In-Vehicle Crossbeam

IN-VEHICLE CROSSBEAM

Five Hundred Montego (Part 1):

Five Hundred Montego (Part 2):

Freestyle (Part 1):

Freestyle (Part 2):

Exploded View

Removal
1. Remove the instrument panel upper section.
2. Evacuate and recover the A/C system.
3. Drain the cooling system.







4. Remove the transaxle roll restrictor bolt.







5. NOTE: LH side shown; RH side similar.

Remove the transaxle roll restrictor bar bolts.







6. Disconnect the heater hoses.
7. Remove the thermostatic expansion valve (TXV) manifold bolt.
- Discard the O-ring seals.

8. Remove the powertrain control module (PCM).







9. Remove the LH instrument panel cowl top bolt.







10. Remove the 2 RH instrument panel cowl top bolts.







11. NOTE: Freestyle shown; Five Hundred, Montego similar.

Remove the steering column pinch bolt.

12. Remove the 4 tunnel brace bolts.
13. Disconnect the small restraints control module (RCM) electrical connector.







14. Disconnect the large RCM electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops.
2 Pull out and disconnect the large RCM electrical connector.

15. CAUTION: To avoid injury or damage to the crossbeam, the help of an assistant is required to carry out this step.

NOTE:
- Mark the location of the crossbeam bolts for correct alignment upon installation.
- Remove the bolts from one side completely and support the crossbeam before removing bolts from the other side.

Remove the crossbeam.
- Remove the tunnel reinforcement bolts.

16. If installing a new in-vehicle crossbeam, remove the heater core and evaporator core housing.

Installation
1. If installing a new in-vehicle crossbeam, install the heater core and evaporator core housing.

2. CAUTION: To avoid injury or damage to the crossbeam, the help of an assistant is required to carry out this step.

NOTE: Install a bolt on each side and finger tighten to support the crossbeam, then install the remaining bolts.

Using the previously marked alignment points, position the crossbeam and install the 6 tunnel reinforcement bolts.
- Tighten to 25 Nm (18 lb-ft).







3. Make sure the large RCM electrical connector position assurance lever is in the full release position before attempting to connect the connector.







4. CAUTION: Placing the large RCM electrical wiring connector into the RCM at an angle can cause bad connections and damage components.

Position the large RCM electrical wiring connector into the RCM.

- CAUTION: Do not push the connector to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector.

With the large RCM electrical wiring connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt.







5. Connect the large RCM electrical wiring connector.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM.
- Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.







6. NOTE: Freestyle shown; Five Hundred, Montego similar.

Install the steering column pinch bolt.
- Tighten to 25 Nm (18 lb-ft).







7. Install the RH instrument panel cowl top bolts.
- Tighten to 25 Nm (18 lb-ft).







8. Install the LH instrument panel cowl top bolt.
- Tighten to 25 Nm (18 lb-ft).

9. Install the TXV manifold bolt.
- Install the new O-ring seals.
- Tighten to 8 Nm (71 lb-in).







10. Connect the heater hoses.
11. Install the PCM.







12. NOTE: LH side shown; RH side similar.

Install the transaxle roll restrictor bar bolts.
- Tighten to 55 Nm (41 lb-ft).







13. Install the transaxle roll restrictor bolt.
- Tighten to 48 Nm (35 lb-ft).

14. Fill and bleed the engine cooling system.
15. Fill the A/C system.
16. Install the instrument panel upper section.