Rear SUBFRAME (G2496456): Removal

CAUTION:

Only tighten the nuts and bolts when the suspension is at the normal ride height. Failure to follow this instruction may result in damage to the vehicle.
Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

The following step(s) applies to:

All vehicles

Disconnect the 12 V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
Raise and support the vehicle on a suitable 2-post lift.
Refer to: LIFTING

The following step(s) applies to:

INGENIUM I6 3.0L Diesel/TDV6 3.0L Diesel
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- Remove the 2 nuts.
- Remove the 4 bolts.
- Remove the center undershield.
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- Release the wiring harness from the clip.
- Disconnect the electrical connector
WARNING: This step requires the aid of another technician.

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- Release the exhaust clamp.
- Release the 4 exhaust mounting rubbers
- With assistance, remove the exhaust rear section.
- Remove and discard the clamp.
The following step(s) applies to:

INGENIUM I4 2.0L Diesel/INGENIUM I4 2.0L Diesel AJ21
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- Remove the 2 nuts.
- Remove the 4 bolts.
- Remove the center undershield.
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- Release the wiring harness from the clip.
- Disconnect the electrical connector
WARNING: This step requires the aid of another technician.

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- Release the exhaust clamp.
- Release the 3 exhaust mounting rubbers
- With assistance, remove the exhaust rear section.
- Remove and discard the clamp.
The following step(s) applies to:

GTDi 2.0L Petrol/INGENIUM I4 2.0L Petrol/INGENIUM I4 2.0L Petrol - PHEV/INGENIUM I6 3.0L Petrol/V6 S/C 3.0L Petrol/V8 S/C 5.0L Petrol
Remove the exhaust system
Refer to: EXHAUST SYSTEM - INGENIUM I4 2.0L PETROL (G2020236)

Refer to: EXHAUST SYSTEM - INGENIUM I6 3.0L PETROL (G2501539)

The following step(s) applies to:

[+] Vehicles with Fuel Fired Booster Heater
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- Release the clip.
- Reposition the wiring harness away from the rear subframe.
The following step(s) applies to:

All vehicles
Remove the rear brake pads.
Refer to: BRAKE PADS - VEHICLES WITH: 324 MM BRAKE DISC
NOTE: Only do this step if a new component is to be installed.

Drain the rear differential.

Refer to: DIFFERENTIAL DRAINING AND FILLING VEHICLES WITH HEAVY DUTY DIFFERENTIAL

Refer to: DIFFERENTIAL DRAINING AND FILLING VEHICLES WITHOUT HEAVY DUTY DIFFERENTIAL
Remove the rear left wheel arch liner.
Refer to: REAR WHEEL ARCH LINER
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- Disconnect the 2 electrical connectors.
- Release the clip.
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- Remove the 17 fasteners.
- Remove the 13 bolts.
- Remove the 2 nuts.
- Remove the left and right undershields.
NOTE: Repeat the step for the other side.

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Remove and discard the shock absorber nut and bolt.
Disconnect the driveshaft from the rear differential.
Refer to: DRIVESHAFT TO REAR DIFFERENTIAL DISCONNECTION
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- Remove the 2 nuts.
- Remove the Noise, Vibration and Harshness (NVH) damper.
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To aid installation, use a straight edge to mark the position of the subframe in relation to the body at the points shown.
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- Remove the 6 bolts.
- Remove the 4 nuts.
NOTE: This step requires the aid of another technician.

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- Position the transmission jack below the rear subframe assembly.
  General Equipment: Transmission jack
- Adjust the transmission jack to support the weight of the rear subframe assembly.
- Remove and discard the 4 bolts.
- With assistance, remove the rear subframe assembly from the vehicle.
NOTE: Only complete the following step(s), if a new component is to be installed.

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Remove the 2 rear springs.
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- Release the clip.
- Disconnect the 3 electrical connectors.
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- Release the 6 grommets.
- Release the 24 wiring harness clips.
- Disconnect the 4 electrical connectors.
- Remove the rear subframe wiring harness.
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- Remove and discard the 2 upper stabilizer bar link nuts.
- Remove the 4 bolts.
- Remove the rear stabilizer bar.
NOTE: Repeat the step for the other side.

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- Release the rear suspension height sensor link.
- Remove the 2 bolts.
- Remove the rear suspension height sensor.
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- Remove and discard the 2 tie-rod to subframe nuts and bolts.
- Remove the 2 washers.
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Remove and discard the 2 upper control arm to subframe nuts and bolts.
CAUTION: Take extra care not to damage the seal.

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Carefully release the 2 rear halfshafts from the differential.
WARNING: The component(s) may be heavy. Take extra care when handling.

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- Remove and discard the 2 nuts and 4 bolts.
- With assistance, remove the suspension assemblies from the subframe.
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Remove and discard the 2 rear differential bolts.
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- Remove and discard the 2 bolts.
- Remove the rear differential from the rear subframe.