Subframe: Service and Repair

Frame Replacement


Tools Required
* J43628 Frame Alignment Fixture
* KM671Bushing Remover/Installer
* KM907 Bushing Remover/Installer
* KM-907-11
* KM-907-12
* KM-907-30
* SA9140E Torque Angle Gauge



Removal

1. On vehicles equipped with L81 engines, remove the rear exhaust manifold pipe heat shield.
2. Remove the rear transaxle mount through bolt, and the transaxle mount-to-frame bolt.
3. Fasten the radiator to the upper radiator support.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

4. Raise the vehicle on a hoist.
5. Remove the front wheel and tire assemblies.
6. Remove the right front lower splash shield.
7. Remove the left front wheel liner push pin from frame.
8 Disconnect the rear O2 sensor connection, and remove the harness from the frame at the attachment points.
9. On L61, remove the O2 sensor clamp to underbody attachment nut.
10. Remove the exhaust manifold pipe on L81 engines, and on L61 engines with a manual transaxle. (L81 shown)
11. Remove the front transaxle mount through bolt.
12. Remove the remaining rear transaxle mount-to-frame bolts.
13. Remove the rear transaxle mount.
14. Remove the steering gear-to-frame bolts. Discard the bolts and nuts.
15. On vehicles equipped with L61 engines and automatic transaxle, remove the steering gear heat shield.
16. Using mechanics wire, secure the steering gear assembly to the body of the vehicle.
17. On L61 with a manual transaxle, remove the frame to shifter link pivot pin clip.
18. Remove the A/C line to frame attachment clip at the front of the vehicle.

Notice: Hold the ball stud from turning when removing/installing the nut. The boot can become torn and damaged if the ball stud turns.

19. Remove the stabilizer bar links from the strut and discard the nuts.

Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

20. Remove the lower ball stud bolt and separate the ball stud from the steering knuckle assembly.
21. Remove the suspension support assemblies.
22. Remove the suspension support cage nuts from the body. Discard the cage nuts and support bolts, as new nuts and bolts must be used for assembly.
23. Using powertrain lifting table and the J43628 Frame Alignment Fixture, support frame assembly.
24. Remove the remaining frame-to-body attachment fasteners.
25. Carefully lower the frame assembly from the vehicle.
26. Remove the frame assembly cage nuts from the body. Discard the cage nuts and frame bolts as new nuts and bolts must be used for assembly.



Disassembly

1. Remove the stabilizer clamp-to-frame bolts.
2. Remove the stabilizer bar and clamps.
3. Remove the control arm-to-frame assembly bolts and discard the bolts.
4. Remove the control arm from the frame.
5. Using tools KM671Bushing Remover/Installer KM907 Bushing Remover/Installer, KM-907-11, KM-907-12 and KM-907-30, press out the outer 4 damping bushings.
6. Using Bushing Remover/Installer KM-907, KM-907-11, and KM-907-12 press out the center 2 damping bushings.



Assembly

1. Install the outer 4 damping bushings using tool KM-671 along with KM-907-13 and KM-907-14.
2. Install center 2 damping bushings using tool KM-907-11 and KM-907-22.
3. Install the stabilizer bar to the frame assembly.

Tighten the stabilizer bar clamp-to-frame bolts to 20 N.m (15 lb ft).


Important: Use new bolts. The torque retention of old bolts may not be sufficient.


4. Using the SA9140E , install the control arms to frame assembly using new bolts.

Tighten the control arm-to-frame to 90 N.m (66 lb ft) +75-90 degrees.




Installation

1. Important: Be sure the frame alignment tool fully engages in all gauge holes.


Install NEW cage nuts into the body as torque retention of old nuts may not be sufficient.
2. Raise the frame assembly to the body.
Important: Do not tighten fastener at this time.



3. Install NEW frame-to-body bolts.
4. Install NEW cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
5. Install suspension supports using NEW bolts and tighten all frame bolts using SA9140E or equivalent.

Tighten the suspension support-to-body bolts to 90 N.m (66 lb ft) +45-60 degrees.


Important: Use a new bolt and nut. The torque retention of old fasteners may not be sufficient.


6. Install the lower control arm ball stud into the steering knuckle. Hold the bolt stationary while turning the nut.

Tighten the lower control arm-to-steering knuckle to 100 N.m (75 lb ft).

7. On vehicles equipped with L61 and manual transaxle, install the frame to shifter link pivot pin clip.
8. Install the steering gear-to-frame using new bolts and nuts and tighten using SA9140E or equivalent).

Tighten the steering gear-to-frame to 45 N.m (35 lb ft) +90 degrees.

9. On vehicles equipped with an L61 engine and automatic transaxle, install steering gear heat shield.

Tighten the steering gear heat shield-to-frame to 7 N.m (35 lb in).


Notice: Hold the ball stud from turning when removing/installing the nut. The boot can become torn and damaged if the ball stud turns.

10. Using new nuts, install the stabilizer bar link-to-strut assembly.

Tighten the stabilizer bar link-to-strut to 65 N.m (48 lb ft).

11. Inspect the rubber boots for damage and replace the boots if damaged.
12. Install the rear transaxle mount.
13. Install the 2 rear transaxle mount to frame bolts.

Tighten the rear transaxle mount-to-frame bolts to 60 N.m (44 lb ft).

14. Install the front transaxle mount through bolt.

Tighten the front transaxle mount through bolt to 55 N.m (41 lb ft).

15. Install the exhaust manifold pipe on L81 engines and on L61 engines with manual transaxles. (L81 shown)
16. Tighten exhaust manifold pipe to exhaust manifold.

Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N.m (22 lb ft).

17. Tighten the exhaust manifold pipe to exhaust pipe.

Tighten the exhaust manifold pipe-to-pipe bolts to 20 N.m (15 lb ft).

18. On L61, install the O2 sensor clamp to underbody attachment nut.

Tighten the O2 sensor clip-to-underbody attachment nut to 4 N.m (35 lb in).

19. Reattach the A/C line clip to the front of the frame assembly.
20. Install the right front lower splash shield.

Tighten the right splash shield-to-body to 5 N.m (44 lb in).

21. Install the left front wheel liner push pin to frame.

Notice: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

22. Connect the O2 sensor electrical connector and reattach the harness to the frame.
23. Position the wheel onto the hub.
24. Install the wheel bolts and tighten in a crisscross pattern.

* Hand tighten all five wheel bolts.
* Use a torque wrench to tighten the wheel bolts using a crisscross pattern.

Tighten the wheel bolts - initial torque to 63 N.m (46 lb ft).

* Use a torque wrench to final tighten the wheel bolts using a crisscross pattern.

Tighten the wheel bolts - final torque to 125 N.m (92 lb ft).

* Lower the vehicle from the hoist.

25. Install the remaining rear transaxle mount to frame bolt.

Tighten the rear transaxle mount-to-frame bolts to 60 N.m (44 lb ft).

26. Install the rear transaxle mount through bolt and heat shield, on vehicles equipped with 4-cylinder engine and automatic transaxle.

Tighten the rear transaxle mount through bolt to 90 N.m (66 lb ft).

27. On vehicles equipped with L81 engines, install the exhaust manifold pipe heat shield.

Tighten the exhaust manifold pipe heat shield bolts (L81) to 8 N.m (71 lb in).

28. Perform the vehicle alignment. Refer to Alignment procedure in the Alignment, Wheels and Tires section in this service manual.