Bushing-Rear CROSSMEMBER Front Mount: Installation

Fig 1: FRONT BUSHINGS - LEFT AND RIGHT

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CAUTION: Prior to bushing installation, inspect the bushing to make sure it is the correct side bushing for the job. Left side bushings have the travel limiter (1) tipped to the right in relationship to the bushing (4) can flange as shown in Fig 1. Right side bushings have the travel limiter (2) tipped to the left in relationship to the bushing (3) can flange as shown. Once installed, the travel limiters with face slightly outward from straight-ahead position.

CAUTION: It is very important that bushing be installed in same position as original to maintain vehicle ride quality and bushing longevity. That is why bushing, once installed, needs to closely match reference marks applied upon removal of original bushing.

1. Position bushing on crossmember bushing bore aligning bushing can flange with reference marks applied during removal.
   Fig 2: FRONT BUSHING INSTALLATION

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2. Assemble tools (See following list) over bushing and crossmember as shown in Fig 2.
   1. (2) Receiver 9031-6
   2. (3) Press C-4212F
   3. (4) Installer 9031-7A
   Fig 3: INSTALLER POSITIONED ON BUSHING

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   NOTE: Ensure Installer (3), Special Tool 9031-7, is positioned that it will clear compression link bracket (1) while bushing is being installed.
3. Tighten Press (2) screw-drive, pressing bushing into crossmember. Install bushing until bushing can flange contacts surface of crossmember.
4. Remove tools.
5. Verify bushing closely lines up with reference marks applied during removal.
   Fig 4: COMPRESSION LINK MOUNTING

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6. Install bolt and nut (1) as shown fastening compression link (3) to crossmember. See Fig 4. Do not tighten bolt at this time. 
   NOTE: Do not reinstall coil springs on spring links at this time. Install as directed in later steps.
   Fig 5: CABLE ROUTING BRACKET AT REAR CROSSMEMBER

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7. Raise crossmember using jack until there is about 10 inches clearance to the to body mounting points.
8. Install screw (2) fastening front parking brake cable routing bracket (1) to rear crossmember.
   Fig 6: Propeller Shaft at Rear Axle

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9. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft (1) onto rear axle differential flange (2) and align shock absorbers with pockets in spring links.
   Fig 7: REAR CROSSMEMBER MOUNTING BOLTS

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   NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
10. Continue to raise crossmember (1) with jack until crossmember mounting bolts (2 and 3) can be installed. Install left side crossmember mounting bolts, but not the right side bolts. It is not necessary to tighten bolts at this point.
    Fig 8: COIL SPRING AND SHOCK ASSY.

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    CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
11. Slowly  lower jack allowing right side of crossmember to drop. Do not lower jack at a fast rate.  Lower jack just enough to allow spring (2) Installation. Do not lower jack any further than necessary. 
    NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
12. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
    Fig 9: SHOCK MOUNTING - LOWER

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13. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
14. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 10: AWD CROSSMEMBER SPACERS

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15. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place.
    Fig 11: REAR CROSSMEMBER MOUNTING BOLTS

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    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
16. Raise right side of crossmember (1) into mounted position. Install right side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time. 
17. Remove both front and rear crossmember mounting bolts (2 and 3) on left  side of vehicle.
    Fig 12: COIL SPRING AND SHOCK ASSY.

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    CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
18. Slowly  lower jack allowing left side of crossmember to drop. Do not lower jack at a fast rate.  Lower jack just enough to allow spring (2) Installation. Do not lower jack any further than necessary. 
    NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
19. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
    Fig 13: SHOCK MOUNTING - LOWER

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20. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
21. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 14: AWD CROSSMEMBER SPACERS

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22. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place.
    Fig 15: REAR CROSSMEMBER MOUNTING BOLTS

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    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
23. Raise left side of crossmember (1) into mounted position. Install left side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time. 
    Fig 16: Marking Location Of Crossmember Mount To Body

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    1 - BODY

    2 - MARKER (OR CRAYON)

    3 - CROSSMEMBER BUSHING FLANGE

24. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
    Fig 17: MEASURING TENSION LINK CLEARANCE

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25. Once mounts are lined up with location marks, on both sides of vehicle, measure distance (1) between the tension link (2) and weld flange (3) on body directly in front of it, just outboard of the front mount bushing (4). This distance must be at least 12 mm to allow proper clearance for suspension movement.  If distance is less than 12 mm on either side of vehicle, shift that side of rear crossmember directly rearward until distance is 12 mm or greater. To do so, loosen 3 mounting bolts slightly, leaving one on opposite side of shift snugged to pivot off of. Shift crossmember rearward and snug loosened bolts. Remeasure opposite side to be sure it still maintains minimum 12 mm distance.
    Fig 18: REAR CROSSMEMBER MOUNTING BOLTS

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26. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.) torque.
    Fig 19: SUPPORT REAR SUSPENSION USING JACK

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27. Remove jack (3) from under rear axle differential.
    Fig 20: PROP SHAFT SUPPORT BY BUNGEE CORD

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28. Remove bungee cord (1) supporting propeller shaft (2).
    Fig 21: Propeller Shaft at Rear Axle

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29. Align propeller shaft index marks (3) placed upon removal. Install propeller shaft rear coupler-to-axle flange bolts and nuts by hand. Tighten propeller shaft rear coupler-to-axle flange bolts to 81 N.m (60 ft. lbs.) torque.
    Fig 22: FILLER TUBE ASSEMBLY

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30. Install fuel filler tube. (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK FILLER TUBE - INSTALLATION)
    Fig 23: LEFT/RIGHT REAR WHEEL SPEED SENSOR ROUTING

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31. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
    Fig 24: SENSOR CONNECTION TO BODY CONNECTOR

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32. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
33. Insert speed sensor connectors (3 and 4) into body wiring harness connector (1) located in luggage compartment floor pan (2). When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.
    Fig 25: REAR CALIPER MOUNTING

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34. On each rear disc brake:
    CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed.
    • Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing.
    • Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3).
    • Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 60 N.m (44 ft. lbs.) torque.
    • Make sure brake hose is properly routed and will not come in contact with suspension components.
    Fig 26: CABLE CONNECTIONS AT REAR

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35. Route parking brake cable above rear crossmember, then slide cable (2) through equalizer (4) above rear differential.
    NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
36. Connect front parking brake cable (2) at connector (1) to right rear parking brake cable (6).
    Fig 27: Exhaust System

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37. Install rear exhaust system (2) (dual-outlet exhaust shown in Fig 27 ). (Refer to EXHAUST SYSTEM .
    Fig 28: TIRE AND WHEEL MOUNTING

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38. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.) torque. (Refer to TIRES/WHEELS - INSTALLATION)
39. Lower vehicle until rear wheels are just above floor level.
40. Apply parking brake lever. Release lever, then reapply.
41. Check to make sure rear wheels will not rotate with lever applied.
42. Lower vehicle.
    Fig 29: LX BATTERY AND CABLES

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43. Connect battery negative cable (2) to battery post. It is important that this is performed properly. (Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
44. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
45. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
    Fig 30: SHOCK MOUNTING - LOWER

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46. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft. lbs.) torque.
    Fig 31: COMPRESSION LINK MOUNTING

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47. Tighten compression link bolt and nut (1) at crossmember to 85 N.m (63 ft. lbs.) torque.
48. Perform wheel alignment. (Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)