Frame and Bumpers: Removal & Installation Dodge Journey I

INSTALLATION

1. Install the fascia to the vehicle.
2. Reconnect the ambient temp sensor wire connector, if equipped.
3. Reconnect the fog lamp wire connector and side marker connector from body harness, if equipped.
4. Slide the fascia (2) into the mounting tab (1) under the headlamp.
5. Install the pushpins (1) for the fascia (2) at the lower closeout panel.
6. Insert and snap into place the fascia tabs (2) at the bracket (1).
7. Install the Torx® screw (3) at the wheel well housing.
8. Install the pop rivets (2) at the wheel well opening.
9. Lower the vehicle.
10. Install the pushpins for the fascia (2) at the radiator support.
11. close the hood and check for proper fit.

Scheme 8

Scheme 9

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

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

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. Open the hatch.
2. Remove the 6 pushpins (1) securing the fascia (2).
3. Remove the rivets (2) and the Torx® screw (3) around the wheel well for the fascia (1).
4. Separate the tabs (2) securing the fascia (3) to the bracket (1).
5. Remove the push pin (2) under the taillight (1) to the fascia (3).
6. Remove fascia (3) from vehicle.

1. Install the fascia (3) to the vehicle and install the pushpin (2) at the tailight (1) to the body.
2. Clip the fascia (3) into the tabs (2) to the bracket (1).
3. Install the Torx® screw (3) for the fascia top the wheel opening and then install the pop rivets (2).
4. Install the 6 push pins (1) to secure the fascia (2) to the body.
5. Close the hatch and check for fit.

Scheme 14

1. Remove the front fascia. See «Removal»(ref-353568-S09877246192010011200000) .
2. Support bumper reinforcement (3) on a suitable lifting device.
3. Mark the position of the bolts (1) on frame rail to aid in installation.
4. Remove the smaller bolts (2) attaching bumper reinforcement (3) to frame rail.
5. Remove the larger bolts (1) attaching bumper reinforcement (3) to frame rail.
6. Remove bumper reinforcement (3) from vehicle.

1. Position the bumper reinforcement (3) on vehicle. NOTE: Use marks made previously to properly position bumper reinforcement
2. Install the larger bolts (1) attaching bumper reinforcement (3) to frame rail. Tighten bolts (1) to 28 N.m (250 in. lbs.).
3. Install the smaller bolts (2) attaching bumper reinforcement (3) to frame rail.
4. Install front fascia. See «Installation»(ref-353568-S00094596782010011200000) .

Scheme 15

1. Remove rear fascia. See «Removal»(ref-353568-S27531773622010011200000) .
2. Support bumper reinforcement (1) on a suitable lifting device.
3. Mark position of bolts (2) on frame rail to aid in installation.
4. Remove bolts (2) attaching rear bumper reinforcement (1) to frame rail.
5. Remove bumper reinforcement (1) from vehicle.

1. Position rear bumper reinforcement (1) on vehicle.
2. Install bolts (2) attaching bumper reinforcement to frame rail. Use marks made previously to properly position bumper reinforcement.
3. Tighten bolts (2) to 28 N.m (250 in. lbs.).
4. Install rear fascia. See «Installation»(ref-353568-S06936957112010011200000) .

1. Install the front engine mount (3) on the crossmember. Install the mounting bolts (2) and damper (1). Tighten the bolts to 50 N.m (37 ft. lbs.).
2. Position the fore-aft crossmember in the engine compartment and install the mounting bolts. Tighten the forward mounting bolts at the radiator support to 55 N.m (41 ft. lbs.). Tighten the rearward mounting bolts at the suspension crossmember to 55 N.m (41 ft. lbs.).
3. Install the front engine mount thru-bolt (4). Tighten the bolt to 60 N.m (44 ft. lbs.).
4. If equipped, install the engine belly pan.
5. Lower the vehicle.

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Raise and support the vehicle. Refer to «Vehicle Quick Reference/Hoisting - Standard Procedure»(ref-353564-S41400590852010011200000) .
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 9360. 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. See «Removal»(ref-353568-S24366143892010011200000) .
7. Remove the rear engine mount. Refer to «Engine/Engine Mounting/INSULATOR, Engine Mount - Removal»(ref-353574-S41762128812010011200000) .
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 (2) to 145 N.m (107 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 55 N.m (41 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 appropriate Engine SERVICE INFORMATION article.
14. Install the fore/aft crossmember. See «Installation»(ref-353568-S00602877582010011200000) .
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 «Tires and Wheels - Installation»(ref-353565-S19491247132010011200000) . 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 «Front Suspension/Wheel Alignment - Standard Procedure»(ref-353563-S22715054122010011200000) .

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. Raise and support the vehicle. Refer to «Vehicle Quick Reference/Hoisting - Standard Procedure»(ref-353564-S41400590852010011200000) .
2. On each side of the vehicle, remove the wheel mounting nuts (3), then the front tire and wheel assembly (1).
3. If equipped with all-wheel-drive, remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft.
4. On each side of the vehicle, remove the screw (1) fastening the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3).
5. Remove the exhaust system from the vehicle. Refer to «Exhaust System/PIPE, Exhaust - Removal»(ref-353615-S42767550362010011200000) .
6. Remove the screws securing the four right rear parking brake cable routing clamps to the rear crossmember.
7. On each side of the vehicle, if equipped with load-leveling shocks, support the lower shock (1) with a jack (2) using just enough force to allow easy removal of the lower shock mounting bolt in the following step. Lower the jack following bolt removal.
8. On each side of the vehicle, remove the lower shock mounting nut (1) and bolt (4).
9. If equipped with all-wheel-drive, remove the rear driveline module, but instead of using a drive-on hoist, place jacks under the outboard ends of the lower control arms and adjust the rear suspension height at the hub and bearings to simulate curb riding height. Refer to «Differential and Driveline/Rear Driveline Module - Removal»(ref-353569-S11252584142010011200000) . Once the rear driveline module is removed, remove the jacks.
10. If equipped with all-wheel-drive, slide the half shaft out of the hub and bearing on each side of the vehicle and remove it.
11. On each side of the vehicle, while holding the stabilizer bar link upper stud stationary, remove the nut (2) securing the link (4) to the stabilizer bar (3).
12. On each side of the vehicle, remove the screws (1) securing the stabilizer bar retainer (5) to the crossmember.
13. Remove the stabilizer bar (3) from the vehicle.
14. On each side of the vehicle: Loosen (do not remove) the nut (2) and bolt (7) securing the lower control arm (3) to the knuckle (1). Remove the nut (4) and bolt (6) securing the lower control arm (3) to the rear crossmember (5). Swing the lower control arm down away from the rear crossmember.
15. On each side of the vehicle: Mark the position of the cam bolt (4) cams on the crossmember using a paint marker or crayon. Do not use any type marker that will scratch or damage the surface of the crossmember. While holding the cam bolt (4) head stationary, loosen and remove the toe link mounting cam bolt nut (3) and washer (1). Remove the cam bolt.
16. On each side of the vehicle, loosen (do not remove) the mounting bolt (2) and nut securing the toe link (3) to the knuckle.
17. On each side of the vehicle: Loosen (do not remove) the nut (3) and bolt (4) securing the upper control arm (5) to the knuckle. Remove the nut (2) and bolt (1) securing the upper control arm (5) to the crossmember.
18. On each side of the vehicle, using wire or a bungee cord, support the knuckle to keep it from sagging. NOTE: Before lowering the rear 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 crossmember is not reinstalled in exactly the same location as before removal, the rear wheel alignment settings may be lost.
19. Using a crayon or marker that will not break the paint surface, mark the location of the rear suspension crossmember on the body near each mounting bolt. Do not use any type of sharp instrument that will damage the underbody of the vehicle.
20. Support the crossmember with a transmission jack. Secure the crossmember to the jack.
21. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body.
22. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts. Remove the brackets.
23. Remove the four mounting bolts securing the crossmember to the body.
24. Slowly lower the crossmember using the jack.

1. Support the rear suspension crossmember with a transmission jack. Secure the crossmember to the jack.
2. Slowly raise the crossmember 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 rear suspension components into place.
3. Install the four mounting bolts (rear bolts have stud heads) securing the crossmember to the body. Tighten the crossmember mounting bolts to 95 N.m (70 ft. lbs.).
4. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time.
5. Install the mounting screws securing the crossmember reinforcement brackets to the body. Tighten the screws to 55 N.m (41 ft. lbs.).
6. Tighten the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.).
7. Remove the transmission jack.
8. On each side of the vehicle, position the upper control arm (5) and install the bolt (1) and nut (2) securing the arm to the crossmember. Do not tighten either upper control arm mounting bolts at this time. CAUTION: When installing the cam bolt (4) and washer make sure the cams stay inside the abutments built into the crossmember. Failure to do so can damage the abutments and make toe adjustment difficult.
9. On each side of the vehicle: Position the toe link (2) and install the cam bolt (4) from the front through the crossmember and link. Match the cam on the bolt to the marks made during removal or position the top of the cam to the 12 O'clock position if not available. Install the cam washer (1) and nut (3) securing the toe link (2) to the crossmember. Do not tighten at this time.
10. On each side of the vehicle, position the lower control arm (3) and install the bolt (6) and nut (4) securing the lower control arm to the crossmember (5). Do not tighten nut and bolt at crossmember or knuckle at this time. NOTE: When installing the stabilizer bar on a vehicle with all-wheel-drive, position the bar so that the bar loops over the axle half shafts once installed, not under the axle half shafts.
11. Position the stabilizer bar (3) on the rear crossmember. CAUTION: Before installing the screws in the following step, it is especially important to clean the threads and apply Mopar® Lock AND Seal Adhesive or equivalent.
12. Install the two retainers (5 - right side shown in illustration) over the cushions at the mounting holes and install the retainer screws (1). Do not tighten the screws at this time. CAUTION: Before installing the nut in the following step, it is especially important to clean the threads and apply Mopar® Lock AND Seal Adhesive or equivalent.
13. On each side of the vehicle, install the stabilizer link (4) upper stud in the end of the stabilizer bar (3). Install the nut (2) on the upper stud and while holding the stabilizer link stud stationary, tighten the nut to 48 N.m (35 ft. lbs.).
14. On each side of the vehicle, tighten the stabilizer bar retainer screws (1) to 25 N.m (18 ft. lbs.). NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.
15. If equipped with all-wheel-drive, slide the half shaft into the hub and bearing on each side of the vehicle and hand-start the washer and hub nut (3) Support the shafts to keep them from overextending the joints.
16. If equipped with all-wheel-drive, install the rear driveline module. In place of using a drive-on hoist, place jacks under the outboard ends of the lower control arms and adjust the rear suspension height at the hub and bearings to simulate curb riding height. Refer to «Differential and Driveline/Rear Driveline Module - Removal»(ref-353569-S11252584142010011200000) . Once the rear driveline module is installed, remove the jacks.
17. On each side of the vehicle, if equipped with load-leveling shocks, place a jack (2) against the lower shock eye and support the lower end of the shock assembly (1). Lift the shock assembly using the jack until the hole in the lower shock eye lines up with that in the lower control arm.
18. On each side of the vehicle, install the mounting bolt (4) and nut (1) fastening the shock assembly (2) to the lower control arm (3). Do not tighten at this time.
19. Position the four parking brake cable routing clamps along the front of the rear crossmember and install the screws. Tighten the screws to 6 N.m (55 in. lbs.).
20. Install the exhaust system. Refer to «Exhaust System/PIPE, Exhaust - Installation»(ref-353615-S06328638972010011200000) .
21. On each side of the vehicle, attach the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3) using the mounting screw (1). Tighten the mounting screw to 20 N.m (15 ft. lbs.).
22. While a helper applies the brakes to keep the hub (1) from rotating, on each side of the vehicle: Tighten the hub nut (3) to 245 N.m (181 ft. lbs.). Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. Wrap the cotter pin (2) ends tightly around the lock nut.
23. On each side of the vehicle, install tire and wheel assembly (1). Refer to «Tires and Wheels - Installation»(ref-353565-S19491247132010011200000) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
24. Lower the vehicle.
25. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts.
26. Tighten the lower control arm mounting bolt nut at the crossmember to 105 N.m (77 ft. lbs.).
27. Tighten the lower control arm mounting bolt nut at the knuckle to 105 N.m (77 ft. lbs.).
28. Tighten the shock assembly lower mounting bolt nut to 99 N.m (73 ft. lbs.).
29. Tighten the upper control arm mounting bolt nut at the crossmember to 105 N.m (77 ft. lbs.).
30. Tighten the upper control arm mounting bolt nut at the knuckle to 105 N.m (77 ft. lbs.).
31. Tighten the toe link mounting bolt nut at the knuckle to 105 N.m (77 ft. lbs.).
32. Perform wheel alignment as necessary. Refer to «Front Suspension/Wheel Alignment - Standard Procedure»(ref-353563-S22715054122010011200000) .
33. Once rear toe is set, while holding the cam bolt (4) head stationary, tighten the toe link mounting cam bolt nut (3) to 100 N.m (74 ft. lbs.).