Front Frame Replacement 3.9L

Special Tools

J 39580 Engine Support Stand

1. Install the engine support fixture. Refer to Engine Support Fixture.
2. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle.
3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
4. Remove the front air deflector. Refer to Front Air Deflector Replacement.
5. Disconnect the antilock brake system (ABS) sensor from the wheel speed sensor and frame.
6. Disconnect the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement.
7. Remove the tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
8. Remove both stabilizer links from the stabilizer bar.
9. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanics wire or equivalent, being sure not to overextend the intermediate shaft. Refer to Steering Gear Replacement.
10. Remove the engine mount nuts from the frame. Refer to Engine Front Mount Replacement and Engine Rear Mount Replacement.
11. Remove the rear transmission mount bolt from the frame. Refer to Transmission Rear Mount Replacement.
12. Remove the left transmission mount nuts from the frame. Refer to Transmission Mount Replacement - Left Side.
13. Remove the rear transmission mount bracket nuts from the frame. Refer to Transmission Rear Mount Bracket Replacement
14. Remove the brake lines from the retainers on the frame.



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



16. Remove the reinforcement bolts (1).



17. Remove the front frame bolts (1).
18. Remove the rear frame bolts (4).
19. Remove the frame reinforcements (3).
20. Raise the vehicle off of the frame.
21. 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).

Caution: Refer to Fastener Caution in the Preface section.

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



6. Install the cradle support bolts (1) and tighten to 100 N·m (74 lb ft).
7. Raise the vehicle.
8. Install the brake lines to the retainers on the frame.
9. Install the rear transmission mount bracket nuts. Refer to Transmission Rear Mount Bracket Replacement
10. Install the left transmission mount nuts to the frame. Refer to Transmission Mount Replacement - Left Side
11. Install the rear transmission mount bracket bolt. Refer to Transmission Rear Mount Replacement
12. Install the engine mount nuts to the frame. Refer to Engine Front Mount Replacement and Engine Rear Mount Replacement
13. Install the power steering gear mounting bolts. Refer to Steering Gear Replacement.



14. Install both stabilizer links to the stabilizer bar and tighten the nut to 65 N·m (48 lb ft) plus 180 degree rotation.
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.

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

•	Reverse the nut ¾ of a turn.

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

17. Connect the ABS sensor to the wheel speed sensor and frame.
18. Install the front air deflector. Refer to Front Air Deflector Replacement.
19. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
20. Remove the engine support fixture.
21. Bleed the power steering system. Refer to Power Steering System Bleeding.

Front Frame Replacement 4.6L

Special Tools

J 39580 Engine Support Stand

1. Install the engine support fixture. Refer to Engine Support Fixture.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation.
4. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement.
5. Remove the bolts retaining the steering gear to the engine frame.
6. Remove the ball joints from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement.
7. Remove the front air deflector. Refer to Front Air Deflector Replacement.
8. Remove the brake pressure modulator valve and bracket from the frame. Refer to Brake Pressure Modulator Valve Replacement.
9. Disconnect the ESC sensor links from the lower control arm ball studs.
10. Remove the secondary air injection pump assembly. Refer to Secondary Air Injection Pump Replacement.



11. Remove the steering gear heat shield fasteners (1) in order to remove the steering gear heat shield (2) and disconnect the electrical harness retainer that is mounted on the heat shield.
12. Disconnect the electrical harness from the heat shield.



13. Remove the brackets (2) retaining the power steering line (1) to the frame.
14. Remove the retainer (3), retaining the power steering line (4) along the left side of the engine frame.
15. Using mechanics wire, retain the steering gear to the body.



16. Lower vehicle until the engine frame rests on the J 39580 or suitable jack stands.



17. Remove the fastener retaining the front engine mount to the engine frame.



18. Remove the fasteners retaining the rear transaxle mount (1) to the engine frame.



19. Remove the engine frame insulator bolts (3) retaining the engine frame (2) to the vehicle.
20. Raise vehicle away from engine frame.
21. Remove the control arms. Refer to Lower Control Arm Replacement.

1. Install the control arms. Refer to Lower Control Arm Replacement.
2. Lower the vehicle onto the engine frame.



3. Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the engine frame insulator retainer bolts in order to retain the engine frame to the vehicle.

Tighten
Tighten the retainers to 181 N·m (133 lb ft).

5. Check the front wheel alignment. Refer to Wheel Alignment Specifications.



6. Raise the vehicle away from the jack stands supporting the engine frame.



7. Install the fasteners in order to retain the rear transaxle mount (1) to the bracket.

Tighten
Tighten the retainers to 50 N·m (37 lb ft).




8. Install the fastener in order to retain the front engine mount to the engine frame.

Tighten
Tighten the fastener to 70 N·m (52 lb ft).

9. Install the fasteners in order to retain the steering gear to the engine frame.

Tighten
Tighten the fastener to 95 N·m (70 lb ft).




10. Install the bracket (2) to retain the power steering line (1) to the engine frame.
11. Install the clips (3) retaining power steering line (4) along engine frame rail.
12. Connect the wiring harness to the heat shield.



13. Install the steering gear heat shield (2) to the vehicle.

Tighten
Tighten the retainers to 9 N·m (80 lb in).

14. Install the secondary air injection pump to the vehicle. Refer to Secondary Air Injection Pump Replacement.
15. Install the brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement.
16. Install the ESC sensor links to the lower control arm ball studs.
17. Install the front air deflector. Refer to Front Air Deflector Replacement.
18. Install the ball joints to the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement.
19. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation.
20. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement.
21. Lower the vehicle.
22. Remove the engine support fixture.
23. Check the front wheel alignment. Refer to Wheel Alignment Specifications.