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Isolator, Rear CROSSMEMBER, Differential: Installation: Installation

WARNING: This page is about a different car, the 2012 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Tools Assembled For Installation
GC0080363Courtesy of CHRYSLER GROUP, LLC
NOTE:

It is important that tapered end (3) of bushing be installed first into forward end of crossmember to ease installation.

NOTE:

When installing Thrust Bearing (7), be sure to place hardened side toward Bolt head.

  1. Insert tapered end of NEW bushing (3) into forward end of crossmember bushing bore.
  2. Assemble tools (See following list) through crossmember and bushing as shown in illustration.
    • (1) Bolt
    • (2) Disc (special tool #9520-1, Installer Disc)
    • (3) Bushing
    • (4) Nut
    • (5) Washer
    • (6) Installer (special tool #9520-2, Installer, Bushing)
    • (7) Thrust Bearing
  3. Insert Installer (6) into end of bushing and Disc (2) into opposite end of crossmember bushing bore.
  4. While holding Nut (4) from rotating, tighten Bolt (1) using hand tools  , pressing bushing into crossmember. Stop when Installer (6) bottoms against bushing bore.
  5. Remove tools.
    Fig 2: Rear Axle-To-Crossmember Bolts
    GC0081134Courtesy of CHRYSLER GROUP, LLC
    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.

  6. Insert differential mounting bolt (1) through mount bushing from rear (198 mm axle differential shown in figure. Other axles differ, but similar).
    NOTE:

    Do not install coil springs on spring links at this time.

    Fig 3: Coil Spring And Shock Assy.
    GC0095728Courtesy of CHRYSLER GROUP, LLC
  7. 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. 
    Fig 4: Rear Crossmember Mounting Bolts
    GC0095727Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.

  8. 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.
    Fig 5: Coil Spring And Shock Assy.
    GC0095728Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).

  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 (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.

  10. 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.
    Fig 6: Lower Shock Mount
    GC0079751Courtesy of CHRYSLER GROUP, LLC
  11. 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.
  12. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 7: AWD Crossmember Spacers
    GC0079752Courtesy of CHRYSLER GROUP, LLC
  13. If vehicle is equipped with AWD, insert spacers (1) on top of right crossmember mount bushings (2) before crossmember is raised into place.
    Fig 8: Rear Crossmember Mounting Bolts
    GC0095727Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.

  14. 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. 
  15. Remove both front and rear crossmember mounting bolts (2 and 3) on left  side of vehicle.
    Fig 9: Coil Spring And Shock Assy.
    GC0095728Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring (2).

  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 (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.

  17. 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.
    Fig 10: Lower Shock Mount
    GC0079751Courtesy of CHRYSLER GROUP, LLC
  18. 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.
  19. Install lower shock mounting bolt (2) and nut (4). Do not tighten at this time. 
    Fig 11: AWD Crossmember Spacers
    GC0079752Courtesy of CHRYSLER GROUP, LLC
  20. If vehicle is equipped with AWD, insert spacers (1) on top of left crossmember mount bushings (2) before crossmember is raised into place.
    Fig 12: Rear Crossmember Mounting Bolts
    GC0095727Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    There are four crossmember mounting bolts. Rear mounting bolts (2) are longer than front mounting bolts (3). Do not interchange mounting bolts.

  21. 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. 
    Fig 13: Marking Location Of Crossmember Mount To Body
    GC0079773Courtesy of CHRYSLER GROUP, LLC
    1 - BODY
    2 - MARKER (OR CRAYON)
    3 - CROSSMEMBER BUSHING FLANGE
  22. Shift crossmember as necessary to line up mounts (3) with location marks drawn on body (1) before removal.
    Fig 14: Measuring Tension Link Clearance
    GC0079754Courtesy of CHRYSLER GROUP, LLC
  23. 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.
    Fig 15: Rear Crossmember Mounting Bolts
    GC0095727Courtesy of CHRYSLER GROUP, LLC
  24. Tighten all four crossmember mounting bolts (2 and 3) to 180 N.m (133 ft. lbs.).
    Fig 16: Jack Positioned Beneath Crossmember
    GC0095726Courtesy of CHRYSLER GROUP, LLC
  25. Remove jack (2) from under rear crossmember.
    Fig 17: Filler Tube Assembly
    GC0079748Courtesy of CHRYSLER GROUP, LLC
  26. Install fuel filler tube. Refer to TUBE, FUEL TANK FILLER, INSTALLATION or TUBE, FUEL TANK FILLER, INSTALLATION .
    Fig 18: Left/Right Rear Wheel Speed Sensor Routing
    GC0079772Courtesy of CHRYSLER GROUP, LLC
  27. Clip left rear wheel speed sensor cable (3) to routing clip (1) near body connector.
    Fig 19: Sensor Connection To Body Connector
    GC0079771Courtesy of CHRYSLER GROUP, LLC
  28. Match left rear wheel speed sensor connector (4) to right sensor connector (3) to make one connector.
  29. 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.
    Fig 20: Rear Caliper Mounting
    GC0079769Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Extreme caution should be taken not to cross-thread caliper guide pin bolts (2) when they are installed.

  30. If equipped with standard or premium disc brakes, on each rear disc brake:
    1. Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing.
    2. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter (3).
    3. Align caliper mounting holes with guide pins, then install guide pin bolts (2). While holding guide pins from turning, tighten bolts to 31 N.m (23 ft. lbs.) torque.
    4. Make sure brake hose is properly routed and will not come in contact with suspension components.
  31. If equipped with SRT8 disc brakes, at each rear disc brake, support spring link using a transmission jack or other appropriate jack as indicated in removal procedure. Refer to ISOLATOR, REAR CROSSMEMBER, DIFFERENTIAL, REMOVAL  or ISOLATOR, REAR CROSSMEMBER, FRONT MOUNT, REMOVAL  or ISOLATOR, REAR CROSSMEMBER, REAR MOUNT, REMOVAL  or ISOLATOR, REAR CROSSMEMBER, SPRING LINK, REMOVAL .
    Fig 21: Rear Caliper Mounting Bolts
    GC0079734Courtesy of CHRYSLER GROUP, LLC
  32. If equipped with SRT8 disc brakes, on each rear disc brake, slide caliper with pads (2) over brake rotor and align with knuckle.
  33. If equipped with SRT8 disc brakes, on each rear disc brake, install caliper mounting bolts (1). Tighten bolts to 130 N.m (96 ft. lbs.) torque.
  34. If equipped with SRT8 disc brakes, on each rear disc brake, remove jack from under spring link.
    Fig 22: Front Cable Installation Into Equalizer
    GC0079767Courtesy of CHRYSLER GROUP, LLC
  35. Route parking brake cable above rear crossmember, then slide cable (1, 3) through equalizer (2) above rear axle differential (once installed).
    Fig 23: Cables AT Equalizer
    GC0079766Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.

  36. Connect front parking brake cable (5) at connector (3) to right rear parking brake cable (4).
    Fig 24: Front Cable AT Left Front Of Crossmember
    GC0079768Courtesy of CHRYSLER GROUP, LLC
  37. Insert front parking brake cable routing bracket locating pin into front flange of crossmember (3), then install screw (2) fastening cable (1) routing bracket to rear crossmember.
    Fig 25: Identifying Hub Nut
    GC0079730Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.

  38. 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. 
  39. Install rear axle differential. Refer to INSTALLATION .
  40. While a helper applies brakes to keep hub from turning, tighten hub nut to 213 N.m (157 ft. lbs.).
    Fig 26: Identifying Clamps & Rear Exhaust System
    GC0081121Courtesy of CHRYSLER GROUP, LLC
  41. Install rear exhaust system (2) (dual-outlet exhaust shown in figure).
    Fig 27: Tire And Wheel Mounting
    GC0079683Courtesy of CHRYSLER GROUP, LLC
  42. Install tire and wheel assemblies (1). Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.). Refer to INSTALLATION .
  43. Lower vehicle.
    Fig 28: Disconnecting/Connecting Battery Cables
    GC0079763Courtesy of CHRYSLER GROUP, LLC
  44. Connect battery negative cable (2) to battery post. It is important that this is performed properly. Refer to STANDARD PROCEDURE .
  45. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  46. Position vehicle on alignment rack/drive-on lift. Raise vehicle as necessary to access mounting bolts.
    Fig 29: Lower Shock Mount
    GC0079751Courtesy of CHRYSLER GROUP, LLC
  47. Tighten shock absorber lower mounting bolt nuts (4) to 72 N.m (53 ft. lbs.).
  48. Perform wheel alignment, paying special attention to thrust angle. If rear crossmember needs to be shifted to align thrust angle, try to avoid compromising tension link clearance (). Refer to  23 or WHEEL ALIGNMENT, STANDARD PROCEDURE .
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