Enusa 20050 Fivehundred 02 000

502-00-i 502-00-iUni-Body, Subframe and Mounting SystemManual Table of Contents

SECTION 502-00 Uni-Body, Subframe and MountingSystem

CONTENTS PAGE

SPECIFICATIONS ....................................................................................................................502-00-1DESCRIPTION AND OPERATION

Frame Assembly ...................................................................................................................502-00-1GENERAL PROCEDURES

Body Misalignment Check ....................................................................................................502-00-2Underbody Misalignment Check...........................................................................................502-00-3

REMOVAL AND INSTALLATIONFront Subframe .....................................................................................................................502-00-3Subframe Bushings.............................................................................................................502-00-10Rear Subframe....................................................................................................................502-00-11

09-04 Development Copy 2005 Freestyle, Five Hundred, Montego, 11/2004

502-00-1 502-00-1Uni-Body, Subframe and Mounting System

Torque Specifications (Continued)SPECIFICATIONSSuperseded by:SGML_id=n746204 Description Nm lb-ft lb-inEffect:Frozen: N 2005 FIVEHUNDRED 02000 Power steering line 12 9 Effect:Frozen: N 2006 FIVEHUNDRED 02 routing bolt000

Front subframe bracket 55 41 boltsTorque SpecificationsFront subframe 200 148 Description Nm lb-ft lb-in front bolts

Front engine mount nut 70 52 Front subframe rear 150 111 Rear engine mount nut 70 52 boltsUpper cross brace bolts 55 41 Rear brake caliper pins 35 26 Upper roll restrictor 48 35 Driveshaft bolts 25 18 bolt Rear shock-to-lower 142 105 Lower roll restrictor 40 30 control arm bolts nut AWDTransfer case bracket 55 41 Rear shock-to-lower 110 81 bolts AWD control arm bolts

FWDTransmission mount 90 66 bolts Trailing 105 77

link-to-subframe boltsPower steering 117 86 gear-to-front subframe Trailing link-to-knuckle 105 77 nuts boltsStabilizer bar upper 55 41 Park brake 12 9 nuts cable-to-body boltLower ball joint nuts 115 85 Rear subframe bracket 63 46

bolts AWDPower steering line 5 44routing bolts Rear subframe bolts 115 85

DESCRIPTION AND OPERATIONSuperseded by:SGML_id=n149039Effect:Frozen: N 2005 FIVEHUNDRED 02000Effect:Frozen: N 2006 FIVEHUNDRED 02000Frame Assembly(id=n844015)The front subframe is bolted to the body and:

aids in structural support. provides the mounting surface for the steering

gear, the front suspension lower arms, the frontengine support brackets, the transmission supportinsulator and the stabilizer bar.

front subframe bushings are serviceable.


502-00-2 502-00-2Uni-Body, Subframe and Mounting SystemDESCRIPTION AND OPERATION (Continued)The rear subframe is bolted to the body and:

aids in structural support. provides the mounting surface for the rear

suspension upper control arms, rear suspensionlower control arms and (if equipped) a mountinglocation for the rear differential.

GENERAL PROCEDURESSuperseded by:SGML_id=n149042 NOTE: All measurements should be made from theEffect:Frozen: N 2005 FIVEHUNDRED 02 bare metal; remove the trim and bumper covers as000

necessary.Effect:Frozen: N 2006 FIVEHUNDRED 02000

NOTE: The subframe is not meant to beBody Misalignmentstraightened. If structural damage occurs to theCheck(id=n844016)subframe, a new subframe should be installed.

CAUTION: Never apply heat to the 1. Repair the badly damaged areas before takingbumper energy absorbers. Heat could cause the measurements for underbody alignment.material in the absorbers to expand and flow outof the absorbers or crack the metal housing. 2. To check the underbody alignment, take theAlways remove the absorbers before carrying out measurements between opposite referencebody frame service near them. Never use a points, such as crease lines or weld joints.bumper energy absorber for pulling.

3. Monitor the upper body structure for excessivestress or movement while making anyCAUTION: Do not attempt to correct anycorrections to the underbody structure. Removeserious misalignment with a pulling/pushingall the necessary glass to prevent breakage. Foroperation. Damage to the structure could occur.additional information, refer to Section

CAUTION: In case of severe or sharp 501-11.bends, it may be necessary to use heat. Anyattempt to cold-straighten a severely bent bracketmay cause ruptures of the welds. It may alsocause cracks in the bent part. Never heat thearea to more than 650C (1,200F). Always usetemperature-indicating crayons when applyingheat to any part.


502-00-3 502-00-3Uni-Body, Subframe and Mounting SystemGENERAL PROCEDURES (Continued)Superseded by:SGML_id=n149043 1. To align or square a body, take 2 oppositeEffect:Frozen: N 2005 FIVEHUNDRED 02 diagonal measurements between pillars. Take000

measurements between reference points such asEffect:Frozen: N 2006 FIVEHUNDRED 02000 crease lines or weld joints, which are diagonallyUnderbody Misalignment opposite each other on the 2 pillars being

measured.Check(id=n844017)2. When repairing a vehicle with damage on both

CAUTION: Do not attempt to correct any sides, take horizontal and vertical measurementsserious misalignment with a pulling/pushing from an intact vehicle and transfer theoperation. Damage to the structure could occur. dimensions to the damaged vehicle. Alignment

can be made by diagonal measurements takenNOTE: To make sure of accurate measurements, from points on the 2 pillars.remove all trim from the reference points to exposebare metal. 3. The dimensions of the underbody must be

restored, in repairing major body damage, toNOTE: The subframe is not meant to beprovide correct front and rear wheel geometry.straightened. If structural damage occurs to theOnce the frame and suspension members aresubframe, a new subframe should be installed.aligned other repair operations can be carriedout.

REMOVAL AND INSTALLATIONSuperseded by:SGML_id=n746205 Special Tool(s)Effect:Frozen: N 2005 FIVEHUNDRED 02

Support Bar, Engine000303-290AEffect:Frozen: N 2006 FIVEHUNDRED 02

000Front Subframe(id=n885126)Special Tool(s)

Lifting Bracket Set, EngineAdapters for 303-290A(3.0L 4V-V6)303-290-01134-00243 or equivalent

Engine Lifting Bracket Set (Continued)303-1140

(Continued)


502-00-4 502-00-4Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)Special Tool(s)

Adapter for 303-290A (SupportLeg)303-290A-03A

Adapter for 303-290A (LiftingHook)303-290A-12


502-00-5 502-00-5Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)

Item Part Number Description Item Part Number Description7 W709583-S Front subframe bracket bolts1 N802978-S Front engine mount nut

(4 required)2 W710736-S Lower roll restrictor bolt8 W520214-S Power steering gear-to-front3 N802068-S Lower roll restrictor nut

subframe nuts (2 required)4 W506544-S Transmission mount bolts (2 9 5G221AA/ Front subframe bracket

required) 5G221AB (LH/RH)5 W520213-S Stabilizer bar upper nuts (2 10 W710922-S Rear engine mount nut

required)11 W710715-S Front subframe rear bolts6 W710015S Lower ball joint nuts (2 (2 required)

required)(Continued)(Continued)



5. Remove the 4 upper cross brace bolts andItem Part Number Descriptionremove the brace.12 W709127-S Power steering gear-to-front

subframe bolts (2 required) To install, tighten to 55 Nm (41 lb-ft). Freestyle (All models)

12 W709123-S Power steering gear-to-frontsubframe bolts (2 required) Five Hundred (FWD)

12 W709124-S Power steering gear-to-frontsubframe bolts (2 required) Five Hundred (AWD)

13 W709474-S Power steering line routingbolts (3 required)

14 W505255-S Power steering line routingbolt

15 W710714-S Front subframe front bolts(2 required)

16 5C145 Front subframe assembly6. Remove the 3 power steering high pressure line

Removal and Installation routing bolts.

All vehicles 7. Remove the positive crankcase ventilation(PCV) pipe.

1. Disconnect the battery. For additional AWD vehiclesinformation, refer to Section 414-01.8. Remove the transfer case bracket.2. Remove the air cleaner outlet pipe and air

cleaner. For additional information, refer to To install, tighten to 55 Nm (41 lb-ft).Section 303-12.

All vehicles3. Remove the cowl vent screen. For additional

information, refer to Section 501-02. 9. Install the lower half of the special tool to theengine block.

4. Remove the upper roll restrictor bolt. To install, tighten to 48 Nm (35 lb-ft).


502-00-7 502-00-7Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)10. Install the upper half of the special tool. 13. Install the special tools to support the engine

assembly.

11. Install the special tools to the LH (front)cylinder head.

14. Install the special tools to the LH (front)cylinder head.12. Install the special tools to the RH (rear)

cylinder head.


502-00-8 502-00-8Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)15. Install the special tools to the RH (rear) 20. Remove the lower roll restrictor bolt and nut.

cylinder head. To install, tighten to 40 Nm (30 lb-ft).

21. Remove the lower ball joint nuts and separatethe lower ball joints from the steering knuckles. To install, tighten to 115 Nm (85 lb-ft).

22. Remove the stabilizer bar upper nuts anddisconnect the stabilizer bar from the front strutbrackets. To install, tighten to 55 Nm (41 lb-ft).

23. Remove the 3 power steering line routing bolts. To install, tighten to 5 Nm (44 lb-in).

16. Install the special tools to the lifting hook near 24. Remove the power steering line routing bolt atthe exhaust gas recirculation (EGR) valve. the rear of the subframe.

To install, tighten to 12 Nm (9 lb-ft).

25. CAUTION: Make sure that theintermediate shaft boot bearing clamp isretained in the open position when removingand installing the clamp, boot bearing orboot assembly.Release the intermediate shaft boot bearingclamp from the intermediate shaft boot. Using a suitable tool, open the intermediate

shaft boot bearing clamp and release theboot from the intermediate shaft.

Retain the intermediate shaft boot bearing17. Remove the front tires and wheels. Forclamp in the open position.

additional information, refer to Section204-04. 26. Remove the intermediate shaft-to-steering gear

bolt.18. Remove the engine exhaust Y-pipe. To install, tighten to 25 Nm (18 lb-ft).

19. Disconnect the 2 coolant hose routing clamps.


502-00-9 502-00-9Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)27. CAUTION: Make sure the end tabs of

the intermediate shaft boot bearing clamp donot contact the boot after installation.

CAUTION: Make sure theintermediate shaft boot bearing is correctlyseated before installing the intermediate shaftboot bearing clamp.Separate the intermediate shaft from thesteering gear. During installation, verify that the steering

column boot bearing is correctly seatedwithin the retention groove in the boot by 33. Remove the 3 RH fender insert-to-frontverifying that the white outer bearing race is

subframe pin-type retainers.not visibly protruding from the groove.

34. Remove the RH front halfshaft. For additional28. Disconnect the power steering gear from theinformation, refer to Section 205-04.front subframe.

Support the power steering gear to the 35. Position a lifting table.underbody of the vehicle with mechanicswire. 36. Remove the 4 front subframe bracket bolts.

Remove the power steering gear-to-subframe To install, tighten to 55 Nm (41 lb-ft).bolts and nuts.

37. Remove the 4 front subframe bolts.X To install, tighten to 117 Nm (86 lb-ft). To install, tighten the front subframe front

29. Remove the 2 transmission mount bolts. bolts to 200 Nm (148 lb-ft). To install, tighten to 90 Nm (66 lb-ft). To install, tighten the front subframe rear

bolts to 150 Nm (111 lb-ft).30. Remove the front engine mount nut.

38. Remove the front subframe. To install, tighten to 70 Nm (52 lb-ft).39. Transfer components as necessary.31. Remove the rear engine mount nut.

To install, tighten to 70 Nm (52 lb-ft). 40. To install, reverse the removal procedure.32. Disconnect the oxygen sensor electrical

connector and position away from the frontsubframe.


502-00-10 502-00-10Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)41. Check the front end alignment and adjust as

necessary. For additional information, refer toSection 204-00.

Superseded by:SGML_id=none InstallationEffect:Frozen: N 2005 FIVEHUNDRED 02000Effect:Frozen: N 2006 FIVEHUNDRED 02 1. Assemble the special tools to the front subframe000 with the new subframe bushing.Subframe Bushings(id=n885128)Special Tool(s)

Front Subframe BushingRemover/Installer204-362

Removal

1. Remove the front subframe. For additional 2. Align the subframe bushing to the frontinformation, refer to Front Subframesubframe.Idref=s3p9283q0 in this section.1 Align the subframe bushing so that the

voids ar oriented in the fore-aft position.2. Assemble the special tools to the frontsubframe.

3. Press the new subframe bushing into the frontsubframe.3. Press out the subframe bushing.

4. Install the front subframe. For additionalinformation, refer to Front SubframeIdref=s3p9283q0 in this section.


502-00-11 502-00-11Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)Superseded by:SGML_id=noneEffect:Frozen: N 2005 FIVEHUNDRED 02000Effect:Frozen: N 2006 FIVEHUNDRED 02000Rear Subframe(id=n885127)

Item Part Number Description Item Part Number Description3 Rear subframe assembly1 5K812 Rear subframe-to-underbody

spacers FWD Freestyle 4 W709433-S/ Rear shock-to-lower controlonly (4 required) W708740 arm bolts (2 required)

(AWD/FWD)2 Rear caliper pin (4 required)(Continued)(Continued)



9. Remove the rear shock-to-lower control armItem Part Number Descriptionbolts.5 W709583-S439 Rear subframe bracket bolts

AWD only (4 required) To install, tighten the rear shock-to-lower6 W710716-S Rear subframe bolts (4 control arm bolts AWD to 142 Nm (105

required) lb-ft).7 Driveshaft washers AWD

To install, tighten the rear shock-to-loweronly (3 required)

control arm bolts FWD to 110 Nm (818 Driveshaft bolts AWD lb-ft).

only (6 required)9 5084AA/ Rear subframe bracket 10. Disconnect the rear wheel speed sensor

5084AB AWD only (LH/RH) electrical connectors.10 W505253-S Park brake cable routing bolt

Removal and Installation

All vehicles

1. Remove the rear wheels. For additionalinformation, refer to Section 204-04.

2. With a wax pencil, mark the relationalalignment of the rear subframe to theunderbody at the mounting locations.

3. Remove the muffler and tailpipe assembly. AWD vehicles4. NOTE: Index the driveshaft before

disconnecting from the rear drive axle. 11. Disconnect the rear drive axle electricalconnector.NOTE: It is necessary to install new driveshaft

bolts during installation. Reuse of the driveshaftbolts is not recommended.Remove the 6 driveshaft bolts. To install, tighten to 25 Nm (18 lb-ft).

5. Loosen the trailing link-to-subframe bolts. To install, tighten to 105 Nm (77 lb-ft).

6. Support and raise the knuckle with a suitablejack. Raise the knuckle until the tilt angle of the

trailing link is horizontal to the body.All vehicles

7. Remove the trailing link-to-knuckle bolts. To install, tighten to 105 Nm (77 lb-ft). 12. Release the park brake cable tension. For

additional information, refer to Section8. Position the trailing link aside. 206-05.


502-00-13 502-00-13Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)13. Disconnect the intermediate park brake cable 18. Disconnect the rear park brake cables from the

from the front park brake cable. park brake brackets.

19. Remove the rear brake caliper pins. To install, tighten to 35 Nm (26 lb-ft).

20. Remove the rear calipers from the rear caliperbrackets and attach aside to the body withmechanics wire. It is not necessary todisconnect the hydraulic brake lines.

AWD vehicles

21. Remove the 4 rear subframe bracket bolts. To install, tighten to 63 Nm (46 lb-ft).

14. Disconnect the intermediate cable from the All vehiclesbody bracket.

22. CAUTION: When positioning thelifting table, be sure to support the rearsubframe on the subframe rails. Do not lifton the rear differential or rear control arms,damage may occur.Position a lifting table.

23. Remove the 4 rear subframe bolts. To install, tighten to 115 Nm (85 lb-ft).

AWD vehicles

24. Remove the 2 rear subframe brackets.15. Remove the park brake cable-to-body bracket. To install, tighten to 12 Nm (9 lb-ft). All vehicles

16. Disconnect the rear park brake cables at the25. Remove the rear subframe assembly.equalizer.

26. Transfer components as necessary.17. Disconnect the rear park brake cables from thepark brake levers at the rear calipers.


502-00-14 502-00-14Uni-Body, Subframe and Mounting SystemREMOVAL AND INSTALLATION (Continued)27. To install, reverse the removal procedure.

For installation, align the subframe to thebody following the alignment specification.


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Filename: D:\Jobs\41f64e06-9b93-40d4-8a82-9892f562fc28\enUSA_20050_FIVEHUNDRED_02_000.cmpCompared to:Format: Shop ManualOutput Device: PDF v2.024 --User: unknownJob ID: 03-6760Date: 3-SEP-04Time: 13:41

Manual Table of ContentsSPECIFICATIONSDESCRIPTION AND OPERATIONFrame Assembly

GENERAL PROCEDURESBody Misalignment CheckUnderbody Misalignment Check

REMOVAL AND INSTALLATIONFront SubframeRemoval and Installation

Subframe BushingsRemovalInstallation

Rear SubframeRemoval and Installation

Documents

Enusa 20050 Fivehundred 02 000