CROSSMEMBER, Front Suspension: Removal: Removal

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Floor Carpet, Intermediate Shaft, Coupling Bolt & Steering Gear Pinion Shaft

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NOTE:

Before proceeding, refer to WARNING .

Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
Remove pinch bolt (3) and separate intermediate shaft (2) from steering gear shaft.

Fig 2: Wheel Lug Bolts
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Raise and support the vehicle. Refer to HOISTING .
Remove wheel mounting bolts (1), then the tire and wheel assembly.

Fig 3: Outer Tie Rod, Knuckle & Nuts
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Remove the nut (2) and pinch bolt clamping the ball joint stud (1) to the knuckle (3).
Remove the nut (4) attaching the outer tie rod (5) to the knuckle (3).

Fig 4: Separating Tie Rod End From Knuckle Using Ball Joint Remover
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On each side of the steering gear, separate the tie rod end (3) from the knuckle (2) using (special tool #9360, Remover, Ball Joint) (1) or equivalent.
If equipped, remove the engine belly pan.

Fig 5: Separating Ball Joint From Knuckle
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CAUTION:
Use care when separating the ball joint stud (2) from the knuckle (3), so the ball joint seal does not get cut or compressed excessively.
Using (special tool #9360, Remover, Ball Joint) (1) or equivalent, separate the ball joint stud (2) from the knuckle (3).

Fig 6: Knuckle, Bolts & Nuts
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While holding the stabilizer stud stationary, remove the nut (1) attaching the stabilizer link to the strut. Separate the stabilizer link stud from the strut.
At each end of the stabilizer bar, while holding the stabilizer bar link lower stud stationary, remove the nut securing the link to the stabilizer bar.

Fig 7: Lower Mount Through-Bolt
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Remove the center, lower mount through-bolt (1).

Fig 8: Cross Car Cradle Brace & Fasteners
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Remove four bolts (1) and the tunnel support brace (2).

Fig 9: Lower Control Arm Rear Mounting Bolts & Steering Gear Bolts
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NOTE:
The steering gear bolts (2) must be removed before attempting to lower the front crossmember so that the crossmember can be moved rearward to disengage it from the front support beams. If the steering gear mounting bolts are not removed before trying to move the crossmember rearward, the steering gear pinion shaft will hit the body.
Remove steering gear bolts (2).
NOTE:
Before lowering the front suspension crossmember, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost.

Fig 10: Crossmember Front & Rear Bolts
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Mark the location of the front crossmember on the body near each mounting bolt.
Remove the bolts securing the stabilizer bushing retainers to the crossmember and discard the bolts.
Support the crossmember with a transmission jack.
Remove the four rear mounting bolts (2) securing the front crossmember to the body.
Remove the two front bolts (1, 3) securing the front crossmember to the body.
Move the jack and crossmember rearward to disengage the crossmember from the front support beams.
Lower the crossmember on the transmission jack and remove from the vehicle.