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CROSSMEMBER, Rear: Installation: Installation

WARNING: This page is about a different car, the 2010 Dodge Charger and 2010 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: REAR CROSSMEMBER POSITIONED ON JACK
GC0080379Courtesy of CHRYSLER LLC
  1. Install rear crossmember (1) on jack (2) head in same position in which it was removed and secure in place.
    Fig 2: CAMBER AND TENSION LINKS
    GC0079753Courtesy of CHRYSLER LLC
  2. Carefully place one side knuckle with links and parking brake cable attached as an assembly into mounted position on rear suspension crossmember. Install nut and bolt (2) mounting camber link to crossmember (1) to hold assembly in place. Do not tighten at this time. 
  3. Carefully place opposite side knuckle with links and parking brake cable attached as an assembly into mounted position on rear suspension crossmember. Install nut and bolt (2) mounting camber link to crossmember (1) to hold assembly in place. Do not tighten at this time. 
  4. On each side of crossmember, install nut and bolt (4) mounting each tension link to crossmember (1). Do not tighten at this time. 
    Fig 3: COMPRESSION LINK MOUNTING
    GC0079756Courtesy of CHRYSLER LLC
  5. On each side of crossmember, Install bolt and nut (1) mounting each compression link (3) at crossmember. Do not tighten at this time. 
    Fig 4: TOE LINK MOUNTING
    GC0079760Courtesy of CHRYSLER LLC
  6. On each side of crossmember, slide cam bolt (2) attaching toe link through crossmember and link (1) from rear.
    Fig 5: REAR TOE ADJUSTMENT BOLT NUT
    GC0079759Courtesy of CHRYSLER LLC
  7. On each side of crossmember, while holding toe adjustment cam bolt from rotating, install cam washer (2) and nut (3) securing toe link at crossmember (1). Do not tighten at this time. 
    Fig 6: SPRING LINK MOUNTING
    GC0095729Courtesy of CHRYSLER LLC
  8. On each side of crossmember, install bolt and nut (1) fastening spring link (4) to crossmember. Do not tighten at this time. 
    Fig 7: CABLES AT CROSSMEMBER BRACKET
    GC0079866Courtesy of CHRYSLER LLC
  9. On each side of crossmember rear, guide leading end of rear parking brake through crossmember bracket (1 - left) (2 - right) near equalizer and press cable housing retainer into bracket allowing retainer fingers to lock cable in place.
    Fig 8: REAR CABLE ROUTING TO KNUCKLE
    GC0079865Courtesy of CHRYSLER LLC
  10. On each side of crossmember rear, install J-nut for parking brake cable guide.
  11. On each side, install screw fastening parking brake cable routing guide (1) to crossmember.
    Fig 9: REAR STABILIZER BAR MOUNTING
    GC0079774Courtesy of CHRYSLER LLC
  12. Install stabilizer bar (4) with cushions and retainers on crossmember.
  13. Install cushion retainer mounting bolts (1). Do not tighten at this time. 
  14. Install bolt (3) and nut fastening stabilizer bar ends to each stabilizer link (2). Do not tighten at this time. 
  15. Tighten cushion retainer mounting bolts (1) to 60 N.m (44 ft. lbs.).
    Fig 10: Rear Axle-to-Crossmember Bolts
    GC0081134Courtesy of CHRYSLER LLC
    CAUTION: Differential mounting bolts (1) must be installed through bushings prior to crossmember installation in vehicle. Bolts cannot be inserted through bushings once crossmember is installed.
  16. Transfer differential mounting bolts (1) from original crossmember differential mount bushings to bushings in replacement crossmember. Install bolts from rear. Be sure to insert bolts through correct mount bushings in crossmember depending on rear axle differential (198 mm axle differential shown in figure).
    NOTE: Do not install coil springs on spring links at this time.
    Fig 11: COIL SPRING AND SHOCK ASSY.
    GC0095728Courtesy of CHRYSLER LLC
  17. Raise crossmember to body mounting points. As crossmember is raised, align shocks (3) with pockets in spring links. Do not install bolts at this time. 
    Fig 12: REAR CROSSMEMBER MOUNTING BOLTS
    GC0095727Courtesy of CHRYSLER LLC
    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  18. 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 13: COIL SPRING AND SHOCK ASSY.
    GC0095728Courtesy of CHRYSLER LLC
    CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  19. 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.
  20. 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 14: SHOCK MOUNTING - LOWER
    GC0079751Courtesy of CHRYSLER LLC
  21. 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.
  22. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 15: AWD CROSSMEMBER SPACERS
    GC0079752Courtesy of CHRYSLER LLC
  23. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place.
    Fig 16: REAR CROSSMEMBER MOUNTING BOLTS
    GC0095727Courtesy of CHRYSLER LLC
    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  24. 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. 
  25. Remove both front and rear crossmember mounting bolts (2 and 3) on left  side of vehicle.
    Fig 17: COIL SPRING AND SHOCK ASSY.
    GC0095728Courtesy of CHRYSLER LLC
    CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  26. 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.
  27. 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 18: SHOCK MOUNTING - LOWER
    GC0079751Courtesy of CHRYSLER LLC
  28. 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.
  29. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 19: AWD CROSSMEMBER SPACERS
    GC0079752Courtesy of CHRYSLER LLC
  30. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place.
    Fig 20: REAR CROSSMEMBER MOUNTING BOLTS
    GC0095727Courtesy of CHRYSLER LLC
    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  31. 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 21: Marking Location Of Crossmember Mount To Body
    GC0079773Courtesy of CHRYSLER LLC
    1 - BODY
    2 - MARKER (OR CRAYON)
    3 - CROSSMEMBER BUSHING FLANGE
  32. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
    Fig 22: MEASURING TENSION LINK CLEARANCE
    GC0079754Courtesy of CHRYSLER LLC
  33. 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. Re-measure opposite side to be sure it still maintains minimum 12 mm distance.
    Fig 23: REAR CROSSMEMBER MOUNTING BOLTS
    GC0095727Courtesy of CHRYSLER LLC
  34. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.).
    Fig 24: JACK POSITIONED BENEATH CROSSMEMBER
    GC0095726Courtesy of CHRYSLER LLC
  35. Remove jack (2) from under rear crossmember.
    Fig 25: FILLER TUBE ASSEMBLY
    GC0079748Courtesy of CHRYSLER LLC
  36. Install fuel filler tube. Refer to Fuel System/Fuel Delivery/TUBE, Fuel Tank Filler - Installation
    Fig 26: WSS ROUTING ALONG LEFT TOE LINK
    GC0079758Courtesy of CHRYSLER LLC
  37. Clip left rear wheel speed sensor cable (2) to routing clip (1) above toe link mount on rear crossmember.
    Fig 27: LEFT WSS ROUTING OVER REAR DIFFERENTIAL
    GC0079877Courtesy of CHRYSLER LLC
  38. Clip left rear wheel speed sensor cable (1) to routing clips (2) along rear of crossmember near rear differential (3).
    Fig 28: LEFT/RIGHT REAR WHEEL SPEED SENSOR ROUTING
    GC0079772Courtesy of CHRYSLER LLC
  39. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
    Fig 29: SENSOR CONNECTION TO BODY CONNECTOR
    GC0079771Courtesy of CHRYSLER LLC
  40. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
  41. 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 30: REAR CALIPER MOUNTING
    GC0079769Courtesy of CHRYSLER LLC
  42. If equipped with standard or premium disc brakes, on each rear disc brake:
    1. Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing.
    2. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3).
    3. Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 31 N.m (23 ft. lbs.) torque.
    4. Make sure brake hose is properly routed and will not come in contact with suspension components.
  43. If equipped with SRT8 disc brakes, at each rear disc brake, support spring link using a transmission jack or other appropriate jack as indicated in removal procedure. See Frame and Bumpers/Frame/CROSSMEMBER - Removal 
    Fig 31: REAR CALIPER MOUNTING - SRT8
    GC0079734Courtesy of CHRYSLER LLC
  44. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
  45. If equipped with SRT8 disc brakes, on each rear disc brake, install caliper mounting bolts (1). Tighten bolts to 130 N.m (96 ft. lbs.).
  46. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.
    Fig 32: CABLES AT EQUALIZER
    GC0079766Courtesy of CHRYSLER LLC
  47. Route front parking brake cable with equalizer above rear crossmember.
    NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
  48. Connect left rear parking brake cable (1) to equalizer (2).
  49. Connect right rear parking brake cable (4) to connector (3) already attached to front parking brake cable (5).
    Fig 33: FRONT CABLE AT LEFT FRONT OF CROSSMEMBER
    GC0079768Courtesy of CHRYSLER LLC
  50. Install J-nut for mounting parking brake cable routing bracket to crossmember.
  51. Insert front parking brake cable routing bracket locating pin into front flange of crossmember (3), then install screw (2) fastening cable (1) routing bracket to rear crossmember.
    Fig 34: HUB NUT
    GC0079730Courtesy of CHRYSLER LLC
    NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.
  52. On each side of vehicle, slide an axle half shaft (2) through hub and bearing and install hub nut (1). Do not tighten hub nuts at this time. 
  53. Install rear axle differential. Refer to Differential and Driveline/Rear Axle - 200MM - Installation . Refer to Differential and Driveline/Rear Axle - 215RII - Installation
  54. While a helper applies brakes to keep hub from turning, tighten hub nut to 213 N.m (157 ft. lbs.).
    Fig 35: Exhaust System
    GC0081121Courtesy of CHRYSLER LLC
  55. Install rear exhaust system (2) (dual-outlet exhaust shown in figure).
    Fig 36: JACK STAND UNDER CONTROL ARM
    GC0079755Courtesy of CHRYSLER LLC
  56. Lower vehicle until front tires contact floor but rear is still suspended. Place jack stands under each rear suspension spring link. Place an appropriate wooden block between stand and link to avoid damaging spring link, then lower vehicle until full vehicle weight is supported by suspension.
    Fig 37: CAMBER AND TENSION LINKS
    GC0079753Courtesy of CHRYSLER LLC
  57. Tighten camber link bolt (2) at crossmember to 85 N.m (63 ft. lbs.).
  58. Tighten tension link bolt nut (2) at crossmember to 85 N.m (63 ft. lbs.).
    Fig 38: COMPRESSION LINK MOUNTING
    GC0079756Courtesy of CHRYSLER LLC
  59. Tighten compression link bolt (2) at crossmember to 85 N.m (63 ft. lbs.) torque.
    Fig 39: SPRING LINK MOUNTING
    GC0095729Courtesy of CHRYSLER LLC
  60. Tighten spring link bolt (1) at crossmember to 108 N.m (80 ft. lbs.).
    Fig 40: SHOCK MOUNTING - LOWER
    GC0079751Courtesy of CHRYSLER LLC
  61. Tighten shock absorber lower mounting bolt nut (4) to 72 N.m (53 ft. lbs.).
    Fig 41: REAR STABILIZER BAR MOUNTING
    GC0079774Courtesy of CHRYSLER LLC
  62. Tighten stabilizer link bolts (3) to 61 N.m (45 ft. lbs.).
    Fig 42: JACK STAND UNDER CONTROL ARM
    GC0079755Courtesy of CHRYSLER LLC
  63. Raise vehicle and remove jack stands (3).
    Fig 43: TIRE AND WHEEL MOUNTING
    GC0079683Courtesy of CHRYSLER LLC
  64. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.). Refer to Tires and Wheels - Installation
  65. Lower vehicle.
    Fig 44: BATTERY AND CABLES
    GC0079763Courtesy of CHRYSLER LLC
  66. Connect battery negative cable (2) to battery post. It is important that this is performed properly. Refer to Electrical/Battery System - Standard Procedure
  67. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  68. Perform wheel alignment, paying special attention to thrust angle. If rear crossmember needs to be shifted to align thrust angle, try to avoid compromising tension link clearance (Refer to  33). Refer to Front Suspension/Wheel Alignment - Standard Procedure
    Fig 45: REAR TOE ADJUSTMENT BOLT NUT
    GC0079759Courtesy of CHRYSLER LLC
  69. On each side of crossmember, while holding cam bolt from turning, tighten toe link cam bolt nut (2) to 108 N.m (80 ft. lbs.) torque.
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