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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1567 (Body Panel System - Full Frame & Body Mounting) >> Removal And Installation >> Crossmember - Number 2 >> Installation

Crossmember - Number 2: Installation

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Position the sway bar and the rear bushing plates into place as the No. 2 crossmember is being raised.
  1. Raise and position the No. 2 crossmember assembly.
  2. Install the 4 No. 2 crossmember bolts.
    • Tighten to 250 Nm (184 lb-ft).
  3. Position the LH and RH No. 2 crossmember brackets.
  4. Remove the support table.
    5. CAUTION: The bolts must be tightened in the sequence shown in illustration, or damage to the crossmember bracket may occur.
  5. Install the LH and RH No. 2 crossmember bracket nuts and bolts.
    1. Tighten the rear bolt.
      • Tighten to 103 Nm (76 lb-ft).
    2. Tighten the front bolt.
      • Tighten to 103 Nm (76 lb-ft).
    3. Tighten the nuts.
      • Tighten to 200 Nm (148 lb-ft).
    6. Fig 1: Crossmember No. 2 Tightening Sequence
    GF0013538Courtesy of FORD MOTOR CO.
  6. Install the 3 LH lower control arm and 3 RH lower control arm rear mounting bolts.
    • Tighten to 90 Nm (66 lb-ft).
  7. Position the brake line into the retaining clips at the rear of the No. 2 crossmember.
    8. Fig 2: Brake Line Retaining Clips On Crossmember No. 2
    GF0013537Courtesy of FORD MOTOR CO.
  8. Install the LH and RH ABS harness.
    1. Install the 2 harness retainers into the frame.
    2. Install the 2 brackets and bolts.
    3. Install the 2 ABS harnesses into the support brackets.
    9. Fig 3: ABS Harnesses Support Bracket & Bolt
    GF0013535Courtesy of FORD MOTOR CO.
  9. Position the LH and RH brake calipers and install the 4 bolts.
    • Tighten to 32 Nm (24 lb-ft).
  10. Position the LH and RH brake hose and brackets and install the 2 bolts.
    11. Fig 4: Brake Hose Bracket & Bolt
    GF0013534Courtesy of FORD MOTOR CO.
  11. Position the steering gear and install the 2 steering gear studs.
    • Tighten to 20 Nm (15 lb-ft).
    12. Fig 5: Steering Gear & Stud
    GF0013536Courtesy of FORD MOTOR CO.
  12. Install the 2 steering gear nuts.
    • Tighten to 103 Nm (76 lb-ft).
    13. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nut.
  13. Position the LH and RH stabilizer bar links and install the 2 nuts.
    • Install new nuts.
    • Tighten to 63 Nm (46 lb-ft).
    14. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nut.
  14. Position the LH and RH tie-rod ends and install the 2 nuts.
    • Install new nuts.
    • Tighten to 80 Nm (59 lb-ft).
  15. Lower the vehicle.
  16. Connect the intermediate shaft to the steering gear and install the bolt.
    • Tighten to 30 Nm (22 lb-ft).
  17. Remove the engine support bar.
    18. Fig 6: Engine Support Bar
    GF0013531Courtesy of FORD MOTOR CO.
  18. Install the LH and RH front wheel and tire assemblies. For additional information, refer to WHEELS AND TIRES article.
  19. Connect the RH ABS electrical connectors.
    20. Fig 7: RH ABS Electrical Connectors
    GF0013532Courtesy of FORD MOTOR CO.
  20. Connect the LH ABS electrical connectors.
    21. Fig 8: LH ABS Electrical Connectors
    GF0013533Courtesy of FORD MOTOR CO.
  21. Install the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  22. Position the radiator sight shield and install the 3 pin-type retainers.
  23. Raise and support the vehicle.
  24. Install the 2 engine mount nuts.
    • Tighten to 90 Nm (66 lb-ft).
    25. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  26. Check the front end alignment and adjust as necessary. For additional information, refer to SUSPENSION SYSTEM - GENERAL INFORMATION article.
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