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Bushing-Rear CROSSMEMBER Rear Mount: Removal

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: Disconnecting/Connecting Battery Cables
GC0012970Courtesy of DAIMLERCHRYSLER CORP.
  1. Disconnect and isolate battery negative cable (2) from battery post.
  2. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
    Fig 2: Tire And Wheel Mounting
    GC0012971Courtesy of DAIMLERCHRYSLER CORP.
  3. On each side of vehicle rear, remove wheel mounting nuts (3), then tire and wheel assembly (1).
    Fig 3: Identifying Clamps & Rear Exhaust System
    GC0012972Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove rear exhaust system (2) (dual-outlet exhaust shown in Fig 3). (Refer to EXHAUST SYSTEM )
    Fig 4: Alignment Marks At Shaft And Flange
    GC0012988Courtesy of DAIMLERCHRYSLER CORP.
  5. Apply alignment index marks (3) to the propeller shaft rubber coupler (1) and axle flange (2).
    Fig 5: Propeller Shaft At Rear Axle Flange
    GC0012989Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove three (four if equipped with 215MM axle) propeller shaft coupler-to-axle flange bolts and nuts.
    Fig 6: Prop Shaft Support By Bungee Cord
    GC0012987Courtesy of DAIMLERCHRYSLER CORP.
  7. Support propeller shaft (2) using a bungee cord (1). Attach ends of cord to fuel tank straps as shown in Fig 6.
    Fig 7: 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.
  8. Disconnect front parking brake cable (5) at connector (3) to right rear parking brake cable (4) above axle differential.
    Fig 8: Front Cable To Equalizer
    GC0039425Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove front parking brake cable (3) from equalizer (2).
    Fig 9: Front Cable At Left Front Of Crossmember
    GC0039423Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove screw (2) fastening front parking brake cable (1) routing bracket to rear crossmember front flange (3).
    Fig 10: Rear Caliper Mounting
    GC0012974Courtesy of DAIMLERCHRYSLER CORP.
  11. If equipped with standard or premium disc brakes, on each rear disc brake:
    • While holding guide pins from turning, remove disc brake caliper guide pin bolts (2).
    • Remove brake caliper (1) from brake adapter (3) and pads.
    • Guide brake caliper up through suspension, following brake hose path. Support caliper above rear suspension using with bungee cord or wire to keep caliper from overextending brake hose when crossmember is lowered.
    Fig 11: Pushing Disc Pistons Into Bore
    GC0039400Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When pushing pistons back into caliper bores, use only a trim stick as shown in Fig 11 or other suitable soft tool. Never use a screwdriver or other metal pry bar due to potential damage to braking surface of rotor, caliper, pistons or dust boots.
  12. If equipped with SRT8 disc brakes, on each rear disc brake, place trim stick (4) between brake pad (2) and outer edge of rotor (3).
  13. If equipped with SRT8 disc brakes, on each rear disc brake, using trim stick, slowly apply pressure against brake pad (2) until both pistons (on that side of caliper) are completely bottomed in bores of caliper half.
    NOTE: Repeat above procedure to opposite brake pad (1) and pistons as necessary.
    Fig 12: Identifying Rear Caliper Mounting Bolts & Related Components
    GC0039409Courtesy of DAIMLERCHRYSLER CORP.
  14. If equipped with SRT8 disc brakes, on each rear disc brake, support spring link (1) using a transmission jack (5) or other appropriate jack. Raise spring link just enough to access brake caliper lower mounting bolt (4) from above compression link (2).
    Fig 13: Rear Caliper Mounting Bolts
    GC0039408Courtesy of DAIMLERCHRYSLER CORP.
  15. If equipped with SRT8 disc brakes, on each rear disc brake, remove the lower and upper caliper mounting bolts (1).
  16. If equipped with SRT8 disc brakes, on each rear disc brake, remove brake caliper (2) with pads from knuckle and brake rotor. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.
  17. If equipped with SRT8 disc brakes, remove jack from under spring link.
    Fig 14: Releasing Wheel Speed Sensor Connector
    GC0012975Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: To remove wheel speed sensor connector from body wiring harness connector, move retaining clip (2) and pull sensor connector outward.
    Fig 15: Sensor Connection to Body Connector
    GC0012976Courtesy of DAIMLERCHRYSLER CORP.
  18. Remove wheel speed sensor connectors (3 and 4) from body wiring harness connector (1) located in luggage compartment floor pan (2).
    Fig 16: Left/Right Rear Wheel Speed Sensor Routing
    GC0012977Courtesy of DAIMLERCHRYSLER CORP.
  19. Unclip left wheel speed sensor cable (3) from routing clip (1) near body connector.
    Fig 17: Shock Mounting - Lower
    GC0012978Courtesy of DAIMLERCHRYSLER CORP.
  20. On each side of vehicle, remove shock absorber (1) lower mounting bolt (2) and nut (4).
    Fig 18: Marking Location of Crossmember Mount to Body
    GC0000269Courtesy of DAIMLERCHRYSLER CORP.
    1 - BODY
    2 - MARKER (OR CRAYON)
    3 - CROSSMEMBER BUSHING FLANGE
  21. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon. Do not use a scratch awl to mark location. 
  22. Position an extra pair of jack stands under and support forward end of engine cradle to help stabilize vehicle during rear suspension removal/installation.
    Fig 19: Support Rear Suspension Using Jack
    GC0012990Courtesy of DAIMLERCHRYSLER CORP.
  23. Position under-hoist utility jack or transmission jack (3) under center of rear axle differential (1). Raise jack head to contact differential and secure in place. When securing crossmember to jack, be sure not to secure stabilizer bar. 
    Fig 20: Filler Tube Assembly
    GC0012979Courtesy of DAIMLERCHRYSLER CORP.
    WARNING: Before opening fuel system, review all Warnings and Cautions.
  24. Remove fuel filler tube. (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK FILLER TUBE - REMOVAL)
    Fig 21: AWD Crossmember Spacers
    GC0012980Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: If equipped with AWD, when removing crossmember mounting bolts in following step, be sure to not to misplace spacers (1) between crossmember mounts (2) and body.
    Fig 22: Rear Crossmember Mounting Bolts
    GC0012981Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove both front (3) and both rear (2) mounting bolts fastening crossmember (1) in place.
  26. Slowly  lower crossmember using jack. Do not lower jack at a fast rate.  Lower just enough to allow propeller shaft removal from rear axle differential. Do not lower jack any further than necessary.  Slide propeller shaft out of rear axle differential and allow bungee cord previously installed to support.
  27. Lower crossmember until crossmember is at a comfortable working level to access bushings. Support rear suspension assembly using jack stands to help stabilize assembly during bushing service.
    Fig 23: Identifying Coil Spring and Shock Assembly
    GC0012983Courtesy of DAIMLERCHRYSLER CORP.
  28. Remove coil springs (2) with isolators (1 and 5) from spring links (4).
    Fig 24: Marking Location of Rear Bushing
    GC0013005Courtesy of DAIMLERCHRYSLER CORP.
    1 - BUSHING CAN FLANGE
    2 - MARKER OR CRAYON
    3 - CROSSMEMBER
  29. As an installation reference, carefully mark location of bushing requiring removal on crossmember (around bushing can flange) using a marker or crayon. Do not use a scratch awl to mark location. 
    Fig 25: Installing Support 9031-11
    GC0013003Courtesy of DAIMLERCHRYSLER CORP.
  30. Slide Support (2), Special Tool 9031-11, into end of crossmember (3) surrounding bushing bore as shown in Fig 25.
  31. Snug set-screws (1) securing Support (2) to crossmember.
    Fig 26: Inserting Brace 9031-12
    GC0013001Courtesy of DAIMLERCHRYSLER CORP.
  32. Insert Brace (1), Special Tool 9031-12, between Support 9031-11 (3) and bushing bore flange (2) matching angle cut in Brace to bore flange.
    Fig 27: Tighten Support 9031-11 Set Screws
    GC0013002Courtesy of DAIMLERCHRYSLER CORP.
  33. Snug set-screws (1) against Brace 9031-12. Do not overtighten set-screws as they will distort and bend bushing bore flange. 
    Fig 28: Tools Positioned to Remove Rear Bushing
    GC0013004Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Prior to using Press (1), Special Tool C-4212F, lubricate screw-drive threads to provide ease of use and promote tool longevity.
  34. Assemble tools (See following list) over bushing as shown in Fig 28.
    • (1) Press C-4212F
    • (2) Remover 9031-2
    • (3) Receiver 9031-1
  35. Tighten Press (1) screw-drive, pressing bushing out of crossmember.
  36. Remove all tools.
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