Frame and Bumpers: Removal & Installation Dodge Avenger II facelift

INSTALLATION

Note. Avenger shown in illustration, Sebring similar.

1. Position the fascia to the vehicle.
2. Align and hand tap the fascia sides to engage the fascia retaining tabs.
3. Install the four fascia to upper radiator support push pins (1).
4. On Sebring models, install the front outboard fastener (1). Tighten the fastener securely. Repeat on the opposite side.
5. On Avenger models, install the front outboard push pin fastener (1). Repeat on the opposite side.
6. Raise the vehicle.
7. Install the fender to fascia fastener (2). Tighten the fastener securely. Repeat for the opposite side.
8. If equipped, connect the fog lamps.
9. Install the fascia lower closeout panel. Refer to «FASCIA, FRONT LOWER, CLOSEOUT, INSTALLATION»(ref-485477-S04155574192012071300000) .
10. Install the front splash shield. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-485483-S00528336772012071300000) .
11. Lower the vehicle.
12. Connect the negative battery cable.
13. Close the hood.

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1. Remove fasteners (5) to lower closeout.
2. Remove push pins (1) to lower closeout.
3. Remove the front lower fascia.

1. Install closeout panel (1) onto fascia (3) push pins (2) and screws (4).
2. Install fasteners (5).

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1. Release decklid latch and open decklid.
2. Remove three push-in fasteners (1) attaching center of fascia to rear closure panel.
3. Remove two wheelhouse fasteners and pull back splash shields exposing fascia to fender hidden fastener (1).
4. Remove lower fascia fasteners (2).
5. Slide fascia rearward to disengage hooks holding fascia to bottom of quarter panel.
6. Remove fascia from vehicle.

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1. Open decklid.
2. Remove upper fascia push pins (1).
3. Raise vehicle.
4. Remove lower fascia push pins (1).
5. Remove left and right splash shield push pins and fasteners.
6. Remove fascia fastener (2).
7. Slide fascia rearward from push pins (1).
8. Disconnect wire connector (1) and (2).

1. Place bumper reinforcement up to vehicle and install fasteners. Tighten to 27 N.m (239 inch lbs.).
2. Install coolant line push pins to bumper.
3. Install ambient temperature sensor. Refer to «SENSOR, AMBIENT TEMPERATURE, INSTALLATION»(ref-485512-S21826627562012071300000) .
4. Install horns and connect electrical connectors. Refer to «HORN, INSTALLATION»(ref-485508-S28392160092012071300000) .
5. Install hood latch fasteners (1).
6. Install braces and fasteners (2).
7. Install fascia. Refer to «FASCIA, FRONT, INSTALLATION»(ref-485477-S06612709572012071300000) .

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1. Remove rear fascia. Refer to «FASCIA, REAR, REMOVAL»(ref-485477-S06816966822012071300000) .
2. Support bumper reinforcement (2) on a suitable lifting device.
3. Mark position of nuts (1) on frame rail to aid in installation.
4. Remove license plate connector push pin from rear bumper reinforcement.
5. Remove nuts (1) attaching rear bumper reinforcement (2) to frame rail.
6. Remove bumper reinforcement (2) from vehicle.

1. Position rear bumper reinforcement (2) on vehicle.
2. Install nuts (1) attaching bumper reinforcement to frame rail. Use marks made previously to properly position bumper reinforcement.
3. Tighten nuts (1) to 28 N.m (250 in. lbs.).
4. Install license plate connector push pin on bumper.
5. Install rear fascia. Refer to «FASCIA, REAR, INSTALLATION»(ref-485477-S17263051932012071300000) .

1. Position the front crossbrace/reinforcement bracket (2) over the crossmember rear mounting bushings and body, then install the mounting screws (1). Do not tighten screws at this time.
2. Install the two rear mounting bolts (2) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 135 N.m (100 ft. lbs.).
3. Tighten the crossbrace/reinforcement bracket mounting screws (1) to 50 N.m (37 ft. lbs.).
4. Lower the vehicle.

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1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. Remove the mounting screws (1) securing the rear crossbrace/reinforcement brackets (2).
3. Remove the brackets.

1. Position the rear crossbrace/reinforcement brackets (1) through the rear crossmember.
2. Install the mounting screws (2) and tighten to 50 N.m (37 ft. lbs.).
3. Lower the vehicle.

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1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. If equipped, remove the two front cross-member bolts (1).
3. Remove the four cross-member bolts (1) in the rear of the fore/aft cross-member.
4. Remove the engine roll mount (2) through bolt (1) and remove the fore/aft cross-member.

1. Install the fore/aft cross-member and install the engine anti-roll mount (3) through bolt (1). Tighten to 50 N.m (37 ft. lbs.).
2. Install front bolts (1) and tighten to 55 N.m (40.5 ft. lbs.).
3. Install the rear bolts (1) and tighten to 55 N.m (41 ft. lbs.).
4. If equipped, install the belly pan.

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1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. On each side of the vehicle, remove the wheel mounting nuts (3), then the front tire and wheel assembly (1).
3. On each side of the vehicle, remove the nut (1) attaching the lower ball joint to the lower control arm (2).
4. On each side of the vehicle, release the lower ball joint (3) from the lower control arm (1) using Remover (2), Special Tool (special tool #9360, Remover, Ball Joint). Do not lift the knuckle out of the lower control arm at this time.
5. If equipped, remove the engine belly pan.
6. Remove the fore/aft crossmember. Refer to «CROSSMEMBER, FRONT FORE AND AFT, REMOVAL»(ref-485477-S17979691932012071300000) .
7. Remove the rear engine mount. Refer to «INSULATOR, ENGINE MOUNT, REAR, REMOVAL»(ref-485475-S26787268242012071300000) or «INSULATOR, ENGINE MOUNT, REAR, REMOVAL»(ref-485476-S39056195622012071300000) .
8. Remove the screws (1) securing the power steering hose routing clamps (2) to the rear of the crossmember.
9. Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2).
10. Remove the two bolts (1) securing the steering gear (2) to the crossmember.
11. Support the steering gear using a bungee cord or other to keep the steering gear from lowering when the crossmember is lowered.
12. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 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.
13. Using a crayon or marker (2) that will not break the paint surface, mark the location of the front crossmember (1) on the body near each mounting bolt. Do not use any type of sharp instrument that will damage the underbody of the vehicle.
14. Support the crossmember (9) with a transmission jack. Secure the crossmember to the jack.
15. Remove the four mounting bolts (6) securing the front crossmember (9) to the body.
16. Remove the mounting screws (8) securing the front crossmember reinforcement brackets (7) (one each side of vehicle) to the body (1). Remove the brackets.
17. Slowly lower the crossmember and control arms to a comfortable working height using the jack.
18. To remove each lower control arm: Remove the front bolt (1) attaching the lower control arm (3) to the front suspension crossmember. Remove the nut on the rear bolt (2) attaching the lower control arm (3) to the front suspension crossmember. Remove the bolt. Remove the lower control arm (3) from the crossmember.

1. Support the crossmember with a transmission jack. Secure the crossmember to the jack.
2. To install each lower control arm on the crossmember: Place the lower control arm (3) into the front suspension crossmember. Insert the rear bolt (2) up through the crossmember and lower control arm (3). Install the nut on the top-end of the bolt, but do not tighten it at this time. Install, but do not fully tighten, the front bolt (1) attaching the lower control arm (3) to the crossmember. With no weight or obstruction on the lower control arm, tighten the lower control arm front mounting bolt (1) to 175 N.m (129 ft. lbs.). With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut to 145 N.m (107 ft. lbs.).
3. Slowly raise the crossmember (9) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. As the crossmember is raised, guide the lower ball joints into the mounting holes in the lower control arms. Also, make sure the stabilizer bar is properly positioned on the crossmember.
4. Position the front crossmember reinforcement brackets (7) (one each side of vehicle) over the crossmember rear mounting bushings and install the mounting screws (8), but do not tighten at this time.
5. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 135 N.m (100 ft. lbs.).
6. Tighten the crossmember reinforcement bracket mounting screws (8) to 50 N.m (37 ft. lbs.).
7. Remove the transmission jack.
8. Position both stabilizer bar bushing retainers and install the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. Tighten all four stabilizer bar cushion retainer screws to 60 N.m (44 ft. lbs.).
9. Remove the bungee cord or other supporting the steering gear (2).
10. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 100 N.m (74 ft. lbs.).
11. Position the heat shield (1) over the steering gear (2). Install the mounting screws and push-pins. Tighten the screws to 6 N.m (53 in. lbs.).
12. Position the power steering hose routing clamps (2) on the crossmember. Install and tighten the screws to 8 N.m (71 in. lbs.).
13. Install the rear engine mount. Refer to «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-485475-S29947108362012071300000) or «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-485476-S34182425092012071300000) .
14. Install the fore/aft crossmember. Refer to «CROSSMEMBER, FRONT FORE AND AFT, INSTALLATION»(ref-485477-S30914186772012071300000) .
15. If equipped, install the engine belly pan. NOTE: If a new or cleaned lower control arm is being installed, it is important to have a film of general purpose grease around the ball joint mounting hole on the lower control arm to avoid any future corrosion issues. Make sure the grease does not get inside the ball joint mounting hole or on the ball joint stud during installation.
16. On each side of the vehicle, install a NEW ball joint stud nut (1). Tighten the nut to 95 N.m (70 ft. lbs.).
17. On each side of the vehicle, install the tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
18. Lower the vehicle.
19. Perform wheel alignment as necessary. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-485471-S16167757252012071300000) .

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1. Remove the spare tire.
2. Remove the upper suspension bracket nuts.
3. Raise and support vehicle.
4. Remove rear wheels.
5. If equipped, remove the rear drive module.
6. Make a reference mark on the toe link cam (3), remove the toe link cam bolt and nut (1) attaching the toe link (2) to the rear suspension cross-member.
7. Loosen the Nut (3) at the knuckle and remove the bolt (4) attaching the upper control arm to the rear suspension cross-member.
8. Remove the lower control arm. Refer to «ARM, LOWER CONTROL, REMOVAL»(ref-485485-S22644901362012071300000) .
9. Support the knuckle and all of the attaching parts using strong cord or wire.
10. Remove the wheel speed sensor bracket bolt.
11. Disconnect the ground strap from the muffler.
12. Remove the extension pipe, muffler and tail pipe. Refer to «REMOVAL»(ref-485503-S03308939842012071300000) .
13. Remove the stabilizer bar bolts from the rear suspension cross-member. Refer to «STABILIZER BAR, REAR SUSPENSION, REMOVAL»(ref-485485-S20803881712012071300000) .
14. Remove the lower nut (3) from the rear suspension bracket from the body and rear suspension cross-member.
15. Position a transmission jack under the center of the rear suspension cross-member to support and lower it during removal. Remove the four bolts attaching the rear suspension cross-member to rear frame rails.
16. Lower the rear suspension cross-member.

Note. Graphics and steps shown are of the right side of the vehicle. Complete the same steps for the left side of the vehicle.

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1. Position the rear suspension crossmember to the center of a trans jack, secure the crossmember to the jack with straps.
2. Raise the rear suspension crossmember into position and install the bolts and studs attaching the rear suspension crossmember to rear frame rails. Tighten bolts and studs to 95 N.m (70 ft. lbs.).
3. Install the rear suspension bracket and tighten the nut to 50 N.m (37 ft. lbs.).
4. Install the stabilizer bar and bolts to the rear suspension crossmember and tighten to 24.5 N.m (18 ft. lbs.).
5. Install the wheel speed sensor bracket and tighten the bolt to 18 N.m (13 ft. lbs.).
6. Remove the strong cord or wire used to support the knuckle and install the lower control arm. Refer to «ARM, LOWER CONTROL, INSTALLATION»(ref-485485-S01873998232012071300000) .
7. Install the upper control arm to the rear suspension crossmember and tighten all bolts to 108.5 N.m (80 ft. lbs.). NOTE: Position the toe link cam (3) to the reference mark made during the removal to ease with setting the rear toe adjustment.
8. Install the toe link cam bolt and nut (1) attaching the toe link (2) to the rear suspension crossmember tighten to 34 N.m (25 ft. lbs.).
9. If equipped, install the rear drive module.
10. Install the exhaust system to the vehicle. Refer to «INSTALLATION»(ref-485503-S25516146662012071300000) .
11. Install tire and wheel assembly and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) .
12. Install the upper suspension bracket nuts and tighten to 23 N.m (17 ft. lbs.).
13. Install spare tire.
14. Check and adjust the rear wheel alignment to specifications. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-485471-S16167757252012071300000) .

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1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. Remove the nuts (2), push pins (3) and the right shield (1) from the vehicle.

Scheme 40

1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
2. Remove the nuts (1), pushpin (3) and the left shield (2) from the vehicle.