Frame & Bumpers: Removal & Installation Chrysler Pacifica CS

REMOVAL

1. Remove front bumper fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-245440-S37590734062006110200000).
2. Support front bumper reinforcement on a suitable lifting device.
3. Remove the three bolts attaching front bumper reinforcement to frame rail. (Scheme 60)
4. Remove front bumper reinforcement from vehicle.

Scheme 60

INSTALLATION

1. Place front bumper reinforcement into position on vehicle.
2. Install the three bolts attaching front bumper reinforcement to frame rail and tighten to 20 N.m (15 ft. lbs.). (Scheme 60)
3. Install front bumper fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-245440-S02961106272006110200000).

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

1. Release hood latch and open hood.
2. Remove the headlamp assemblies «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP - REMOVAL)»(ref-245432-S11668533472006110200000).
3. Hoist vehicle and support with safety stands, as necessary.
4. Remove the four screws attaching bottom of fascia/air dam to radiator closure panel. (Scheme 61) 1 - PUSH PINS (4) 2 - ATTACHING SCREW 3 - FRONT BUMPER REINFORCEMENT 4 - FASCIA TO FENDER ATTACHING SCREW 5 - FASCIA ATTACHING SCREWS
5. Remove three screws attaching front fascia to front splash shield on each side. «(Refer to BODY/EXTERIOR/WHEELHOUSE SPLASH SHIELD - REMOVAL)»(ref-245423-S11069336432006110200000).
6. Remove the screw attaching fascia to the front fenders on each side.
7. Disconnect fog lamp wire connectors, if necessary.
8. Lower vehicle.
9. Remove push pins attaching the upper appearance panel to upper crossmember.
10. Remove screw attaching the upper grille support to the headlamp mounting panel at each side of the grille.
11. Remove bumper fascia from vehicle.
12. Place fascia on a clean surface. (Scheme 62) 1 - FRONT UPPER FASCIA 2 - GRILLE 3 - BRIGHT CHROME MOLDING 4 - FRONT LOWER FASCIA
13. Remove spring clips attaching upper and lower fascia together. (Scheme 63) 1 - FRONT UPPER FASCIA 2 - LOCKING TABS AND SPRING CLIPS 3 - FRONT LOWER FASCIA
14. Using a trim stick release locking tabs and separate the upper and lower fascia.
15. Remove the bright chrome molding from the upper fascia. (Scheme 64) Using a trim stick, starting at the outer edge of the fascia release the locking tabs. (Scheme 65) Grip the molding and pull outward from the fascia while releasing the locking tabs. (Scheme 66) 1 - UPPER AND LOWER FASCIA 2 - LOCKING TABS 1 - FRONT UPPER FASCIA 2 - TRIM STICK 3 - BRIGHT CHROME MOLDING LOCKING TABS 1 - FRONT UPPER FASCIA 2 - PULL BRIGHT CHROME MOLDING
16. Remove molding from fascia.
17. Remove grille from fascia. «(Refer to BODY/EXTERIOR/GRILLE - REMOVAL)»(ref-245423-S15269820532006110200000).

Scheme 67

1. Place bright chrome molding in position on the upper fascia.
2. Using hand presser press bright chrome molding locking tabs in the full lock position. (Scheme 66)
3. Position upper and lower fascia on a clean surface so that locking tabs align with the slots. (Scheme 62)and. (Scheme 63)
4. Press the fascia together to lock locking tabs into position.
5. Install new spring clips attaching upper and lower fascia together. The spring clips are not reusable.
6. Place bumper fascia into position on vehicle.
7. Install grille to fascia. «(Refer to BODY/EXTERIOR/GRILLE - INSTALLATION)»(ref-245423-S07540243912006110200000).
8. Install screw attaching the upper grille support to the headlamp mounting panel at each side of the grille.
9. Install push pins attaching the upper appearance panel to upper crossmember.
10. Raise vehicle and support with safety stands, as necessary.
11. Connect fog lamp wire connectors, if necessary.
12. Position and align fascia slotted cut out into fender push fastener. (Scheme 67) 1 - FASCIA ATTACHING FASTENER 2 - FRONT FENDER
13. Install screw attaching fascia to the front fenders on each side.
14. Install front wheelhouse splash shields fasteners as necessary «(Refer to BODY/EXTERIOR/WHEELHOUSE SPLASH SHIELD - INSTALLATION)»(ref-245423-S28973532292006110200000).
15. Install front wheels.
16. Install the four screws attaching bottom of fascia/air dam to radiator closure panel.
17. Lower vehicle.
18. Install the headlamp assemblies «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP - INSTALLATION)»(ref-245432-S02418175942006110200000).
19. Close hood.

1. Remove rear fascia. «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL)»(ref-245440-S24365190422006110200000).
2. Remove rear bumper reinforcement. «(Refer to FRAME & BUMPERS/BUMPERS/REAR BUMPER REINFORCEMENT - REMOVAL)»(ref-245440-S38308823142006110200000).
3. Remove two screws attaching reinforcement bracket (left or right side). (Scheme 68)or (Scheme 69).

Scheme 68

Scheme 69

1. Place reinforcement bracket into position.
2. Install two screws attaching reinforcement bracket (left or right side). (Scheme 68)or (Scheme 69).
3. Tighten screws to 95 N.m (70 ft. lbs.) torque.
4. Install rear bumper reinforcement «(Refer to FRAME & BUMPERS/BUMPERS/REAR BUMPER REINFORCEMENT - INSTALLATION)»(ref-245440-S40530648172006110200000).
5. Install rear fascia. «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - INSTALLATION)»(ref-245440-S11325234212006110200000).

1. Remove rear bumper fascia «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL)»(ref-245440-S24365190422006110200000).
2. Support rear bumper reinforcement on a suitable lifting device.
3. Remove the six nuts attaching rear bumper reinforcement to frame rail extensions. (Scheme 70)
4. Remove rear bumper reinforcement from vehicle.

Scheme 70

1. Support rear bumper reinforcement using a suitable lifting device to lift into position.
2. Position rear bumper reinforcement on vehicle.
3. Install the six nuts attaching rear bumper reinforcement to frame rail extensions and tighten to 27 N.m (20 ft. lbs.) torque. (Scheme 70)
4. Install rear bumper fascia. «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - INSTALLATION)»(ref-245440-S11325234212006110200000).

Scheme 71

Scheme 72

Scheme 73

1. Open liftgate.
2. Remove two push pin fasteners per side at the liftgate tower area. (Scheme 71) 1 - REAR FASCIA 2 - PUSH PIN FASTENERS 3 - SCREWS (2) 4 - CHECK ALIGNMENT 5 - SCREWS (2 PER SIDE) 6 - PUSH PINS (4)
3. Hoist and support vehicle with safety stands, as necessary.
4. Disconnect the park assist wire connector under the vehicle and the push pin fasteners attaching wire harness under the vehicle. (Scheme 72)1 - PARK ASSIST WIRE CONNECTOR 2 - REAR FASCIA 3 - PUSH PIN FASTENERS ATTACHING WIRE HARNESS
5. Remove the four push pin fasteners attaching rear fascia to reinforcement bumper.
6. Remove two screws (each side) attaching fascia to rear fascia bracket in the wheelhouse.
7. Remove the screw on each side attaching the upper fascia in the tail lamp bucket area.
8. Remove rear fascia from vehicle by lifting sides of fascia up and outboard to release from rear fascia brackets.
9. Place fascia on a clean surface.
10. Remove park assist sensors, if necessary. (Scheme 73) «(Refer to ELECTRICAL/CHIME/BUZZER/PARK ASSIST SENSOR - REMOVAL)»(ref-245441-S14238256542006110200000). 1 - BRIGHT CHROME MOLDING 2 - STEP PAD 3 - REAR FASCIA 4 - FASCIA FASTENER 5 - PARK ASSIST SENSOR
11. Remove spring clips attaching upper and lower fascia together. (Scheme 74)
12. Using a trim stick release locking tabs and separate the upper and lower fascia.
13. Remove move the bright chrome molding from the upper fascia. (Scheme 75) Using a trim stick, starting at the out edge of the fascia release the locking tabs. (Scheme 76) Grip the molding and pull outward from the fascia while releasing the locking tabs.
14. Remove molding from fascia.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

1. Place bright chrome molding in position on the upper fascia.
2. Using hand presser press molding locking tabs in the full lock position. see scheme 18 1 - REAR UPPER FASCIA 2 - BRIGHT CHROME MOLDING 3 - REAR LOWER FASCIA
3. Position upper and lower fascia on a clean surface so that locking tabs align with the slots. (Scheme 74)and. (Scheme 77) 1 - LOCKING TABS 2 - LOWER FASCIA NOTE: Using care not to scratch the surface of the fascias.
4. Press the fascias together to lock locking tabs into position.
5. Install new spring clips attaching upper and lower fascia together. The spring clips are not reusable. see scheme 20 1 - REAR UPPER FASCIA 2 - REAR LOWER FASCIA 3 - INTERLOCKING SEAM AND SPRING CLIPS
6. Install park assist sensors, if necessary. see scheme 21 «(Refer to ELECTRICAL/CHIME/BUZZER/PARK ASSIST SENSOR - INSTALLATION)»(ref-245441-S42446263172006110200000). 1 - BRIGHT CHROME MOLDING 2 - STEP PAD 3 - REAR FASCIA 4 - FASCIA FASTENER 5 - PARK ASSIST SENSOR
7. Place bumper fascia into position on vehicle. see scheme 22 1 - REAR FASCIA 2 - PUSH PIN FASTENERS 3 - SCREWS (2) 4 - CHECK ALIGNMENT 5 - SCREWS (2 PER SIDE) 6 - PUSH PINS (4)
8. Stretch fascia around fascia aperture brackets and slide fascia between body side aperture and fascia aperture brackets.
9. Install the two screws attaching the upper fascia in the tail lamp bucket area.
10. Install two screws (each side) attaching fascia to rear fascia bracket in the wheelhouse.
11. Install the four new push pin fasteners attaching rear fascia to reinforcement bumper.
12. Connect park assist sensor wire harness under vehicle. see scheme 23 1 - PARK ASSIST WIRE CONNECTOR 2 - REAR FASCIA 3 - PUSH PIN FASTENERS ATTACHING WIRE HARNESS
13. Lower vehicle.
14. Install push pin fasteners two per side at the liftgate tower area.
15. Close liftgate.

1. Remove rear fascia. «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL)»(ref-245440-S24365190422006110200000) .
2. Remove two push pins on each side attaching splash shield to rear fascia aperture bracket.
3. Remove rear fascia bracket to aperture panel (left or right side).

Scheme 78

1. Place rear fascia bracket to aperture panel (left or right side) into position and start screws. Holding bracket up so the stand off ribs on bracket are against aperture panel. Ensure bracket is up until ribs hit at top for a good fit.
2. Tighten aperture bracket screws in sequence to 3 N.m (23 in. lbs.) torque. (Scheme 78)
3. Install rear fascia. «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - INSTALLATION)»(ref-245440-S11325234212006110200000).

Scheme 79

Scheme 80

1. Position bushing over crossmember bushing bore aligning bushing can flange with reference marks applied during removal.
2. Assemble tools over bushing and crossmember as shown (remember crossmember is upside-down). (Scheme 83) Ensure Installer, Special Tool 9031-7, is positioned that it will clear compression link bracket when bushing is installed. (Scheme 84) 1 - PRESS C-4212F 2 - INSTALLER 9031-7 3 - BUSHING 4 - RECEIVER 9031-6 1 - INSTALLER 9031-7 2 - COMPRESSION LINK 3 - LINK BRACKET ON CROSSMEMBER 4 - PRESS C-4212F
3. Using hand tools, tighten Press 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.
6. Place compression link back into mounting bracket and install bolt and nut as shown. (Scheme 81) Do not tighten bolt at this time.
7. Turn rear suspension module right-side-up and center it on jack in same position as upon removal. Secure crossmember to jack.
8. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft onto alignment pin on end of rear driveline module input flange and align shocks with pockets in spring links.
9. Continue to raise crossmember with jack until two crossmember mounting bolts can be installed. see scheme 66 Install left side crossmember mounting bolts, but not the right side bolts. see scheme 66 It is not necessary to tighten bolts at this point.
10. 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 Installation. Do not lower jack any further than necessary.
11. Install coil spring and isolator. see scheme 67, top end first.
12. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
13. Install lower shock mounting bolt. see scheme 65 Do not tighten at this time.
14. Raise right side of crossmember into mounted position. Install right side crossmember mounting bolts. see scheme 66 Snug, but do not fully tighten bolts at this time.
15. Remove both front and rear crossmember mounting bolts on left side of vehicle. see scheme 66
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 installation. Do not lower jack any further than necessary.
17. Install coil spring and isolator. see scheme 67, top end first.
18. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
19. Install lower shock mounting bolt. see scheme 65 Do not tighten at this time.
20. Raise left side of crossmember into mounted position and install previously removed mounting bolts. see scheme 66 Snug, but do not fully tighten bolts at this time.
21. Shift crossmember as necessary to line up mounts with location marks drawn in before removal. see scheme 64
22. Once mounts are lined up with location marks, tighten all four crossmember mounting bolts to 163 N.m (120 ft. lbs.) torque.
23. Tighten shock absorber lower mounting bolts to 102 N.m (75 ft. lbs.) torque.
24. Remove jack from under rear driveline module/crossmember.
25. If equipped with AWD, line up location reference marks and install propeller shaft-to-rear driveline module mounting bolts. Tighten mounting bolts to 54 N.m (40 ft. lbs.) torque.
26. Clip each wheel speed sensor connector to spare tire mounting support. see scheme 92
27. Connect vehicle wiring harness to each wheel speed sensor connector. see scheme 92
28. Install each rear brake caliper on its mount as follows: Make sure abutment shims are in place on both slide abutments of caliper adapter. CAUTION: Use care when installing brake caliper onto adapter so guide pin bushings and sleeves do not get damaged by mounting bosses on adapter. Retract caliper guide pins to clear mounting bosses on caliper adapter when installing caliper. Install brake caliper in opposite way it was removed. Starting with upper end, carefully position caliper and brake shoes over brake rotor and align outboard shoe's upper edge with caliper slide abutment. Rotate lower end of caliper into mounting position on adapter. CAUTION: Extreme caution should be taken not to cross thread caliper guide pin bolts when they are installed. Carefully install caliper guide pin bolts. see scheme 89 Tighten bolts to 22 N.m (192 in. lbs.) torque.
29. Install screw mounting right rear brake hose routing bracket to front of rear crossmember. see scheme 63
30. Install screw mounting left rear brake hose routing bracket to front of rear crossmember. see scheme 63
31. While holding cable connector on end of front cable secure with a pair of pliers at the front cable button, Place right rear cable button into cable connector. see scheme 62 Release cables allowing button to seat. It may take some hand pressure to completely seat button.
32. Place left rear parking brake cable button into equalizer. see scheme 62 Release cables allowing button to seat. It may take some hand pressure to completely seat button.
33. Install rear half of exhaust system. «(Refer to EXHAUST SYSTEM - INSTALLATION)»(ref-245439-S07137004912006110200000)
34. Install tire and wheel assemblies «(Refer to TIRES/WHEELS - INSTALLATION)»(ref-245427-S08018737732006110200000). Tighten wheel mounting nuts to 135 N.m (100 ft. lbs.) torque.
35. Lower vehicle.
36. Unlock automatic adjuster in parking brake lever. «(Refer to BRAKES/PARKING BRAKE - STANDARD PROCEDURE)»(ref-245442-S21246028042006110200000)
37. Connect battery negative cable to battery post.
38. If vehicle is not equipped with All Wheel Drive (AWD), Install spare tire under vehicle.
39. Position vehicle on alignment rack/drive-on hoist. Raise vehicle as necessary to access mounting bolts.
40. Tighten compression link bolt at crossmember to 68 N.m (50 ft. lbs.) torque.
41. Perform wheel alignment. «(Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)»(ref-245426-S19121663772006110200000)

Scheme 81

Scheme 82

1. Disconnect and isolate battery negative cable from battery post.
2. If vehicle is not equipped with All Wheel Drive (AWD), remove spare tire.
3. Lock out automatic adjuster in parking brake lever. «(Refer to BRAKES/PARKING BRAKE - STANDARD PROCEDURE)»(ref-245442-S21246028042006110200000)
4. Raise and support vehicle. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(ref-245418-S28339325062006110200000)
5. Position an extra pair of jack stands under and support forward end of engine cradle to help stabilize vehicle during rear suspension removal/installation.
6. Remove both rear wheel and tire assemblies. «(Refer to TIRES/WHEELS - REMOVAL)»(ref-245427-S13023816952006110200000)
7. Remove rear half of exhaust system. «(Refer to EXHAUST SYSTEM - REMOVAL)»(ref-245439-S26117270372006110200000)
8. Slide left rear parking brake cable button inboard and remove from equalizer. see scheme 62
9. While holding parking brake cable connector on end of front cable secure with a pair of pliers at the front cable button, slide right rear parking brake cable button inboard and remove from cable connector. see scheme 62
10. Remove screw mounting left rear brake hose routing bracket to front of rear crossmember. see scheme 63
11. Remove screw mounting right rear brake hose routing bracket to front of rear crossmember. see scheme 63
12. Remove each rear caliper from its mount and support as follows: Remove two caliper guide pin bolts. see scheme 89 Remove caliper assembly from brake adapter by first rotating bottom of caliper away from rotor, then lifting caliper (with shoes) away from upper adapter abutment. see scheme 90 To prevent weight of caliper from overextending and damaging brake hose and tubing while caliper is off mount, hang brake caliper from vehicle using wire or cord. see scheme 91 Be sure to hang caliper and brake hose far enough forward on body, away from crossmember, to allow sufficient room to lower crossmember without interference.
13. Disconnect vehicle wiring harness from each rear wheel speed sensor connector. see scheme 92
14. Unclip each rear wheel speed sensor connector from spare tire mounting support. see scheme 92
15. If equipped with AWD: Reference mark propeller shaft-to-rear driveline module input flange connection. Remove three propeller shaft-to-rear driveline module mounting bolts. Do not attempt removal of shaft from module at this time due to alignment pin interference. Removal happens as crossmember is lowered in a later step.
16. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon. see scheme 99 Do not use a scratch awl to mark location. 1 - BUSHING CAN FLANGE 2 - MARKER OR CRAYON 3 - CROSSMEMBER
17. Position under-hoist utility jack or transmission jack under center of rear suspension crossmember (without AWD) or rear driveline module (with AWD). (Scheme 79) Raise jack head to contact driveline module/suspension crossmember and secure in place.
18. Remove lower mounting bolt and nut at each rear shock absorber. see scheme 65
19. Remove both front and rear crossmember mounting bolts on left side of vehicle. see scheme 66 CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to remove coil spring.
20. 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 removal. Do not lower jack any further than necessary.
21. Remove coil spring and isolator. see scheme 67, lower end first.
22. Raise left side of crossmember back into mounted position and install previously removed mounting bolts. It is not necessary to tighten bolts at this point.
23. Remove both front and rear crossmember mounting bolts on right side of vehicle. see scheme 66
24. 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 removal. Do not lower jack any further than necessary.
25. Remove coil spring and isolator. see scheme 67, lower end first.
26. Raise right side of crossmember back into mounted position. It is not necessary to install mounting bolts.
27. Remove both front and rear crossmember mounting bolts previously removed on left side of crossmember. see scheme 66
28. Slowly lower jack. Do not lower jack at a fast rate. As jack is lowered, remove propeller shaft from alignment pin on end of rear driveline module input flange and support it with a bungee or cord, keeping it at its normal height. Do not allow propeller shaft to hang on its own.
29. Continue to lower jack until rear suspension module is at a comfortable working level.
30. Remove rear suspension module from jack.
31. Turn rear suspension module upside down and place on appropriate working surface.
32. As an installation reference, carefully mark location of bushing requiring removal on crossmember using a marker or crayon. see scheme 99 Do not use a scratch awl to mark location.
33. Assemble tools over bushing as shown (remember crossmember is upside-down). (Scheme 85) Ensure Receiver straddles can flange on bushing. 1 - RECEIVER 9031-1 2 - PRESS C-4212F 3 - REMOVER 9031-2 4 - BUSHING
34. Tighten Press screw-drive, pressing bushing out of crossmember.

Scheme 83

Scheme 84

1. Position bushing over crossmember bushing bore aligning bushing can flange with reference marks applied during removal.
2. Assemble tools over bushing and crossmember as shown (remember crossmember is upside-down). (Scheme 86) Ensure Installer, Special Tool 9031-4, is positioned to match cutout with can flange on bushing. see scheme 102 1 - INSTALLER 9031-4 2 - PRESS C-4212F 3 - RECEIVER 9031-3 4 - BUSHING 1 - PRESS C-4212F 2 - INSTALLER 9031-4 3 - BUSHING 4 - CROSSMEMBER
3. Using hand tools, tighten Press 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.
6. Turn rear suspension module right-side-up and center it on jack in same position as upon removal. Secure crossmember to jack.
7. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft onto alignment pin on end of rear driveline module input flange and align shocks with pockets in spring links.
8. Continue to raise crossmember with jack until two crossmember mounting bolts can be installed. see scheme 66 Install left side crossmember mounting bolts, but not the right side bolts. see scheme 66 It is not necessary to tighten bolts at this point.
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 Installation. Do not lower jack any further than necessary.
10. Install coil spring and isolator. see scheme 67, top end first.
11. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
12. Install lower shock mounting bolt. see scheme 65 Do not tighten at this time.
13. Raise right side of crossmember into mounted position. Install right side crossmember mounting bolts. see scheme 66 Snug, but do not fully tighten bolts at this time.
14. Remove both front and rear crossmember mounting bolts on left side of vehicle. see scheme 66 CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring.
15. 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 installation. Do not lower jack any further than necessary.
16. Install coil spring and isolator. see scheme 67, top end first. NOTE: Verify spring lower end coil is correctly placed against abutment built into spring link.
17. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
18. Install lower shock mounting bolt. see scheme 65 Do not tighten at this time.
19. Raise left side of crossmember into mounted position and install previously removed mounting bolts. see scheme 66 Snug, but do not fully tighten bolts at this time.
20. Shift crossmember as necessary to line up mounts with location marks drawn in before removal. see scheme 99
21. Once mounts are lined up with location marks, tighten all four crossmember mounting bolts to 163 N.m (120 ft. lbs.) torque.
22. Tighten shock absorber lower mounting bolts to 102 N.m (75 ft. lbs.) torque.
23. Remove jack from under rear driveline module/crossmember.
24. If equipped with AWD, line up location reference marks and install propeller shaft-to-rear driveline module mounting bolts. Tighten mounting bolts to 54 N.m (40 ft. lbs.) torque.
25. Clip each wheel speed sensor connector to spare tire mounting support. see scheme 92
26. Connect vehicle wiring harness to each wheel speed sensor connector. see scheme 92
27. Install each rear brake caliper on its mount as follows: Make sure abutment shims are in place on both slide abutments of caliper adapter. CAUTION: Use care when installing brake caliper onto adapter so guide pin bushings and sleeves do not get damaged by mounting bosses on adapter. Retract caliper guide pins to clear mounting bosses on caliper adapter when installing caliper. Install brake caliper in opposite way it was removed. Starting with upper end, carefully position caliper and brake shoes over brake rotor and align outboard shoe's upper edge with caliper slide abutment. Rotate lower end of caliper into mounting position on adapter. CAUTION: Extreme caution should be taken not to cross thread caliper guide pin bolts when they are installed. Carefully install caliper guide pin bolts. see scheme 89 Tighten bolts to 22 N.m (192 in. lbs.) torque.
28. Install screw mounting right rear brake hose routing bracket to front of rear crossmember. see scheme 63
29. Install screw mounting left rear brake hose routing bracket to front of rear crossmember. see scheme 63
30. While holding cable connector on end of front cable secure with a pair of pliers at the front cable button, place right rear cable button into cable connector. see scheme 62 Release cables allowing button to seat. It may take some hand pressure to completely seat button.
31. Place left rear parking brake cable button into equalizer. see scheme 62 Release cables allowing button to seat. It may take some hand pressure to completely seat button.
32. Install rear half of exhaust system. «(Refer to EXHAUST SYSTEM - INSTALLATION)»(ref-245439-S07137004912006110200000)
33. Install tire and wheel assemblies «(Refer to TIRES/WHEELS - INSTALLATION)»(ref-245427-S08018737732006110200000). Tighten wheel mounting nuts to 135 N.m (100 ft. lbs.) torque.
34. Lower vehicle.
35. Unlock automatic adjuster in parking brake lever. «(Refer to BRAKES/PARKING BRAKE - STANDARD PROCEDURE)»(ref-245442-S21246028042006110200000)
36. Connect battery negative cable to battery post.
37. If vehicle is not equipped with All Wheel Drive (AWD), Install spare tire under vehicle.
38. Perform wheel alignment. «(Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)»(ref-245426-S19121663772006110200000)

Scheme 85

1. Raise and support vehicle. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(ref-245418-S28339325062006110200000)
2. Access and remove rear spring on side of repair. «(Refer to SUSPENSION/REAR/SPRING - REMOVAL)»(ref-245426-S38244671272006110200000)
3. Remove bolt and nut fastening spring link to crossmember. see scheme 103 1 - CROSSMEMBER 2 - MOUNTING BOLT AND NUT 3 - SPRING LINK 4 - MOUNTING BOLT AND NUT
4. Position spring link downward, away from bushing in crossmember.
5. Assemble tools over bushing as shown. see scheme 104 Ensure Receiver, Special Tool 9032-1, sets against crossmember and not welds. 1 - BUSHING 2 - REMOVER 9032-2 3 - PRESS C-4212F 4 - RECEIVER 9032-1
6. Tighten Press screw-drive, pressing bushing out of crossmember.

Scheme 86

1. Position bushing over rear or crossmember bushing bore.
2. Assemble tools over bushing and crossmember as shown. see scheme 105 Ensure Receiver, Special Tool 9032-3, is positioned to avoid welds on rear of crossmember bushing bore. 1 - BUSHING 2 - REMOVER/INSTALLER 9032-2 3 - PRESS C-4212F 4 - RECEIVER 9032-3
3. Using hand tools, tighten Press screw-drive, pressing bushing into crossmember. Install bushing until screw-drive stops, when bushing contacts Receiver on opposite side of crossmember.
4. Remove tools.
5. Swing spring link up to bushing in crossmember and install bolt and nut fastening spring link to crossmember. see scheme 70 Do not tighten bolt at this time.
6. Install rear spring as well as all components necessary to access it. «(Refer to SUSPENSION/REAR/HUB / BEARING - INSTALLATION)»(ref-245426-S40268008932006110200000)
7. Lower vehicle.
8. Position vehicle on alignment rack/drive-on hoist. Raise vehicle as necessary to access mounting bolt.
9. Tighten spring link bolt at crossmember to 109 N.m (80 ft. lbs.) torque.
10. Perform wheel alignment. «(Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)»(ref-245426-S19121663772006110200000)