Crossmember - Number 2

Crossmember - Number 2













Removal

NOTICE: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major repair expense. A new part with the same part number must be installed if installation is necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

1. Remove the generator. For additional information, refer to Charging System Service and Repair.

2. Remove the 3 pin-type retainers and the radiator sight shield.

3. Install the Engine Support Bars.





4. Disconnect the RH ABS electrical connectors.





5. Disconnect the LH ABS electrical connectors.





6. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury Procedures.

WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury.

Remove the LH and RH front wheel and tire assemblies. For additional information, refer to Wheels and Tires Removal and Replacement.

7. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring may result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Supplemental Restraint System Service and Repair.

Remove the bolt and detach the intermediate shaft from the steering gear.

8. Remove the 2 nuts and the 2 bolts from the LH No. 2 crossmember bracket and the 2 nuts and the 2 bolts from the RH No. 2 crossmember bracket.
- Separate the No. 2 crossmember brackets from the crossmember.

9. Raise and support the vehicle.

10. Remove the 2 engine mount nuts.

11. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut.

Remove the 2 nuts and disconnect the LH and RH stabilizer bar links.

12. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut.

Remove the 2 nuts and disconnect the LH and RH outer tie-rod ends.

13. Remove the 2 bolts and position the LH and RH brake hose and brackets assemblies aside.





14. Remove the 4 bolts and position the LH and RH brake calipers aside.
- Support the brake calipers away from the No. 2 crossmember.

15. Position the front LH and RH ABS harness aside.

1. Release the 2 ABS harnesses from the support bracket.

2. Remove the 2 bolts and the brackets.

3. Remove the 2 harness retainers from the frame.





16. Remove the 2 steering gear nuts.

17. Remove the 2 studs and position the steering gear aside.
- Support the steering gear away from the No. 2 crossmember.





18. Release the brake line from the retaining clips at the rear of the No. 2 crossmember.





19. Lower the vehicle.

20. Using the engine support bar, raise the engine to remove the engine weight from the No. 2 crossmember.

21. Raise and support the vehicle.

22. Remove the 3 LH lower control arm and 3 RH lower control arm rear mounting bolts.

23. Position a suitable support table under the No. 2 crossmember.

24. Remove the 4 No. 2 crossmember bolts.

25. Lower and remove the No. 2 crossmember assembly.

Installation

1. NOTE: Position the sway bar and the rear bushing plates into place as the No. 2 crossmember is being raised.

Raise and position the No. 2 crossmember assembly.

2. Install the 4 No. 2 crossmember bolts.
- Tighten to 250 Nm (184 lb-ft).

3. Position the LH and RH No. 2 crossmember brackets.

4. Remove the support table.

5. NOTICE: The bolts must be tightened in the sequence shown or damage to the crossmember bracket may occur.

Install the LH and RH No. 2 crossmember bracket nuts and bolts.

1. Tighten the rear bolt.
- Tighten to 103 Nm (76 lb-ft).

2. Tighten the front bolt.
- Tighten to 103 Nm (76 lb-ft).

3. Tighten the nuts.
- Tighten to 200 Nm (148 lb-ft).





6. Install the 3 LH lower control arm and 3 RH lower control arm rear mounting bolts.
- Tighten to 90 Nm (66 lb-ft).

7. Position the brake line into the retaining clips at the rear of the No. 2 crossmember.





8. Install the LH and RH ABS harness.

1. Install the 2 harness retainers into the frame.

2. Install the 2 brackets and bolts.

3. Install the 2 ABS harnesses into the support brackets.





9. Position the LH and RH brake calipers and install the 4 bolts.
- Tighten to 32 Nm (24 lb-ft).

10. Position the LH and RH brake hose and brackets and install the 2 bolts.





11. Position the steering gear and install the 2 steering gear studs.
- Tighten to 20 Nm (177 lb-in).





12. Install the 2 steering gear nuts.
- Tighten to 103 Nm (76 lb-ft).

13. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nut.

Position the LH and RH stabilizer bar links and install the 2 nuts.

- Install new nuts.

- Tighten to 63 Nm (46 lb-ft).

14. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nut.

Position the LH and RH tie-rod ends and install the 2 nuts.

- Install new nuts.

- Tighten to 80 Nm (59 lb-ft).

15. Lower the vehicle.

16. Connect the intermediate shaft to the steering gear and install the bolt.
- Tighten to 30 Nm (22 lb-ft).

17. Remove the Engine Support Bars.





18. Install the LH and RH front wheel and tire assemblies. For additional information, refer to Wheels and Tires Removal and Replacement.

19. Connect the RH ABS electrical connectors.





20. Connect the LH ABS electrical connectors.





21. Install the generator. For additional information, refer to Charging System Service and Repair.

22. Position the radiator sight shield and install the 3 pin-type retainers.

23. Raise and support the vehicle.

24. Install the 2 engine mount nuts.
- Tighten to 90 Nm (66 lb-ft).

25. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury Description and Operation.

26. Check the front end alignment and adjust as necessary. For additional information, refer to Suspension System - General Information Service and Repair.