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Frame & Bumpers: Removal & Installation Dodge Magnum I

Frames, Subframes & Crossmembers 26 illustrations ~4632 words

INSTALLATION

  1. Position the bumper. NOTE: It is not necessary to spot weld the bumper back into place.
  2. Install the bolts and tighten to 28 N.m (21 ft. lbs.).
  3. Install the fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FASCIA-FRONT - INSTALLATION)»(ref-246924-S38090517282007011000000)

Scheme 45

Scheme 45: REMOVAL
Scheme 45: REMOVAL
  1. Remove the fascia assembly. «(Refer to FRAME & BUMPERS/BUMPERS/FASCIA-REAR - REMOVAL)»(ref-246924-S42757534582007011000000)
  2. Remove the six nuts and washers and remove the bumper.
  1. Position the bumper.
  2. Install the nuts and washers and tighten to 28 N.m (21 ft. lbs.).
  3. Install the fascia assembly. «(Refer to FRAME & BUMPERS/BUMPERS/FASCIA-REAR - INSTALLATION)»(ref-246924-S05568706482007011000000)

Scheme 46

Scheme 46: REMOVAL
Scheme 46: REMOVAL

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49
  1. Remove the wheel house splash shield rivets three per side.
  2. Remove the nine belly pan (1) screws (2).
  3. Remove the two fascia to fender screw (5), one per side.
  4. Open the hood and remove the upper push pin fasteners (2), four per sedan, and six per wagon.
  5. Remove the fascia assembly (4) from the vehicle.
  6. Disconnect the electrical connectors and remove the fascia.

Scheme 50

Scheme 50: INSTALLATION
Scheme 50: INSTALLATION
  1. Verify that the clip (1) and the push pin (2) are secured into the fender.
  2. Place the fascia into position near the bumper to connect the electrical connector.
  3. Install the fascia (4) onto the bumper and side the open fascia slots over the two push pin fasteners (6).
  4. Install the upper push pin fasteners (2) four per sedan and six per wagon.
  5. Install the four upper push pin fasteners (2).
  6. Install the fascia to fender screws (5) and secure into the fender clip (1).
  7. Position the front belly pan (1).
  8. Install the nine belly pan fasteners (2).
  9. Install the wheel house splash shield rivets.

Scheme 51

Scheme 51: REMOVAL
Scheme 51: REMOVAL

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54
  1. Remove the wheel house splash shield rivets (1) three per side.
  2. Remove the fascia to quarter panel screws.
  3. Remove the two deck lid bumper stops (1) sedan only.
  4. Remove the fascia push pin fasteners (2), three per sedan and five per wagon.
  5. Remove the fascia (5) from the vehicle.
  6. Disconnect the electrical connector and remove the fascia assembly.

Scheme 55

Scheme 55
Scheme 55

Remove park assist senors (1) from the rear fascia (2), if necessary. (Refer to ELECTRICAL/CHIME/BUZZER/PARK ASSIST SENSOR - REMOVAL) .

Install park assist sensors (1) to the rear fascia (2), if necessary. (Refer to ELECTRICAL/CHIME/BUZZER/PARK ASSIST SENSOR - INSTALLATION) .

Scheme 56

Scheme 56
Scheme 56
  1. Verify that the clips (1) and the push pins (2) are secured into the fenders.
  2. Place the fascia assembly into position near the bumper and connect the electrical connector.
  3. Install the fascia (5) onto the bumper and slide the open fascia slots over the for push pin fasteners (2).
  4. Install the push pin fasteners (4), three per sedan and five per wagon.
  5. Install the two bumper stops (1), sedan only.
  6. Install the fascia to quarter panel screws and secure into the quarter pan.
  7. Install the wheel house splash shield rivets (2).
CAUTIONIt is very important that bushing be installed in same position as original to maintain vehicle ride quality and bushing longevity. That is why bushing, once installed, needs to closely match reference marks applied upon removal of original bushing.

Scheme 57

Scheme 57
Scheme 57
  1. Position bushing on crossmember bushing bore aligning bushing can flange (3) with reference marks applied during removal.
  2. Assemble tools (See following list) over bushing (3) and crossmember (Scheme 57) (1) Press C-4212F (2) Receiver 9031-3 (4) Installer 9031-4
  3. Tighten Press (1) 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. NOTE: Do not reinstall coil springs on spring links at this time. Install as directed in later steps.
  6. Raise crossmember using jack until there is about 10 inches clearance to the to body mounting points.
  7. Install screw (2) fastening front parking brake cable routing bracket (1) to rear crossmember.
  8. Raise crossmember to body mounting points. As crossmember is raised, slide propeller shaft (1) onto rear axle differential flange (2) and align shock absorbers with pockets in spring links. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  9. Continue to raise crossmember (1) with jack until crossmember mounting bolts (2 and 3) can be installed. Install left side crossmember mounting bolts, but not the right side bolts. It is not necessary to tighten bolts at this point. CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  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 (2) Installation. Do not lower jack any further than necessary. NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
  11. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
  12. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
  13. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.
  14. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  15. Raise right side of crossmember (1) into mounted position. Install right side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time.
  16. Remove both front and rear crossmember mounting bolts (2 and 3) on left side of vehicle. CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  17. 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 (2) Installation. Do not lower jack any further than necessary. NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
  18. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
  19. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
  20. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.
  21. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  22. Raise left side of crossmember (1) into mounted position. Install left side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time. 1 - BODY 2 - MARKER (OR CRAYON) 3 - CROSSMEMBER BUSHING FLANGE
  23. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
  24. Once mounts are lined up with location marks, on both sides of vehicle, measure distance (1) between the tension link (2) and weld flange (3) on body directly in front of it, just outboard of the front mount bushing (4). This distance must be at least 12 mm to allow proper clearance for suspension movement. If distance is less than 12 mm on either side of vehicle, shift that side of rear crossmember directly rearward until distance is 12 mm or greater. To do so, loosen 3 mounting bolts slightly, leaving one on opposite side of shift snugged to pivot off of. Shift crossmember rearward and snug loosened bolts. Remeasure opposite side to be sure it still maintains minimum 12 mm distance.
  25. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.) torque.
  26. Remove jack (3) from under rear axle differential.
  27. Remove bungee cord (1) supporting propeller shaft (2).
  28. Align propeller shaft index marks (3) placed upon removal. Install propeller shaft rear coupler-to-axle flange bolts and nuts by hand. Tighten propeller shaft rear coupler-to-axle flange bolts to 81 N.m (60 ft. lbs.) torque.
  29. Install fuel filler tube. «(Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK FILLER TUBE - INSTALLATION)»(ref-246920-S09802251292007011000000)
  30. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
  31. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
  32. Insert speed sensor connectors (3 and 4) into body wiring harness connector (1) located in luggage compartment floor pan (2). When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.
  33. On each rear disc brake: Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3). CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed. Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 60 N.m (44 ft. lbs.) torque. Make sure brake hose is properly routed and will not come in contact with suspension components.
  34. Route parking brake cable above rear crossmember, then slide cable (2) through equalizer (4) above rear differential. NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
  35. Connect front parking brake cable (2) at connector (1) to right rear parking brake cable (6).
  36. Install rear exhaust system (2) (dual-outlet exhaust see scheme 181). (Refer to «EXHAUST SYSTEM»(ref-246923).
  37. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.) torque. «(Refer to TIRES/WHEELS - INSTALLATION)»(ref-246926-S21024494472007011000000)
  38. Lower vehicle until rear wheels are just above floor level.
  39. Apply parking brake lever. Release lever, then reapply.
  40. Check to make sure rear wheels will not rotate with lever applied.
  41. Lower vehicle.
  42. Connect battery negative cable (2) to battery post. It is important that this is performed properly. «(Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)»(ref-246907-S06752275242007011000000)
  43. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  44. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
  45. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft. lbs.) torque.
  46. Perform wheel alignment. «(Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)»(ref-246927-S10951687702007011000000)

Scheme 58

Scheme 58: REMOVAL
Scheme 58: REMOVAL

Scheme 59

Scheme 59
Scheme 59

Scheme 60

Scheme 60
Scheme 60
  1. Raise and support vehicle. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(ref-246906-S06883027062007011000000)
  2. Access and remove rear spring on side of repair. «(Refer to SUSPENSION/REAR/SPRING - REMOVAL)»(ref-246927-S34012251292007011000000)
  3. Export Only - If servicing right side bushing, disconnect headlamp leveling sensor (1) link at spring link (3).
  4. Remove bolt and nut (1) fastening spring link (4) to crossmember.
  5. Position spring link downward, away from bushing in crossmember. 1 - BUSHING 2 - REMOVER 9032-2 3 - PRESS C-4212F 4 - RECEIVER 9032-1 NOTE: Prior to using Press (3), Special Tool C-4212F, lubricate screw-drive threads to provide ease of use and promote tool longevity.
  6. Assemble tools over bushing (Scheme 60)(See following list). Ensure Receiver, Special Tool 9032-1, sets against crossmember and not welds. (2) Remover 9032-2 (3) Press C-4212F (4) Receiver 9032-1
  7. Tighten Press screw-drive, pressing bushing out of crossmember.

Scheme 61

Scheme 61: INSTALLATION
Scheme 61: INSTALLATION
1 - BUSHING
2 - REMOVER/INSTALLER 9032-2
3 - PRESS C-4212F
4 - RECEIVER 9032-3
  1. Position bushing (1) over rear of crossmember bushing bore.
  2. Assemble tools over bushing and crossmember (Scheme 61)(See following list). Ensure Receiver, Special Tool 9032-3, is positioned to avoid welds on rear of crossmember bushing bore. (2) Remover/Installer 9032-2 (3) Press C-4212F (4) Receiver 9032-3
  3. 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 (1) fastening spring link (4) to crossmember. Do not tighten bolt at this time.
  6. Export Only - If servicing right side bushing, connect headlamp leveling sensor (1) link at spring link (3).
  7. Install rear spring as well as all components necessary to access it. «(Refer to SUSPENSION/REAR/SPRING - INSTALLATION)»(ref-246927-S23536479312007011000000)
  8. Lower vehicle.
  9. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolt.
  10. Tighten spring link bolt (1) at crossmember to 108 N.m (80 ft. lbs.) torque.
  11. Perform wheel alignment. «(Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)»(ref-246927-S10951687702007011000000)

Scheme 62

Scheme 62
Scheme 62

Scheme 63

Scheme 63
Scheme 63

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65
Scheme 65

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67

Scheme 68

Scheme 68
Scheme 68
  1. Disconnect and isolate battery negative cable (2) from battery post.
  2. Raise and support vehicle. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(ref-246906-S06883027062007011000000)
  3. On each side of vehicle rear, remove wheel mounting nuts (3), then tire and wheel assembly (1).
  4. On each side of vehicle rear, while a helper applies brakes to keep hub from rotating, remove hub nut (1) from half shaft (2).
  5. Remove rear exhaust system (2) (dual-outlet exhaust see scheme 195). (Refer to «EXHAUST SYSTEM»(ref-246923).
  6. Remove rear axle differential. «(Refer to DIFFERENTIAL & DRIVELINE/REAR AXLE - 198MM - REMOVAL)»(ref-246916-S32637523682007011000000) or «(Refer to DIFFERENTIAL & DRIVELINE/REAR AXLE - 210MM - REMOVAL)»(ref-246916-S10537093332007011000000)
  7. Slide each axle half shaft from hub and bearing and remove from vehicle. NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
  8. Disconnect front parking brake cable (2) at connector (1) to right rear parking brake cable.
  9. Remove front parking brake cable (2) from equalizer (4).
  10. On each rear disc brake: While holding guide pins from turning, remove disc brake caliper guide pin bolts (2). Remove brake caliper (1) from brake adapter (3) and pads. Guide brake caliper up through suspension, following brake hose path. Support caliper above rear suspension using with bungee cord or wire to keep caliper from overextending brake hose when crossmember is lowered. NOTE: To remove wheel speed sensor connector from body wiring harness connector, move retaining clip (2) and pull sensor connector outward.
  11. Remove wheel speed sensor connectors (3 and 4) from body wiring harness connector (1) located in luggage compartment floor pan (2).
  12. Unclip left wheel speed sensor cable (3) from routing clip (1) near body connector.
  13. Unclip left sensor cable (1) from routing clips (2) along rear of crossmember near rear differential (3).
  14. Unclip left sensor cable (2) from routing clip (1) above toe link mount on rear crossmember.
  15. On each side of vehicle, remove shock absorber (1) lower mounting bolt (2) and nut (4). 1 - BODY 2 - MARKER (OR CRAYON) 3 - CROSSMEMBER BUSHING FLANGE
  16. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon. Do not use a scratch awl to mark location.
  17. Position an extra pair of jack stands under and support forward end of engine cradle to help stabilize vehicle during rear suspension removal/installation.
  18. Position under-hoist utility jack or transmission jack (2) under center of rear crossmember (1). Raise jack head to contact crossmember and secure in place. When securing crossmember to jack, be sure not to secure stabilizer bar. WARNING: Before opening fuel system, review all Warnings and Cautions.
  19. Remove fuel filler tube. «(Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK FILLER TUBE - REMOVAL)»(ref-246920-S39552126992007011000000) NOTE: If equipped with AWD, when removing crossmember mounting bolts in following step, be sure to not to misplace spacers (1) between crossmember mounts (2) and body.
  20. Remove both front (3) and both rear (2) mounting bolts fastening crossmember (1) in place.
  21. Slowly lower crossmember several inches using jack.
  22. Remove screw (2) fastening front parking brake cable routing bracket (2) to rear crossmember.
  23. Continue to lower jack until crossmember is at a comfortable working level to access link and stabilizer bar fasteners.
  24. On each end, remove bolt (3) and nut fastening stabilizer bar (4) to stabilizer link (2).
  25. Remove bolts (1) fastening each stabilizer bar cushion retainer to crossmember.
  26. Remove stabilizer bar (4) with cushions and retainers.
  27. Remove coil springs and isolators (1, 2 and 5) from spring links.
  28. For each rear parking brake cable, place 14 mm 12-point deep well socket (3) over cable strand (1) onto cable retainer at crossmember bracket (Scheme 65)to collapse retainer fingers. It may be necessary to wiggle the socket around somewhat to collapse fingers. With socket in place, pull cable (2) from bracket. NOTE: For installation purposes, when removing fasteners for any rear suspension links, it is important to note which bolt fastens what component and in what direction it is installed in.
  29. On each side of crossmember, remove bolt and nut (1) fastening spring link (4) to crossmember.
  30. On each side of crossmember, while holding toe adjustment cam bolt from rotating, remove nut (3) securing toe link at crossmember (1).
  31. On each side of crossmember, slide cam bolt (2) attaching toe link rearward, out of crossmember and link (1).
  32. On each side of crossmember, remove bolt and nut (1) mounting link (3) at crossmember.
  33. On each side of crossmember, remove nut and bolt (4) mounting tension link to crossmember (1).
  34. On each side of crossmember, remove nut and bolt (2) mounting camber link to crossmember (1).
  35. Carefully lift knuckle with links and parking brake cable attached from rear suspension crossmember.
  36. Remove crossmember from jack.

Scheme 69

Scheme 69: INSTALLATION
Scheme 69: INSTALLATION

Scheme 70

Scheme 70
Scheme 70
  1. Install rear crossmember (1) on jack (2) head in same position in which it was removed and secure in place.
  2. Carefully place one side knuckle with links and parking brake cable attached as an assembly into mounted position on rear suspension crossmember. Install nut and bolt (2) mounting camber link to crossmember (1) to hold assembly in place. Do not tighten at this time.
  3. Carefully place opposite side knuckle with links and parking brake cable attached as an assembly into mounted position on rear suspension crossmember. Install nut and bolt (2) mounting camber link to crossmember (1) to hold assembly in place. Do not tighten at this time.
  4. On each side of crossmember, install nut and bolt (4) mounting each tension link to crossmember (1). Do not tighten at this time.
  5. On each side of crossmember, Install bolt and nut (1) mounting each compression link (3) at crossmember. Do not tighten at this time.
  6. On each side of crossmember, slide cam bolt (2) attaching toe link through crossmember and link (1) from rear.
  7. On each side of crossmember, while holding toe adjustment cam bolt from rotating, install cam washer (2) and nut (3) securing toe link at crossmember (1). Do not tighten at this time.
  8. On each side of crossmember, install bolt and nut (1) fastening spring link (4) to crossmember. Do not tighten at this time.
  9. Install end of each rear parking brake cable into mounting bracket on crossmember. Press retainer through bracket until retainer fingers lock cable into place.
  10. Install stabilizer bar (4) with cushions and retainers on crossmember.
  11. Install cushion retainer mounting bolts (1). Do not tighten at this time.
  12. Install bolt (3) and nut fastening stabilizer bar ends to each stabilizer link (2). Do not tighten at this time.
  13. Tighten cushion retainer mounting bolts (1) to 60 N.m (44 ft. lbs.) torque. CAUTION: Differential mounting bolts (1) must be installed through bushings prior to crossmember installation in vehicle. Bolts cannot be inserted through bushings once crossmember is installed.
  14. Transfer differential mounting bolts (1) from original crossmember differential mount bushings to bushings in replacement crossmember. Install bolts from rear. Be sure to insert bolts through correct mount bushings in crossmember depending on rear axle differential (198 mm axle differential see scheme 225). NOTE: Do not install coil springs on spring links at this time.
  15. Raise crossmember using jack until there is about 10 inches (250 mm) clearance to the to body mounting points.
  16. Install screw (2) fastening front parking brake cable routing bracket (1) to rear crossmember.
  17. Raise crossmember to body mounting points. As crossmember is raised, align shocks (3) with pockets in spring links. Do not install bolts at this time. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  18. Continue to raise crossmember (1) with jack until crossmember mounting bolts (2 and 3) can be installed. Install left side crossmember mounting bolts, but not the right side bolts. It is not necessary to tighten bolts at this point. CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  19. 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 (2) Installation. Do not lower jack any further than necessary. NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
  20. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
  21. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
  22. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.
  23. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  24. Raise right side of crossmember (1) into mounted position. Install right side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time.
  25. Remove both front and rear crossmember mounting bolts (2 and 3) on left side of vehicle. CAUTION: To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).
  26. 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 (2) Installation. Do not lower jack any further than necessary. NOTE: Before installing coil spring, make sure isolators (1 and 5) are completely installed on ends of spring.
  27. Install coil spring (2) with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
  28. Carefully raise jack, guiding coil spring and lower end of shock absorber (1) into mounted positions. Once shock absorber (1) lower mounting hole lines up with hole in spring link (3), stop jacking.
  29. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time.
  30. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place. NOTE: There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.
  31. Raise left side of crossmember (1) into mounted position. Install left side crossmember mounting bolts (2 and 3). Snug, but do not fully tighten bolts at this time. 1 - BODY 2 - MARKER (OR CRAYON) 3 - CROSSMEMBER BUSHING FLANGE
  32. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
  33. Once mounts are lined up with location marks, on both sides of vehicle, measure distance (1) between the tension link (2) and weld flange (3) on body directly in front of it, just outboard of the front mount bushing (4). This distance must be at least 12 mm to allow proper clearance for suspension movement. If distance is less than 12 mm on either side of vehicle, shift that side of rear crossmember directly rearward until distance is 12 mm or greater. To do so, loosen 3 mounting bolts slightly, leaving one on opposite side of shift snugged to pivot off of. Shift crossmember rearward and snug loosened bolts. Remeasure opposite side to be sure it still maintains minimum 12 mm distance.
  34. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.) torque.
  35. Remove jack (3) from under rear crossmember.
  36. Install fuel filler tube. «(Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL TANK FILLER TUBE - INSTALLATION)»(ref-246920-S09802251292007011000000)
  37. Clip left rear wheel speed sensor cable (2) to routing clip (1) above toe link mount on rear crossmember.
  38. Clip left rear wheel speed sensor cable (1) to routing clips (2) along rear of crossmember near rear differential (3).
  39. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
  40. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
  41. Insert speed sensor connectors (3 and 4) into body wiring harness connector (1) located in luggage compartment floor pan (2). When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.
  42. On each rear disc brake: CAUTION: Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed. Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3). Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 60 N.m (44 ft. lbs.) torque. Make sure brake hose is properly routed and will not come in contact with suspension components.
  43. Route parking brake cable above rear crossmember, then slide cable (2) through equalizer (4) above rear differential. NOTE: Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.
  44. Connect front parking brake cable (2) at connector (1) to right rear parking brake cable (6).
  45. On each side of vehicle, slide an axle half shaft (2) through hub and bearing and install hub nut (1). Do not tighten hub nuts at this time.
  46. Install rear axle differential. «(Refer to DIFFERENTIAL & DRIVELINE/REAR AXLE - 198MM - INSTALLATION)»(ref-246916-S02801355132007011000000) «(Refer to DIFFERENTIAL & DRIVELINE/REAR AXLE - 210MM - INSTALLATION)»(ref-246916-S34521625822007011000000)
  47. While a helper applies brakes to keep hub from turning, tighten hub nut to 213 N.m (157 ft. lbs.) torque.
  48. Install rear exhaust system (2) (dual-outlet exhaust see scheme 250). (Refer to «EXHAUST SYSTEM»(ref-246923).
  49. Lower vehicle until front tires contact floor but rear is still suspended. Place jack stands under each rear suspension spring link. Place an appropriate wooden block between stand and link to avoid damaging spring link, then lower vehicle until full vehicle weight is supported by suspension.
  50. Tighten camber link bolt (2) at crossmember to 85 N.m (63 ft. lbs.) torque.
  51. Tighten tension link bolt nut (2) at crossmember to 85 N.m (63 ft. lbs.) torque.
  52. Tighten compression link bolt (2) at crossmember to 85 N.m (63 ft. lbs.) torque.
  53. Tighten spring link bolt (1) at crossmember to 108 N.m (80 ft. lbs.) torque.
  54. Tighten shock absorber lower mounting bolt nut (4) to 72 N.m (53 ft. lbs.) torque.
  55. Tighten stabilizer link bolts (3) to 61 N.m (45 ft. lbs.) torque.
  56. Raise vehicle and remove jack stands (3).
  57. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.) torque. «(Refer to TIRES/WHEELS - INSTALLATION)»(ref-246926-S21024494472007011000000)
  58. Lower vehicle.
  59. Connect battery negative cable (2) to battery post. It is important that this is performed properly. «(Refer to ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)»(ref-246907-S06752275242007011000000)
  60. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  61. Perform wheel alignment. «(Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)»(ref-246927-S10951687702007011000000)
  62. On each side of crossmember, while holding cam bolt from turning, tighten toe link cam bolt nut (2) to 108 N.m (80 ft. lbs.) torque.

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