Frame Replacement 2.4L

Special Tools

J 39580 Engine Support Stand

1. Install the engine support fixture. Refer to Engine Support Fixture.
2. Support the radiator and condenser from above using the condenser tabs on each side.
3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle.
4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
5. Remove the front fender liner. Refer to Front Fender Liner Replacement.
6. LE5 only, remove the front catalytic converter. Refer to Catalytic Converter Replacement.
7. Remove the engine splash shields. Refer to Engine Splash Shield Replacement , Engine Splash Shield Replacement - Left Side and Engine Splash Shield Replacement - Right Side.



8. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement.
9. Remove the tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.



10. Remove both stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement.
11. Separate the steering gear from the intermediate shaft. Refer to Intermediate Steering Shaft Replacement.



12. Remove the front transmission mount bolt from the frame. Refer to Transmission Front Mount Replacement.
13. Remove the rear transmission mount bracket fasteners from the frame. Refer to Transmission Rear Mount Replacement.



14. Lower the vehicle until the frame contacts the J 39580 .



15. Remove the reinforcement bolts (1).



16. Remove the front frame bolts (1).
17. Remove the rear frame bolts (4).
18. Remove the frame reinforcements (3).
19. Raise the vehicle off of the frame.
20. Remove the following components if replacing the frame:

•	The steering gear--Refer to Steering Gear Replacement.

•	The lower control arms--Refer to Lower Control Arm Replacement.

•	The stabilizer shaft--Refer to Stabilizer Shaft Replacement.

•	The radiator support brackets

1. Install the following components on the suspension crossmember if removed:

•	The radiator support brackets

•	The stabilizer shaft--Refer to Stabilizer Shaft Replacement.

•

•	The lower control arms--Refer to Lower Control Arm Replacement.

•	The steering gear--Refer to Steering Gear Replacement.




2. Lower the vehicle on to the frame.
3. Install the frame reinforcements (3).
4. Install the front frame bolts. Hand tighten ONLY.
5. Install the reinforcement bolts. Hand tighten ONLY.

Caution: Refer to Fastener Caution in the Preface section.

6. Install the rear frame bolts (4) and tighten to 100 N·m (74 lb ft) plus 90 degrees rotation.
7. Tighten the front frame bolts (1) and tighten to 100 N·m (74 lb ft).



8. Install the cradle support bolts (1) and tighten to 100 N·m (74 lb ft).
9. Raise the vehicle.
10. Install the rear transmission mount bracket fasteners. Refer to Transmission Rear Mount Replacement.



11. Install the front transmission mount bracket bolt. Refer to Transmission Front Mount Replacement.
12. Install the power steering gear mounting bolts. Refer to Steering Gear Replacement.
13. Connect the steering gear to the intermediate shaft. Refer to Intermediate Steering Shaft Replacement.



14. Install both stabilizer links to the stabilizer bar and tighten the stabilizer link nut to 65 N·m (48 lb ft).
15. Install the tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.



16. Install the lower ball joints to the steering knuckles.

16.1.

Tighten the ball stud to steering knuckle pinch nut to 50 N·m (37 lb ft)

16.2.

Reverse the nut ¾ of a turn.

16.3.

Tighten to 50 N·m (37 lb ft) plus 60 degrees.

17. Install the front fender liner. Refer to Front Fender Liner Replacement.
18. Install the engine splash shields. Refer to Engine Splash Shield Replacement , Engine Splash Shield Replacement - Left Side and Engine Splash Shield Replacement - Right Side.
19. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
20. LE5 only, install the front catalytic converter. Refer to Catalytic Converter Replacement.
21. Remove the engine support fixture.

Frame Replacement 3.6L

Special Tools

J 39580 Engine Support Stand

1. Install the engine support fixture. Refer to Engine Support Fixture.
2. Support the radiator and condenser from above.
3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle.
4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
5. Remove the front fender liner. Refer to Front Fender Liner Replacement.
6. Remove the engine splash shields. Refer to Engine Splash Shield Replacement , Engine Splash Shield Replacement - Left Side and Engine Splash Shield Replacement - Right Side.



7. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement.
8. Remove the tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.



9. Remove both stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement.
10. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft. Refer to Steering Gear Replacement.



11. Remove the engine mount fasteners from the frame. Refer to Engine Mount Replacement - Right Side.



12. Remove the front transmission mount bolt from the frame. Refer to Transmission Front Mount Replacement.



13. Remove the left transmission mount fasteners from the frame. Refer to Transmission Mount Replacement - Left Side.



14. Remove the rear transmission mount bracket fasteners from the frame. Refer to Transmission Rear Mount Replacement.
15. Remove the brake lines from the retainers on the frame.
16. Remove the power steering outlet pipe/hose from the frame. Refer to Power Steering Gear Outlet Pipe/Hose Replacement.
17. Remove the rear catalytic converter. Refer to Catalytic Converter Replacement - Left Side or Catalytic Converter Replacement - Right Side.



18. Lower the vehicle until the frame contacts the J 39580 .



19. Remove the reinforcement bolts (1).



20. Remove the front frame bolts (1).
21. Remove the rear frame bolts (4).
22. Remove the frame reinforcements (3).
23. Raise the vehicle off of the frame.
24. Remove the following components if replacing the frame:

•	The lower control arms--Refer to Lower Control Arm Replacement.

•

•	The stabilizer shaft--Refer to Stabilizer Shaft Replacement.

•

1. Install the following components on the suspension crossmember if removed:

•	The stabilizer shaft--Refer to Stabilizer Shaft Replacement.

•	The lower control arms--Refer to Lower Control Arm Replacement.




2. Lower the vehicle on to the frame.
3. Install the frame reinforcements (3).
4. Install the front frame bolts. Hand tighten ONLY.
5. Install the reinforcement bolts. Hand tighten ONLY.

Caution: Refer to Fastener Caution in the Preface section.

6. Tighten the rear frame bolts (4) and tighten to 100 N·m (74 lb ft) plus 90 degrees rotation.
7. Tighten the front frame bolts (1) to specifications.

Tighten the bolts to 100 N·m (74 lb ft) plus 90 degrees rotation.




8. Install the cradle support bolts (1) and tighten to 100 N·m (74 lb ft).
9. Raise the vehicle.
10. Install the power steering outlet pipe/hose to the frame. Refer to Power Steering Gear Outlet Pipe/Hose Replacement.
11. Install the brake lines to the retainers on the frame.



12. Install the rear transmission mount bracket fasteners. Refer to Transmission Rear Mount Replacement.



13. Install the left transmission mount fasteners to the frame. Refer to Transmission Mount Replacement - Left Side.



14. Install the front transmission mount bracket bolt. Refer to Transmission Front Mount Replacement.



15. Install the engine mount fasteners to the frame. Refer to Engine Mount Replacement - Right Side.
16. Install the power steering gear mounting fasteners. Refer to Steering Gear Replacement.



17. Install both stabilizer links to the stabilizer bar and tighten the stabilizer link nut to 65 N·m (48 lb ft) plus 180 degrees rotation.
18. Install the tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.



19. Install the lower ball joints to the steering knuckles.

19.1.

Reverse the nut ¾ of a turn

19.2.

Tighten the ball stud to steering knuckle pinch nut to 50 N·m (37 lb ft).

19.3.

Tighten to 50 N·m (37 lb ft) plus 60 degrees.

20. Install the rear catalytic converter. Refer to Catalytic Converter Replacement - Left Side or Catalytic Converter Replacement - Right Side.
21. Install the front fender liner. Refer to Front Fender Liner Replacement.
22. Install the engine splash shields. Refer to Engine Splash Shield Replacement , Engine Splash Shield Replacement - Left Side and Engine Splash Shield Replacement - Right Side.
23. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
24. Lower the vehicle.
25. Remove the temporary radiator and condenser support.
26. Remove the engine support fixture.