Service Procedure

The following procedure provides instructions for inspecting, and if necessary, replacing the front frame (cradle) assembly.

1. Raise the vehicle on a suitable hoist and support as necessary.





Important
If the inspection in the next step determines that a frame replacement is required, contact the Technical Assistance Center to obtain one.

2. Locate the date code stamped on the frame assembly near the transmission pan as shown. For this inspection we are looking for frames made during a certain time frame on one particular day this year. The date codes involved are J4, 128, 10, 20, 27 to J4, 128, 13, 25, 54 A date code is broken down as follows: J4 = Calendar Year 2004 128 = Day 128 (May 7th) 10 = Hour (10 am) 20 = Minute (10:20 am) 27 = Second (10:20 am and 27 seconds)

^ "DAY" Begin with the Day number. If the "day" number in the date code is not 128, the frame does NOT need to be replaced. If the "day" number is 128, proceed to the next step and inspect the "hour."

^ "HOUR" If the "hour" number in the date code is 9 or less, or 14 or higher, the frame does NOT need to be replaced. If the number on the frame is 11 or 12, the frame must be replaced. If the number is 10 or 13, proceed to the next step and inspect the "minute."

^ "MINUTE" If the "hour" number is 10 and the "minute" number in the date code is 19 or less, then the frame does NOT need to be replaced. If the "minute" number on the frame is 21 or higher, the frame must be replaced. If the "minute" number is 20, then continue and inspect the "second" OR "MINUTE" If the "hour" number is 13 and the "minute" number in the date code is 24 or less, the frame must be replaced. If the "minute" number on the frame is 26 or higher the frame does NOT need to be replaced. If the "minute" number is 25, then proceed to the next step and inspect the "second."

^ "SECOND" If the "minute" number is 20 and the "second" number in the date code is 26 or less, the frame does NOT need to be replaced. If the "second" number is 27 or higher, the frame must be replaced. OR "SECOND" If the "minute" number is 25 and the "second" number in the date code is 54 or less, the frame must be replaced. If the "second" number is 55 or higher, the frame does NOT have to be replaced.

Frame Replacement

Tools Required

^ J 28467-B Universal Engine Support Fixture

^ J 36462-A Engine Support Adapter Leg Set

^ J 28467-501 Engine Support Fixture Adapters

The procedure should only be performed if the results of the inspection above indicated that frame replacement is required.

For additional information, see the appropriate sections of the service manual.








1. Lower the vehicle and open the hood.





2. Install universal engine support fixture J 28467-B with adapters (J 36462-A and J 28467-501) or equivalent.

3. Raise the vehicle and support as necessary.

4. Remove both front wheel/tire assemblies.





5. Remove the nut attaching the stabilizer bar link to the stabilizer bar.

6. Separate the link from the bar.

7. Position an adjustable support at the rear of the frame.

8. Remove the two rear frame to body bolts.





9. Remove the two nuts attaching the left side transmission mount to the frame.





10. Remove the two nuts attaching the right side engine mount to the frame.

11. Partially lower the rear of the frame.





12. Remove the two bolts attaching the steering gear to the frame.

13. Remove and reposition the steering gear from the frame.

14. Remove the one power steering cooler line retainer from the right side of the frame.





15. Remove the bolts from both lower control arms.

16. Separate both lower control arms from the frame.

17. Release the two clips attaching the wiring harness to the front of the frame.

18. Release the two clips attaching the power steering cooler lines to the front of the frame.

19. Release the clip attaching the left side ABS wiring harness to the frame.

20. Support the frame assembly as necessary.

21. Remove both front frame to body bolts.

22. Carefully lower and remove the frame assembly.





23. With the frame out of the vehicle, remove the bolts attaching the clamps, insulators, and stabilizer bar to the frame.

24. Install the stabilizer bar, insulators, and clamps to the NEW frame and install the bolts.

Tighten

Tighten the bolts to 30 Nm (22 lb ft).

25. Raise the NEW frame assembly to the body and install the front two frame to body bolts. DO NOT tighten at this time.

26. Attach the clip for the ABS wiring harness to the left side of the frame.

27. Attach the two clips for the power steering cooler lines to the front of the frame.

28. Attach the two clips for the wiring harness to the front of the frame.

29. Position both lower control arms to the frame and install the bolts. DO NOT tighten at this time.

30. Attach the one power steering cooler line retainer to the right side of the frame.

31. Install the steering gear in the frame brackets.

32. Install the steering gear to frame attaching bolts.

Tighten

Tighten the bolts to 90 Nm (66 lb ft).

33. Partially raise the frame closer to the body.

34. Align the right side engine mount to the frame and install the two nuts.

Tighten

Tighten the nuts to 47 Nm (35 lb ft).

35. Align the left side transmission mount to the frame and install the two nuts.

Tighten

Tighten the nuts to 47 Nm (35 lb ft).

36. Raise the frame to the body and install the rear frame to body bolts.

Tighten

Tighten the bolts to 180 Nm (133 lb ft).

37. Tighten the front frame to body bolts.

Tighten

Tighten the bolts to 180 Nm (133 lb ft).

38. Attach the stabilizer links to the stabilizer bar and install the nuts.

Tighten

Tighten the nuts to 45 Nm (33 lb ft).

39. Place an adjustable support under the outboard end of the lower control arms and raise the arms to normal curb height position.

Tighten

Tighten the lower control arm bolts to 125 Nm (92 lb ft).

40. Install the front wheels/tires and wheel nuts.

Tighten

Tighten the nuts to 140 Nm (103 lb ft).

41. Remove all supports and lower the vehicle.

42. Remove the engine support fixture.

43. Close the hood.