Frame Assembly

FRAME ASSEMBLY

TOOLS REQUIRED
- J43628 Frame Alignment Tool

REMOVAL





1. On L81 vehicles, remove rear exhaust manifold pipe heat shield.





2. Remove rear transaxle mount through bolt, and transaxle mount to frame bolt.





3. Fasten radiator to upper radiator support.
4. Raise vehicle.
5. Remove front wheel and tire assemblies.





6. Remove right front lower splash shield.
7. Remove left front wheel liner push pin from frame.





8. On vehicles equipped with L61 engines, disconnect rear O2 sensor connection, and remove harness from frame at attachment points.





9. On L81 vehicles, remove exhaust manifold pipe.





10. Remove front transaxle mount through bolt.





11. Remove remaining rear transaxle mount-to-frame bolts.





12. Remove the A/C line-to-frame attachment clip at front of vehicle.





13. Remove steering gear-to-frame assembly bolts.





14. On L61 vehicles, remove steering gear heat shield.
15. Using mechanics wire, secure the steering gear assembly to body of vehicle.
16. Remove stabilizer bar links from strut assembly.

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





17. Remove lower ball stud bolt and separate ball stud from steering knuckle assembly.





18. Remove suspension support assemblies.
19. Remove suspension support cage nuts from body. Discard cage nuts and support bolts, as new nuts and bolts must be used for assembly.





20. Using powertrain lifting table and the Frame Alignment Tool J43628, support frame assembly.





21. Remove remaining frame-to-body attachment fasteners.
22. Carefully lower frame assembly from vehicle.
23. Remove frame assembly cage nuts from body. Discard cage nuts and frame bolts as new nuts and bolts must be used for assembly.

INSTALLATION





NOTICE: Install new cage nuts into the body as torque retention of old nuts may not be sufficient.

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

1. Raise frame assembly to body.

IMPORTANT: Do not tighten fastener at this time.





2. Install new frame-to-body bolts.





3. Install new cage nuts into body for suspension supports, as torque retention of old nuts may not be sufficient.
4. Install suspension supports using new bolts. Tighten all frame bolts.
Torque:
Suspension Support-to-Frame Bolts: 90 Nm (66 ft. lbs.) + 45 to 60°





5. Install ball stud into steering knuckle.
Torque:
Lower Control Arm-to-Steering Knuckle Nut and Bolt: 100 Nm (75 ft. lbs.)





6. Install steering gear-to-frame using new bolts and nuts.
Torque:
Steering Gear-to-Frame Assembly Bolts: 45 Nm (33 ft. lbs.) + 45 to 60°
7. On L61 vehicles, install steering gear heat shield.
Torque:
Steering Gear Heat Shield: 4 Nm (35 inch lbs.)





8. Install stabilizer bar link-to-strut assembly
Torque:
Stabilizer Bar Link-to-Strut Assembly: 65 Nm (48 ft. lbs.)





9. Install rear transaxle mount to frame bolts
Torque:
Transaxle Mount (Rear)-to-Frame Assembly Bolts: 60 Nm (44 ft. lbs.)





10. Install front transaxle mount through bolt
Torque:
Front Transaxle Mount Thru Bolt: 55 Nm (41 ft. lbs.)
11. On L81 vehicles, install exhaust manifold pipe.





12. Tighten exhaust manifold pipe-to-exhaust manifold nuts.
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (22 ft. lbs.)
13. Tighten exhaust manifold pipe-to-exhaust pipe bolts.
Torque:
Exhaust Manifold Pipe-to-Exhaust Pipe Bolts: 20 Nm (15 ft. lbs.)





14. Reattach A/C line clip to front of frame assembly.





15. Install right front lower splash shield.
Torque:
Splash Shield Fasteners: 5 Nm (44 ft. lbs.)
16. Install left front wheel liner push pin to frame.





17. Connect O2 sensor electrical connector and reattach harness to frame.

CAUTION: BEFORE INSTALLING WHEELS, REMOVE RUST OR CORROSION FROM WHEEL MOUNTING SURFACES AND BRAKE ROTORS. FAILURE TO DO SO CAN CAUSE WHEEL BOLTS TO LOOSEN IN SERVICE.

18. Install wheel and tire assemblies onto hub.
19. Install wheel bolts and tighten in a cries-cross pattern.
19.1 Hand tighten all five wheel bolts.
19.2 Use a torque wrench to tighten wheel bolts using a criss-cross pattern.
Torque:
Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
19.3 Use a torque wrench to final tighten wheel bolts using a cries-cross pattern.
Torque:
Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
20. Lower vehicle.





21. Install remaining rear transaxle mount-to-frame bolts.
Torque:
Transaxle Mount (Rear)-to-Frame Assembly Bolts: 60 Nm (44 ft. lbs.)
22. Install rear powertrain mount through bolt.
Torque:
Transaxle Mount (Rear) Through Bolts: 90 Nm (66 ft. lbs.)





23. On L81 vehicles, install exhaust manifold pipe heat shield.
Torque:
Exhaust Manifold Pipe Heat Shield Bolts: 8 Nm (71 inch lbs.)
24. Perform vehicle alignment.