Frame Replacement

Frame Replacement

Tools Required
* J 43628 Frame Alignment fixture
* SA9140E Torque Angle Gauge

Removal Procedure




1. If equipped with a L81 engine, remove the rear exhaust manifold pipe heat shield. Refer to Exhaust Pipe Heat Shield Replacement in Engine Exhaust.




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




3. Secure the radiator to the upper radiator support.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.




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




8. Disconnect the rear O2 sensor harness push pins from the frame.




9. If equipped with a L61 engine, remove the O2 sensor harness to underbody clamp attachment nut.
10. Disconnect the exhaust manifold pipe from the exhaust manifold on L61 engine or manifolds on the L81 engine. Refer to Exhaust Manifold Pipe Replacement (Automatic Transmission - L61) Exhaust Manifold Pipe Replacement (Manual Transmission - L61) .




11. Remove the front transaxle mount through bolt.




12. Remove the remaining rear transaxle mount to frame bolts.
13. Remove the rear transaxle mount from the vehicle.




14. Remove the steering gear to frame bolts and nuts. Discard the bolts and nuts.
15. If equipped with a L61 engine, remove the steering gear heat shield. Refer to Power Steering Gear Heat Shield Replacement in Power Steering System.
16. Using mechanics wire, secure the steering gear to the vehicle body.




17. If equipped with a manual transmission, disconnect the frame to shiftier link pivot pin clip.




18. Disconnect the A/C pipe to frame clip at the front of the vehicle.




19. Disconnect the stabilizer bar link from the struts. Discard the nuts.




20. Disconnect the lower control arms from the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.




21. Remove the suspension support assemblies. Discard the bolts.
22. Remove the suspension support cage nuts from the body. Discard the nuts.
23. Use a powertrain lifting table and the J 43628 to support the frame assembly.




24. Remove the remaining frame to body bolts. Discard the frame to body bolts.
25. Lower the frame from the vehicle.
26. Remove all frame assembly cage nuts from the body and discard.




27. Remove the stabilizer shaft assembly. Refer to Stabilizer Shaft Replacement (W/L61) Stabilizer Shaft Replacement (W/L81) in Front Suspension.




28. Remove the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.
29. Remove the frame assembly from the powertrain lifting table and the J 43628 .

Installation Procedure

1. Install new frame cage nut and support cage nuts to the vehicle body.




2. Install the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.




3. Install the stabilizer shaft assembly to the frame. Refer to Stabilizer Shaft Replacement (W/L61) Stabilizer Shaft Replacement (W/L81) in Front Suspension.

Important: The J 43628 must fully engage in all frame gage holes.


4. Install the frame assembly to the powertrain lifting table and the J 43628 .
5. Raise the frame assembly to the body.




6. Loosely install new frame to body bolts.




7. Install the suspension supports using new bolts.

Notice: Refer to Fastener Notice in Cautions and Notices.

8. Tighten the suspension support bolts and frame mounting bolts using a SA9140E .

Tighten the bolts to 90 Nm (66 lb ft) plus an additional 45-60 degrees.




9. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.




10. On vehicles equipped with a manual transmission, install the frame to shiftier link pivot pin clip.




11. Install the steering gear to the frame using new frame to steering gear bolts.

Tighten the bolts to 45 Nm (35 lb ft).

12. If equipped with a L61 engine, install the steering gear heat shield. Refer to Power Steering Gear Heat Shield Replacement in Power Steering System.




13. Using new nuts, connect the stabilizer bar link to the struts. Refer to Stabilizer Shaft Link Replacement in Front Suspension.




14. Place the rear transaxle mount to the frame and install two mount to frame bolts.

Tighten the bolts to 60 Nm (44 lb ft).




15. Install the front transaxle mount through bolt.

Tighten the bolt to 55 Nm (41 lb ft).

16. Connect the exhaust manifold pipe to the manifold on the L61 engine or manifolds on the L81 engine. Refer to Exhaust Manifold Pipe Replacement (Automatic Transmission - L61) Exhaust Manifold Pipe Replacement (Manual Transmission - L61) in Engine Exhaust.




17. If equipped with a L61 engine, install the O2 sensor clamp to underbody nut.

Tighten the nut to 4 Nm (35 lb in).




18. Secure the A/C pipe clip to the front frame assembly.




19. Install the right front lower splash shield.

Tighten the splash shield to body bolts to 5 Nm (445 lb in).

20. Install the left front wheel liner push pin to the frame assembly.




21. Attach the O2 sensor harness to the frame assembly.
22. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
23. Lower the vehicle.




24. Install the remaining rear mount to frame bolt.

Tighten the bolt to 60 Nm (44 lb ft).

25. Install the rear transaxle mount through bolt.

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




26. If equipped with a L81 engine, install the rear exhaust manifold pipe heat shield. Refer to Exhaust Pipe Heat Shield Replacement in Engine Exhaust.
27. Align the front end. Refer to Measuring Wheel Alignment in Wheel Alignment.