SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHRYSLER2005PT CRUISER GT, 4D WAGON, STANDARDREPAIR AND DIAGNOSISBODY & FRAMEFRAMES, SUBFRAMES & CROSSMEMBERSFRAMES & BUMPERSFRONT CROSSMEMBERINSTALLATION
2005 Chrysler PT Cruiser GT, 4D Wagon, Standard

Front CROSSMEMBER: Installation

2005 Chrysler PT Cruiser GT, 4D Wagon, StandardSECTION Installation
CAUTION: If the front suspension crossmember is being replaced due to collision damage, inspect the steering column lower coupling for damage. Refer to COLUMN for the procedure.
  1. Install the lower control arms on the front suspension crossmember. Install the pivot bolts, but do not completely tighten them at this time.
  2. Using the transmission jack, raise the front suspension crossmember and lower control arms until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the power steering gear into mounting position.
  3. Start the two crossmember mounting bolts through the lower control arm rear isolator bushings into the tapping plates mounted in the body. Next, install the two front and the two rear mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all six mounting bolts to approximately 2 N.m (20 in. lbs.) to hold the front suspension crossmember in position at this time.
    NOTE: When reinstalling the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost.
  4. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle. See Figure. Once the front suspension crossmember is correctly positioned, tighten the two crossmember mounting bolts through the lower control arm rear isolator bushings to a torque of 250 N.m (185 ft. lbs.), then tighten the four remaining crossmember mounting bolts to a torque of 153 N.m (120 ft. lbs.).
  5. Tighten the lower control arm front pivot bolts to a torque of 163 N.m (120 ft. lbs.).
  6. Remove the wire or bungee cord suspending the power steering gear to the underbody.
  7. Attach the steering gear to the front suspension crossmember. See Figure. Install the four power steering gear mounting bolts. Tighten the mounting bolts to a torque of 61 N.m (45 ft. lbs.).
  8. Install the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler.
  9. Install each ball joint stud into the steering knuckle aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud.
  10. Install a new ball joint stud pinch bolt and nut. See Figure. Tighten the nut to a torque of 95 N.m (70 ft. lbs.).
  11. Fasten the engine torque strut to the right forward corner of the front suspension crossmember using its mounting bolt. See Figure. Follow the procedure described in 1.6L SOHC or 2.4L DOHC to properly align and tighten the torque strut and it's mounting bolts.
  12. Install the washer on the end of the stud extending from the torque strut bolt. See Figure.
  13. Install the pencil strut to the right front corner of the crossmember and body of the vehicle. See Figure. Tighten the pencil strut nuts to a torque of 58 N.m (43 ft. lbs.).
  14. Install the drive-belt splash shield and fasteners. See Figure.
  15. Install the screws fastening the front fascia to the reinforcement. See Figure.
    NOTE: Before installing the stabilizer bar, make sure the bar is not upside-down. The stabilizer bar must be installed with the curve on the outboard ends of the bar facing downward to clear the control arms once fully installed. See Fig 1.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.