Service Procedure (FX35 and FX45)
Remove the rear suspension member assembly and replace four fuel hoses (from the kit) as follows.Preliminary Steps
1. Record all radio station presets.
2. Disconnect the negative battery cable.
3. Raise the vehicle on a hoist.
NOTE:
Make sure the parking brake is released.
Remove Rear Wheels/Brake Calipers
4. Remove both rear wheels/tires.
5. Remove both brake calipers and hang them from the brake line supports with wire (see Figure 39).
Remove Center Exhaust Tube/Rear Muffler
6. Remove the exhaust system ground strap from the vehicle under body (see Figure 40).
7. On the passenger (RH) side: release clips and remove the rear plastic under cover (see Figure 41).
8. Below the plastic cover you just removed: release clips and remove the driver's (LH) side rear plastic under cover (see Figure 42).
9. Remove the nut that holds the center muffler mount bracket (see Figure 43).
10. Remove nuts and bolts and remove the tunnel stay side covers and the tunnel stay (see Figure 44).
11. Remove and discard the exhaust system center tube front nuts (see Figure 45).
^ You will install new nuts at re-assembly. See Parts Information for the nut part number.
12. Support the exhaust system (see Figure 46).
13. Remove the rear muffler bracket bolts (see Figure 47a and 47b).
NOTE:
If the vehicle is equipped with a factory installed tow hitch you must:
^ Remove the passenger side muffler bracket
^ Slide the driver's side rubber muffler hanger off of the muffler hanger pin
14. Remove the rear muffler rubber support bolt (see Figure 48).
15. Carefully remove the exhaust system and place it in a safe location (see Figure 49).
Disconnect Parking Brake Cables
16. Remove four nuts and remove the propeller shaft heat insulator (see Figure 50).
17. Apply an index (line up) mark across the propeller shaft and differential pinion flange for correct re-assembly (see Figure 51).
18. Remove the front and rear parking brake brackets (see Figure 52a and 52b).
19. Remove the parking brake cables from the front equalizer (see Figure 53).
20. Remove the parking brake cables from the support clips (see Figure 54).
Re-Position Propeller Shaft
21. Remove and discard the propeller shaft nuts and bolts (see Figure 55).
^ You will install new nuts and bolts at reassembly. See Parts Information for the bolt kit part number.
22. Position a support jack about six inches below the propeller shaft (see Figure 56). Then remove and discard the propeller shaft center bearing nuts and carefully lower the shaft onto the support jack.
^ You will install new nuts at re-assembly. See Parts Information for the nut part number.
CAUTION:
Make sure to properly support the propeller shaft as it's being lowered.
^ When you remove the center bearing nuts the propeller shaft rear flange will drop away from the differential pinion flange.
23. Use a piece of wire to hang the propeller shaft from one of the heat shield brackets (see Figure 57). Make sure the shaft is positioned to one side of the differential pinion flange.
Disconnect ABS Harness Connector/Remove Tie Wrap
24. Disconnect the ABS harness connector (see Figure 58a). Then remove the tie wrap from the suspension member using a pair of needle-nose pliers (see Figure 58b).
^ If you accidentally break the tie wrap install a new one at re-assembly. The tie wrap part number is 24225-89960.
Disconnect Shock Absorber From Lower Link
25. Now place a support jack under the front lower link. Then disconnect the shock absorber from the link (see Figure 59).
IMPORTANT:
DO NOT disconnect the shock absorber from the studs at the top of the wheel well housing (see Figure 60).
26. Place an index mark across the bushing and cross bar for proper re-assembly (see Figure 61).
Install Jack Adapter Tool # J-47441-A To Differential
27. Install the jack adapter tool # J-47441-A to the differential pinion flange and suspension member as follows:
a. Install part "A" of the adapter tool onto the pinion flange. Make sure both pins on the tool are inserted into the pinion flange bolt holes (see Figure 62).
b. Slide part "B" of the adapter tool over the rear of part "A". Then insert the locator pins at the upper corners of the tool into the rear suspension member (see Figure 63).
c. Install and tighten the bolt that holds part "C" to part B as shown in Figure 63.
d. Install jack adapter part C as shown in Figure 64.
e. Install and tighten the bolt that holds "part C" to "part A" as shown in Figure 64.
Remove Rear Suspension Member
28. Use bolts to install a transmission jack to the jack adapter as shown in Figure 65.
29. Place an additional support jack under the front suspension member to help stabilize the vehicle on the lift (see Figure 66).
30. Remove the bolts and nuts that hold the suspension member stay brackets (both passenger and driver's side brackets). See Figure 67. Then remove the stay brackets.
NOTE:
The larger nuts hold the suspension member.
31. Remove the rear stay bracket and suspension member rear nuts (see Figure 68).
32. Carefully lower the suspension member out of the vehicle (see Figure 69) and place it in a safe location.
Install Fuel Hoses
CAUTION:
Make sure the fuel tank is less than 1/4 full before you perform this procedure.
33. Remove three nuts and remove the evaporative canister shield (see Figure 70).
34. Remove and replace the four fuel hoses (provided in the kit). See Figure 71.
^ Replace hoses one at a time making sure they are correctly positioned and secured.
^ Tighten the fuel filler hose clamps so that the distance between the bolt head and metal plate is set to the proper dimension (see Figure 71).
Re-Assembly
33. Re-install all components in the reverse order of removal making sure of the following:
A. Make sure the additional support jack under the center of the front suspension member is in place and contacting the front suspension member. (see Figure 36A)
B. Raise the rear suspension assembly on the studs until approximately 1.0 inch/ 25.4 mm of the rear stud and approximately 1.25 inch /31 .7 mm of the front stud is sticking through the mount.
C. Use a single nut on each side to hold the front suspension stay bracket in place.
D. Use a single nut on each side to hold the rear suspension bracket in place.
E. Use a support jack to raise one corner of the rear suspension assembly until the bushing assembly is flush to the body. Tighten the nut until the nut contacts the bushing inner sleeve.
F. Repeat the same procedure on the other side.
G. Use a support jack to raise one corner of the front suspension assembly until the assembly is flush to the body. Tighten the nut until the nut contacts the bushing inner sleeve.
H. Repeat the same procedure on the other side.
I. Torque the front and rear suspension mounting nuts to 89 Nm (9.1 kg-m 66 ft.lb.)
^ All highlighted suspension fasteners are tightened to the proper torque specification (see Figure 72). All index marks that you made earlier are lined up.
^ Use new nuts/bolts (provided in the kit) for securing the propeller shaft to the differential pinion flange. Tighten the nuts to: 56.9 Nm (5.8 kg-m 42 ft-lb).
^ Use new nuts (see Parts Information) for mounting the propeller shaft center bearing assembly. Tighten these nuts/bolts to: 44 Nm (4.5 kg-m 70 ft-lb).
^ Use a new gasket (see Parts Information) between the front and center exhaust tubes. Also use new nuts (see Parts Information) for securing these tubes together.
36. Re-connect the negative battery cable.
37. Re-program all radio station pre-sets.