front cross member replacement on 99 Boxster

[JRBLACKBOX]

I have to replace the front cross member on my base 99 Boxster. I ran over a rock and it broke off the bracket for the strut. I don't know where to begin, are there any step by step instructions somewhere? I have installed lowering springs on the car following a good DIY guide that I found online I am hoping that it won't be neccesary to have to remove rotors and shocks. I am not having any luck locating any reference material on line though for my current dilemna. Thanks Jim

[usaf-lt-g]

Well... no easy way to put it.... this is going to be some work.

First you'll have to remove the wheel and suport the vehicle

Then you'll need to remove the front plastic underbody shield by removing the plastic retaining nuts, and then prying off the six retaining clips (carefuly because these are easily damaged during removal.

Next you'll need to disconnect the control arm retaining bolts both at the diagonal control arm where it fastens to the the transverse control arm and where the transverse control arm fastens to crossmember

You may need to physically remove the control arms on both sides of the vehicle to gain access to complete removal of the crossmember, which would require separating the transverse control arm from the wheel bearing carrier, loosining the ball joint nut which will require special tool 9560 or something similar.

Also, if you plan to replace the control arms as well, you'll need to reset the wheel alignment, and tighten the bolts to the following torques:

Control Arm to cross-member 88 ft-lb

Diagonal control arm to transverse control arm 118 ft-lb

Transverse control arm to wheel bearing carrier 56 ft-lb

This is by no means a complete guide to how-to-DIY. But it's a start....

Hope it helps.

[Bristol]

I have to replace the front cross member on my base 99 Boxster. I ran over a rock and it broke off the bracket for the strut.

I think you need to give a little more detail, maybe a picture would help. I don't really see how you could damage the cross member by hitting a rock and the strut assembly (shock and spring) mount directly to the hub, so what bracket you broke is unclear. The procedure that usaf-lt-g gave you a taste of is correct for removing the cross member, but the cross member is the HUGE support that makes up the lower sub-frame in the front and ties both sides of the suspension together along with the steering. I really don't think you're looking at replacing this!

Kirk

[usaf-lt-g]

I have to replace the front cross member on my base 99 Boxster. I ran over a rock and it broke off the bracket for the strut.

I think you need to give a little more detail, maybe a picture would help. I don't really see how you could damage the cross member by hitting a rock and the strut assembly (shock and spring) mount directly to the hub, so what bracket you broke is unclear. The procedure that usaf-lt-g gave you a taste of is correct for removing the cross member, but the cross member is the HUGE support that makes up the lower sub-frame in the front and ties both sides of the suspension together along with the steering. I really don't think you're looking at replacing this!

Kirk

Not to mention the rack and pinion piece as well ;) It's an integral and important piece of the crash crumpling for safety as well... It's hard to believe the actual cross member is what's damaged.