH.

- Remove upper wishbone fulcrum shaft nut RH / LH.

- Support wishbone / hub assembly RH / LH and withdraw upper wishbone fulcrum shaft.

Note: Note position of, and retain wishbone fulcrum serrated washers.

- Remove engine mounting RH / LH.

- Remove 'V' mounting RH / LH.

- Reassembly of the crossmember and fining to the vehicle is the reversal of this procedure with special attention to the following:

Renew all self locking nuts.

Renew all bolts that were originally fined with thread locking adhesive.

Replace all '0' rings.

Check operation of brakes.

Check and adjust as required, steering geometry.

Fill power steering system with fresh fluid, start engine and cycle lock to lock three times; stop engine.

Check and correct oil level no sooner than 10 minutes after running.