Cross member — removal and installation

Special tool

	Subframe alignment pins 205-316 (15-097A)
	Ball joint puller 211-020 (13-006)

General equipment:

• Gearbox jack
• Allen key 5mm

Removal

All cars

1.

NOTE: Make sure the drive wheels are facing straight ahead.

Set the steering gear to the center position and lock it in this position.



Cars manufactured up to 12.1998.

2. Disconnect the steering column shaft from the steering gear.

• 1. Loosen the top bolt.
• 2. Remove the bottom bolt.
• 3. Lift the sleeve.

Cars manufactured since 12.1998.

3. Disconnect the steering column shaft from the steering gear.

• Discard the bolt as it is no longer needed.

All cars


4. Drain the power steering fluid.

• Remove the tank.
• Allow the liquid to drain into a suitable container.

5. Remove the front wheels and tires. For additional information, refer to Section 204-04.

6.

CAUTION: Leave the tie rod end nuts in place to protect the ball joint studs.

Loosen the tie rod end mounting nuts on both sides.



7.

CAUTION: Using a soft cloth, cover the ball joint seal to prevent damage.

Using a special tool, disconnect the tie rod end from the steering knuckle on both sides.

• Remove the tie rod end mounting nuts and discard them as no longer needed.

8.

NOTE: Use a 5mm socket wrench to prevent the ball joint from turning.

Disconnect the stabilizer bar link from the stabilizer bar on both sides.



9.

CAUTION: Using a soft cloth, cover the ball joint seal to prevent damage.

Disconnect the lower control arm ball joint from the steering knuckle on both sides.

• Remove the heat shields.

10. Unscrew the central bolt securing the engine support cushion to the gearbox in the block with the drive axle.



11. Remove the steering gear heat shield (two bolts).




12. Release the power steering line from the clamp.



13. Disconnect the power steering line from the steering gear.

• 1. Remove the bolt.
• 2. Turn the power steering line clamp clockwise.
• Allow the oil to drain into a suitable container.

14. Support the cross member using a suitable transmission jack.


15. Unscrew the cross member mounting bolts (for clarity, the support has been removed).



16. Remove the cross member.

Installation

All cars

1.

CAUTION: Make sure the crossmember ball bearing washers are installed correctly.

Using a suitable transmission jack and special tool, install the crossmember and align it in position.

• 1. Insert the dowel pins into the crossmember alignment holes and into the washers.
• 2. Install the locking plates onto the washers and into the tool groove, then tighten the dowel pin sleeve
• 3. Raise the crossmember by inserting the locating pins into the chassis alignment holes.

2.

CAUTION: When tightening the cross member mounting bolts, the cross member must not move.

Install the crossbar mounting bolts (the support has been removed for clarity).



3. Lower and remove the transmission jack.

4. Remove the crossmember mounting pins.

5.

NOTE: Check the O-rings for wear, cuts or cracks.

Install new O-rings if necessary.



6. Connect the power steering lines to the steering gear.

• Turn the power steering line clamp counterclockwise.

7. Secure the power steering line to the clamp.



8. Install the steering gear heat shield (two bolts).



9. Install the central bolt securing the engine support cushion to the gearbox in the block with the drive axle.



10.

CAUTION: Make sure the heat shield is installed to prevent damage to the ball joint.

Attach the heat shield on both sides.



11. Connect the lower arm ball joint to the steering knuckle on both sides.



12.

NOTE: Use a 5mm socket wrench to prevent the ball joint from turning.

Connect the connecting lever of the anti-roll bar to the anti-roll bar on both sides.



13.

NOTE: Install new nuts.

Connect the tie rod ends to the steering knuckles on both sides.



14. Install the front wheel and tire assemblies. Refer to Section 204-04 for additional information.

Cars manufactured up to 12.1998.

15.

CAUTION: Make sure the front wheels are pointing straight ahead.

Connect the steering column shaft to the steering gear pinion shaft.



Cars manufactured since 12.1998.

16.

WARNING: Install a new bolt. Failure to follow these instructions may result in personal injury.

CAUTION: Make sure the front wheels are pointing straight ahead.

Connect the steering column shaft to the steering gear pinion shaft.



All cars

17. Fill the power steering system with fluid and bleed the system. Refer to Section 211-00 for additional information.