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Thread: refitting front crossmember

  1. #1
    discolaw Guest

    refitting front crossmember

    'day all
    took my front crossmember off to do a few things including cleaning the rust & crap off the mating surfaces (worthwhile checking) now the holes are too far out of alignment to get the bolts back in. Member has had some rock therapy in that the centre is a little bashed up towards the floor pan. Thought that would shorten the bar but the misalignment is the other way as if the member is too long. WTF? I've read the chassis rails flex and sometimes its necessary to use a big bar to prise things to line up the holes. Any other magic answers? Say jacking up off the diff or one side to flex the rails or elongating the holes in the member. Don't feel comfortabe driving without the c/member alth' I believe some do
    Suggestions appreciated.

  2. #2
    Join Date
    Jul 2011
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    Adelaide
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    It's normal to get a little bit of chassis flex when taking crossmember off, when i took mine off the holes were off by a few mm's.
    I got it back in by first putting all four bolts in and only turn them slightly, like one turn or so - should be able to do that unless the holes are too far off. Then just tighten them gradually one at a time and you should be able to get them all in.

  3. #3
    discolaw Guest
    Quote Originally Posted by Rocky88 View Post
    It's normal to get a little bit of chassis flex when taking crossmember off, when i took mine off the holes were off by a few mm's.
    I got it back in by first putting all four bolts in and only turn them slightly, like one turn or so - should be able to do that unless the holes are too far off. Then just tighten them gradually one at a time and you should be able to get them all in.
    Thanks, but mine are too far off for that. Using a big bar I can prise things closer but still not enough. If the rails have flexed outwards I am hoping they can somehow flex back in

  4. #4
    Join Date
    Dec 2011
    Location
    sydney - pining for the western desert
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    When I dropped the gearbox out of my defender (now gone) I had to use the defender pillar jack to spread the chassis rails to get the xmember under the g-box out & ditto to refit it. If you don't have access to a defender jack you may be able to use a hi-lift (didn't work for me) or hydraulic jack operating horizontally.
    hope this all helps

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