REAR CROSSMEMBER REMOVAL/INSTALLATION [4WD]

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Warning
•  Verify that the rear crossmember is securely supported by a jack. If the rear crossmember falls off, it can cause serious injury or death, and damage to the vehicle.
Caution
•  Performing the following procedures could cause an open circuit in the rear ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the rear ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

1.  Align the rear crossmember component and rear upper arm and mark them.

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2.  Switch the ignition ON (engine off).

3.  Release the electric parking brake.

4.  Switch the ignition off.

5.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

6.  Remove the wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

7.  Drain the differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

8.  Disconnect the wiring harness clips and connectors installed to the rear crossmember.

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9.  Set the rear differential breather hose aside.

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10.  Remove the auto leveling sensor. (With auto leveling sensor)

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11.  Disconnect the rear ABS wheel-speed sensor wiring harness and the electric parking brake motor gear unit connector and set it aside so that it does not interfere with the servicing.

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12.  Remove the following parts:

(1)  Floor under cover No.2 (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
(2)  Floor under cover No.1 (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
(3)  Brace bar
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(4)  Tunnel member
(5)  Strut bar
(6)  TWC (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
(7)  Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
(8)  Wheel hub component (See WHEEL HUB COMPONENT REMOVAL/INSTALLATION [4WD].)
(9)  Dust cover (See WHEEL HUB COMPONENT REMOVAL/INSTALLATION [4WD].)

13.  Disconnect the rear stabilizer control link from the rear lower arm.

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14.  Disconnect the rear trailing link from the hub support. (See REAR TRAILING LINK REMOVAL/INSTALLATION.)

15.  Remove the rear coil spring. (See REAR COIL SPRING REMOVAL/INSTALLATION.)

16.  Disconnect the rear shock absorber from the hub support. (See REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)

17.  Disconnect the rear lateral link from the hub support. (See REAR LATERAL LINK REMOVAL/INSTALLATION.)

18.  Disconnect the rear upper arm from the hub support. (See REAR UPPER ARM REMOVAL/INSTALLATION [4WD].)

19.  Remove the following parts:

(1)  Hub support (See WHEEL HUB COMPONENT REMOVAL/INSTALLATION [4WD].)
(2)  Rear drive shaft (See REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
(3)  Rear lateral link (See REAR LATERAL LINK REMOVAL/INSTALLATION.)
(4)  Rear lower arm (See REAR LOWER ARM REMOVAL/INSTALLATION.)

20.  Remove in the order indicated in the table.

21.  Install in the reverse order of removal. (See Suspension Links Installation Note.)

22.  Add differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)

23.  Inspect the wheel alignment and adjust it if necessary. (See REAR WHEEL ALIGNMENT.)

24.  Perform the headlight auto leveling system initial setting. (With auto leveling sensor) (See HEADLIGHT AUTO LEVELING SYSTEM INITIALIZATION.)

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1
Rear crossmember component
(See Rear Crossmember Component Removal Note.)
(See Rear Crossmember Component Installation Note.)
2
Rear stabilizer component
3
Rear upper arm
(See REAR UPPER ARM REMOVAL/INSTALLATION [4WD].)
4
Rear crossmember mudguard
5
Front differential mounting rubber
(See REAR DIFFERENTIAL MOUNT RUBBER REMOVAL/INSTALLATION.)
6
Rear differential
(See REAR DIFFERENTIAL REMOVAL/INSTALLATION.)
7
Rear crossmember

Rear Crossmember Component Removal Note

Warning
•  Verify that the rear crossmember is securely supported by a jack. If the rear crossmember falls off, it can cause serious injury or death, and damage to the vehicle.

1.  Support the rear crossmember with the jack and remove the nut.

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2.  Remove the rear crossmember component.

3.  Disconnect the wiring harness clips and connector shown in the figure.

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Suspension Links Installation Note

1.  When installing the joint sections with rubber bushings, perform the following procedures.

(1)  Temporarily tighten the bolts, nuts, and stud bolts with the vehicle lifted up.
(2)  Lower the vehicle to the ground and tighten the bolts, nuts, and stud bolts to the specified torque.


Rear Crossmember Component Installation Note

Warning
•  Verify that the rear crossmember is securely supported by a jack. If the rear crossmember falls off, it can cause serious injury or death, and damage to the vehicle.

1.  Assemble the wiring harness clips and connector shown in the figure.

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2.  Support the rear crossmember component and install the rear crossmember.

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