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Bushing-Rear CROSSMEMBER Front Mount: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Front Bushings - Left and Right
GC0012998Courtesy of DAIMLERCHRYSLER CORP.
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 in Fig 1. 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
    GC0013000Courtesy of DAIMLERCHRYSLER CORP.
  2. Assemble tools (See following list) over bushing and crossmember as shown in Fig 2.
    • (2) Receiver 9031-6
    • (3) Press C-4212F
    • (4) Installer 9031-7A
    Fig 3: Installer Positioned on Bushing
    GC0012999Courtesy of DAIMLERCHRYSLER CORP.
    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
    GC0012997Courtesy of DAIMLERCHRYSLER CORP.
  6. Install bolt and nut as shown in Fig 4 (1) fastening compression link (3) to crossmember. 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: Propeller Shaft At Rear Axle Flange
    GC0012989Courtesy of DAIMLERCHRYSLER CORP.
  7. 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 6: Rear Crossmember Mounting Bolts
    GC0012981Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  8. 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 7: Identifying Coil Spring and Shock Assembly
    GC0012983Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  9. 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.
  10. 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 8: Shock Mounting - Lower
    GC0012978Courtesy of DAIMLERCHRYSLER CORP.
  11. 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.
  12. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 9: AWD Crossmember Spacers
    GC0012980Courtesy of DAIMLERCHRYSLER CORP.
  13. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place.
    Fig 10: Rear Crossmember Mounting Bolts
    GC0012981Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  14. 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. 
  15. Remove both front and rear crossmember mounting bolts (2 and 3) on left  side of vehicle.
    Fig 11: Identifying Coil Spring and Shock Assembly
    GC0012983Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  16. 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.
  17. 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 12: Shock Mounting - Lower
    GC0012978Courtesy of DAIMLERCHRYSLER CORP.
  18. 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.
  19. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 13: AWD Crossmember Spacers
    GC0012980Courtesy of DAIMLERCHRYSLER CORP.
  20. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place.
    Fig 14: Rear Crossmember Mounting Bolts
    GC0012981Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  21. 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 15: Marking Location of Crossmember Mount to Body
    GC0000269Courtesy of DAIMLERCHRYSLER CORP.
    1 - BODY
    2 - MARKER (OR CRAYON)
    3 - CROSSMEMBER BUSHING FLANGE
  22. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
    Fig 16: Measuring Tension Link Clearance
    GC0012986Courtesy of DAIMLERCHRYSLER CORP.
  23. 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 17: Rear Crossmember Mounting Bolts
    GC0012981Courtesy of DAIMLERCHRYSLER CORP.
  24. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.).
    Fig 18: Support Rear Suspension Using Jack
    GC0012990Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove jack (3) from under rear axle differential.
    Fig 19: Prop Shaft Support By Bungee Cord
    GC0012987Courtesy of DAIMLERCHRYSLER CORP.
  26. Remove bungee cord (1) supporting propeller shaft (2).
    Fig 20: Propeller Shaft At Rear Axle Flange
    GC0012989Courtesy of DAIMLERCHRYSLER CORP.
  27. 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.).
    Fig 21: Filler Tube Assembly
    GC0012979Courtesy of DAIMLERCHRYSLER CORP.
  28. Install fuel filler tube. (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK FILLER TUBE - INSTALLATION)
    Fig 22: Left/Right Rear Wheel Speed Sensor Routing
    GC0012977Courtesy of DAIMLERCHRYSLER CORP.
  29. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
    Fig 23: Sensor Connection to Body Connector
    GC0012976Courtesy of DAIMLERCHRYSLER CORP.
  30. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
  31. 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 24: Rear Caliper Mounting
    GC0012974Courtesy of DAIMLERCHRYSLER CORP.
  32. If equipped with standard or premium disc brakes, on each rear disc brake:
    • 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).
      • CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed.
    • 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.
    • Make sure brake hose is properly routed and will not come in contact with suspension components.
  33. 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. (Refer to FRAME & BUMPERS/FRAME/BUSHING - REMOVAL) 
    Fig 25: Rear Caliper Mounting Bolts
    GC0039408Courtesy of DAIMLERCHRYSLER CORP.
  34. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
  35. 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.) torque.
  36. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.
    Fig 26: Front Cable To Equalizer
    GC0039425Courtesy of DAIMLERCHRYSLER CORP.
  37. Route parking brake cable above rear crossmember, then slide cable (1, 3) through equalizer (2) above rear axle differential (once installed).
    Fig 27: Cables At Equalizer
    GC0039426Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
  38. Connect front parking brake cable (5) at connector (3) to right rear parking brake cable (4).
    Fig 28: Front Cable At Left Front Of Crossmember
    GC0039423Courtesy of DAIMLERCHRYSLER CORP.
  39. 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 29: Identifying Clamps & Rear Exhaust System
    GC0012972Courtesy of DAIMLERCHRYSLER CORP.
  40. Install rear exhaust system (2) (dual-outlet exhaust shown in Fig 29). (Refer to EXHAUST SYSTEM )
    Fig 30: Tire And Wheel Mounting
    GC0012971Courtesy of DAIMLERCHRYSLER CORP.
  41. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.). (Refer to TIRES/WHEELS - INSTALLATION)
  42. Lower vehicle until rear wheels are just above floor level.
  43. Apply parking brake lever. Release lever, then reapply.
  44. Check to make sure rear wheels will not rotate with lever applied.
  45. Lower vehicle.
    Fig 31: Disconnecting/Connecting Battery Cables
    GC0012970Courtesy of DAIMLERCHRYSLER CORP.
  46. Connect battery negative cable (2) to battery post. It is important that this is performed properly. (Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
  47. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  48. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
    Fig 32: Shock Mounting - Lower
    GC0012978Courtesy of DAIMLERCHRYSLER CORP.
  49. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft. lbs.).
    Fig 33: Compression Link Mounting
    GC0012997Courtesy of DAIMLERCHRYSLER CORP.
  50. Tighten compression link bolt and nut (1) at crossmember to 85 N.m (63 ft. lbs.).
  51. 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 step  23.). (Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)
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