300, 300C & Magnum 2006-2008, Charger 2006-2008

Stabilizer Bar (Sway Bar) & Links

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate negative battery cable from battery post.
  4.  
  5. Raise and support vehicle.
  6.  
  7. On each side of vehicle rear, remove wheel mounting nuts, then tire and wheel assembly.
  8.  
  9. Remove rear exhaust system.
  10.  
  11. Apply alignment index marks to the driveshaft rubber coupler and axle flange.
  12.  
  13. Remove three driveshaft coupler-to-axle flange bolts and nuts.

    Click image to see an enlarged view

    Fig. Support driveshaft (2) using a bungee cord (1)

  14.  
  15. Support driveshaft using a bungee cord. Attach ends of cord to fuel tank straps as shown.
    NOTE
    Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.

  16.  
  17. Disconnect front parking brake cable at connector to right rear parking brake cable.
  18.  
  19. Remove front parking brake cable from equalizer.
  20.  
  21. On each rear disc brake:
    1. While holding guide pins from turning, remove disc brake caliper guide pin bolts.
    2.  
    3. Remove brake caliper from brake adapter and pads.
    4.  
    5. Guide brake caliper up through suspension, following brake hose path. Support caliper above rear suspension using with bungee cord or wire to keep caliper from overextending brake hose when crossmember is lowered.
      NOTE
      To remove wheel speed sensor connector from body wiring harness connector, move retaining clip and pull sensor connector outward.

    6.  

  22.  
  23. Remove wheel speed sensor connectors from body wiring harness connector located in luggage compartment floor pan.
  24.  
  25. Unclip left wheel speed sensor cable from routing clip near body connector.
  26.  
  27. On each side of vehicle, remove shock absorber lower mounting bolt and nut.

    Click image to see an enlarged view

    Fig. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker

  28.  
  29. Carefully mark location of rear crossmember on body at all four mount (bushing) locations using a marker or crayon. Do not use a scratch awl to mark location.
  30.  
  31. Position an extra pair of jackstands under and support forward end of engine cradle to help stabilize vehicle during rear suspension removal/installation.
  32.  
  33. Position under-hoist utility jack or transmission jack under center of rear axle differential. Raise jack head to contact differential and secure in place. When securing crossmember to jack, be sure not to secure stabilizer bar.
    CAUTION
    Before opening fuel system, review all warnings and cautions under Fuel System.

  34.  
  35. Disconnect negative battery cable.
  36.  
  37. Drain fuel from tank.
  38.  
  39. Fuel filler tube assembly.
  40.  
  41. Open filler tube door.
  42.  
  43. Remove retaining wire from inside filler tube rubber.
  44.  
  45. Start removing rubber from body sheet metal.
  46.  
  47. Remove retaining wire from inside filler tube rubber.
  48.  
  49. Start removing rubber from body sheet metal.
  50.  
  51. Filler tube and rubber removed from body sheet metal.
  52.  
  53. Remove the left inner splash shield.
  54.  
  55. Disconnect the filler tube vent line.
  56.  
  57. Remove the filler tube mounting bolt.
  58.  
  59. Remove the under body splash shield.
  60.  
  61. Loosen the filler tube hose clamp. Leave the clamp tight on the hose and fuel tank location.
  62.  
  63. Move clamp toward the fuel tank.
  64.  
  65. Remove the filler tube assembly from the vehicle.
    NOTE
    If equipped with AWD, when removing crossmember mounting bolts in following step, be sure to not to misplace spacers between crossmember mounts and body.

  66.  
  67. Remove both front and both rear mounting bolts fastening crossmember in place.
  68.  
  69. Slowly lower crossmember using jack. Do not lower jack at a fast rate. Lower just enough to allow driveshaft removal from rear axle differential. Do not lower jack any further than necessary. Slide driveshaft out of rear axle differential and allow bungee cord previously installed to support.
  70.  
  71. Slowly lower crossmember several inches.
  72.  
  73. Remove screw fastening front parking brake cable routing bracket to rear crossmember.
  74.  
  75. Continue to lower jack until crossmember is at a comfortable working level to access stabilizer bar fasteners.

    Click image to see an enlarged view

    Fig. Rear stabilizer bar and fasteners

  76.  
  77. On each end, remove bolt (3) and nut fastening stabilizer bar (4) to stabilizer link (2).
  78.  
  79. Remove bolts (1) fastening each stabilizer bar isolator retainer to crossmember.
  80.  
  81. Remove stabilizer bar (4) with isolators and retainers.
  82.  
  83. Remove retainers from isolators.
  84.  
  85. Remove isolators from stabilizer bar utilizing slits in bushings.
  86.  

To install:

  1. Install isolators on stabilizer bar utilizing slits in bushings. Install each isolator so its slit faces forward and flat side is positioned toward crossmember once installed.
  2.  
  3. Install retainers on isolators.
  4.  
  5. Install stabilizer bar with isolators and retainers on crossmember.
  6.  
  7. Install isolator retainer mounting bolts. Do not tighten at this time.
  8.  
  9. Install bolt and nut fastening stabilizer bar ends to each stabilizer links. Do not tighten at this time.
  10.  
  11. Tighten isolator retainer mounting bolts to 45 ft. lbs. (61 Nm).
  12.  
  13. Remove coil springs with isolators from spring links.
  14.  
  15. Raise crossmember using jack until there is about 10 inches clearance to the body mounting points.
  16.  
  17. Install screw fastening front parking brake cable routing bracket to rear crossmember.
  18.  
  19. Raise crossmember to body mounting points. As crossmember is raised, slide driveshaft onto rear axle differential flange and align shocks with pockets in spring links.
    NOTE
    There are four crossmember mounting bolts. Rear mounting bolts are longer than front mounting bolts. Do not interchange mounting bolts.

  20.  
  21. Continue to raise crossmember with jack until crossmember mounting bolts can be installed. Install left side crossmember mounting bolts, but not the right side bolts. It is not necessary to tighten bolts at this point.
    WARNING
    To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring.

  22.  
  23. Slowly lower jack allowing right side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring Installation. Do not lower jack any further than necessary.
    NOTE
    Before installing coil spring, make sure isolators are completely installed on ends of spring.

  24.  
  25. Install coil spring with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
  26.  
  27. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
  28.  
  29. Install lower shock mounting bolt and nut. Do not tighten at this time.
  30.  
  31. If vehicle is equipped with AWD, insert spacers on top of right crossmember mount bushings before crossmember is raised into place.
    NOTE
    There are four crossmember mounting bolts. Rear mounting bolts are longer than front mounting bolts. Do not interchange mounting bolts.

  32.  
  33. Raise right side of crossmember into mounted position. Install right side crossmember mounting bolts. Snug, but do not fully tighten bolts at this time.
  34.  
  35. Remove both front and rear crossmember mounting bolts on left side of vehicle.
    WARNING
    To avoid damaging other components of vehicle, do not lower crossmember any further than necessary to install coil spring.

  36.  
  37. Slowly lower jack allowing left side of crossmember to drop. Do not lower jack at a fast rate. Lower jack just enough to allow spring installation. Do not lower jack any further than necessary.
    NOTE
    Before installing coil spring, make sure isolators are completely installed on ends of spring.

  38.  
  39. Install coil spring with isolators into spring pocket of spring link fitting the lower isolator to the shape of the pocket, then align top of spring with body mount.
  40.  
  41. Carefully raise jack, guiding coil spring and lower end of shock absorber into mounted positions. Once shock absorber lower mounting hole lines up with hole in spring link, stop jacking.
  42.  
  43. Install lower shock mounting bolt and nut. Do not tighten at this time.
  44.  
  45. If vehicle is equipped with AWD, insert spacers on top of left crossmember mount bushings before crossmember is raised into place.
    NOTE
    There are four crossmember mounting bolts. Rear mounting bolts are longer than front mounting bolts. Do not interchange mounting bolts.

  46.  
  47. Raise left side of crossmember into mounted position. Install left side crossmember mounting bolts. Snug, but do not fully tighten bolts at this time.
  48.  
  49. Shift crossmember as necessary to line up mounts with location marks drawn on body before removal.
  50.  
  51. Once mounts are lined up with location marks, on both sides of vehicle, measure distance between the tension link and weld flange on body directly in front of it, just outboard of the front mount bushing. This distance must be at least 12mm to allow proper clearance for suspension movement. If distance is less than 12mm on either side of vehicle, shift that side of rear crossmember directly rearward until distance is 12mm or greater. To do so, loosen 3 mounting bolts slightly, leaving one on opposite side of shift snugged to pivot off of. Shift crossmember rearward and snug loosened bolts. Re-measure opposite side to be sure it still maintains minimum 12mm distance.
  52.  
  53. Tighten all four crossmember mounting bolts to 133 ft. lbs. (180 Nm).
  54.  
  55. Remove jack from under rear axle differential.
  56.  
  57. Remove bungee cord supporting driveshaft.
  58.  
  59. Align driveshaft index marks placed upon removal. Install driveshaft rear coupler-to-axle flange bolts and nuts by hand. Tighten driveshaft rear coupler-to-axle flange bolts to 60 ft. lbs. (81 Nm).
  60.  
  61. Insert filler tube into the fuel tank rubber hose.
  62.  
  63. Slide hose clamp into place and tighten.
  64.  
  65. Hose clamp in place and tighten.
  66.  
  67. Install filler tube mounting bolt.
  68.  
  69. Install filler tube vent line.
  70.  
  71. Install the underbody splash shield.
  72.  
  73. Install the left inner splash shield.
  74.  
  75. Clip left rear wheel speed sensor cable to routing clip near body connector.
  76.  
  77. Match left rear wheel speed sensor connector to right sensor connector to make one connector.
  78.  
  79. Insert speed sensor connectors into body wiring harness connector located in luggage compartment floor pan. When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.
  80.  
  81. On each rear disc brake:
    1. Push caliper guide pins into caliper adapter to clear caliper mounting bosses when installing.
    2.  
    3. Guide caliper and brake hose down through rear suspension, then slide caliper over brake pads and onto caliper adapter.
      WARNING
      Extreme caution should be taken not to cross-thread caliper guide pin bolts when they are installed. Align caliper mounting holes with guide pins, then install guide pin bolts. While holding guide pins from turning, tighten bolts to 44 ft. lbs. (60 Nm).

    4.  
    5. Make sure brake hose is properly routed and will not come in contact with suspension components.
    6.  

  82.  
  83. Route parking brake cable above rear crossmember, then slide cable through equalizer above rear differential.
    NOTE
    Due to short travel and low spring tension, it is not necessary to lock-out parking brake lever to service parking brake components.

  84.  
  85. Connect front parking brake cable at connector to right rear parking brake cable.
  86.  
  87. Install rear exhaust system.
  88.  
  89. Install tire and wheel assemblies. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm).
  90.  
  91. Lower vehicle until rear wheels are just above floor level.
  92.  
  93. Apply parking brake lever. Release lever, then reapply.
  94.  
  95. Check to make sure rear wheels will not rotate with lever applied.
  96.  
  97. Lower vehicle.
  98.  
  99. Connect negative battery cable to battery post. It is important that this is performed properly.
  100.  
  101. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  102.  
  103. Position vehicle on alignment rack/drive-on hoist. Raise vehicle as necessary to access mounting bolts.
  104.  
  105. Tighten shock absorber lower mounting bolt nuts to 53 ft. lbs. (72 Nm).
  106.  
  107. Tighten stabilizer link fasteners to 45 ft. lbs. (61 Nm).
  108.  
  109. Perform wheel alignment.
  110.  

 
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