Front Suspension .pdf

7/22/2019 Front Suspension .pdf

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SECTION 204-01 Front Suspension

PAGECONTENTS

SPECIFICATIONS

204-01-2Specifications......................................................................................................................

DESCRIPTION AND OPERATION

204-01-3Front Suspension................................................................................................................204-01-3Overview.............................................................................................................................204-01-4Front Suspension — 2.5L Duratec-RS (VI5) (Overview)....................................................204-01-4General information............................................................................................................

204-01-5Front Suspension — 2.5L Duratec-RS (VI5) (System Operation and Component

Description).......................................................................................................................204-01-5System Operation...............................................................................................................204-01-5Revo spindle...................................................................................................................

DIAGNOSIS AND TESTING

204-01-7Front Suspension................................................................................................................

REMOVAL AND INSTALLATION

204-01-8(14 371 0)Wheel Hub......................................................................................................204-01-10(14 371 0)Wheel Hub — 2.5L Duratec-RS (224kW/305PS) - VI5..................................204-01-11(14 706 0)Lower Arm......................................................................................................

204-01-15

(14 706 0;14 707 0;14 709 0)

Lower Arm — 2.5L Duratec-RS (224kW/305PS) - VI5...................................

204-01-17Front Stabilizer Bar .............................................................................................................204-01-26(14 752 0)Front Stabilizer Bar — 2.5L Duratec-RS (224kW/305PS) - VI5.....................204-01-33(14 735 0)Lower Arm Ball Joint.......................................................................................204-01-36Wheel Knuckle....................................................................................................................204-01-42(14 343 0)Wheel Knuckle — 2.5L Duratec-RS (224kW/305PS) - VI5............................

204-01-46Strut and Spring Assembly.................................................................................................

204-01-50(14 781 0;14 782 0)

Front Strut and Spring Assembly — 2.5L Duratec-RS (224kW/305PS) - VI5.

204-01-53

(14 411 0;14 411 4;

Front Wheel Bearing — 2.5L Duratec-RS (224kW/305PS) - VI5...................

14 412 0;14 414 4;14 416 4)

204-01-55(14 754 0;14 754 4)

Front Stabilizer Bar Bushing — 2.5L Duratec-RS (224kW/305PS) - VI5.......

204-01-56(14 758 0)Front Stabilizer Bar Ball Joint — 2.5L Duratec-RS (224kW/305PS) - VI5......

DISASSEMBLY AND ASSEMBLY

204-01-61Strut and Spring Assembly.................................................................................................

204-01-1Front Suspension204-01-1

.

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VEHICLE APPLICATION: 2011.00 Focus

FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL

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Torque Specifications

lb-inlb-ftNmDescription

-2432Top mount retaining bolts

-1825Top mount brace to bulkhead retaining nuts

-3750Thrust bearing retaining nut

-3548Stabilizer bar link retaining nuts

-6690Wheel knuckle to strut and spring assembly pinchbolt

71-8Headlamp leveling front sensor bracket retainingbolt

80-9Lower arm ball joint heat shield retaining nut

-85115Brake caliper anchor plate retaining bolts

-5270Lower arm ball joint retaining nut

-3548Tie-rod end retaining nut

-3548Stabilizer bar to stabilizer bar link retaining nut

-3548Stabilizer bar clamp retaining bolts

-129175Lower arm front retaining bolt

-85115Lower arm rear clamp retaining bolts

-5270Lower arm ball joint to lower arm retaining bolts

-85115Front axle crossmember front retaining bolts

-203275Front axle crossmember rear retaining bolt

-5270Front axle crossmember bracket retaining bolts

--a)Wheel hub retaining bolt

-3851Catalytic converter to rear muffler flange retainingnuts - Vehicles with diesel engine

-3548Catalytic converter to rear muffler flange retainingnuts - All except vehicles with diesel engine

-5980Engine support insulator front retaining bolt

80-9Wheel speed sensor retaining bolt-2128Steering column to steering gear pinion retaining

bolt

a) Refer to the procedure in this section.

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SPECIFICATIONS


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Front Suspension

Overview

E42462

NOTE: The Anti-lock Brake System (ABS) sensor ring is incorporated into the wheel hub. Incorrectinstallation of the wheel hub would result in an ABSmalfunction.

The front suspension features McPherson strutsand 'L' shaped lower arms which are attached tothe front axle crossmember by means of twomaintenance-free bushings.

The ball joint is attached to the lower arm by meansof three rivets. Bolt-on replacement ball joints areavailable for service operations.

The correct installation position must be observedwhen installing the strut and spring assembly turretsupport bearings. To make sure that the strut andspring assembly turret support bearings, springsand piston rods are all aligned correctly, the springretainers and strut and spring assembly turretsupport bearings have alignment marks.

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Front Suspension — 2.5L Duratec-RS (VI5) – Overview

General information

The front axle is based on the McPherson strutlayout. The front wheel suspension is a newdevelopment, the so-called "Revo" axle.

It is designed to reduce the effects of torquesteering.

E112840

1

2

7

6

3

8

5

4

9

DescriptionItem

Subframe1

Lower Control Arm2

Lower support insulator 3

wheel hub assembly,4

DescriptionItem

Wheel knuckle5

Top mount6

Spring7

Stabilizer bar mount8

Stabilizer bar 9

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Front Suspension — 2.5L Duratec-RS (VI5) – System Operation

and Component Description

System Operation

Revo spindle

When front-wheel drive, highly motorized vehiclesaccelerate out of a corner, disruptive steeringtorques often occur. These make it more difficultfor the driver to keep the vehicle in the lane.

The steering torque results from the combinationof forces that have a disruptive effect on thesteering, and the steering axis offset.

The following influences of the disruptive forcesact on the steering:

• High, one-sided drive forces

• Road unevennesses or ruts

• Imbalanced tires.

• Brake disc imbalance.

E113364

3

2

1

A B

DescriptionItem

Revo spindle A

McPherson spindleB

DescriptionItem

Steering axis offset1

Steering shaft2

Center of wheel3

The steering torque can be reduced by

• reducing the steering axis offset• minimizing the acting forces.

With the Revo spindle, the distance between thecenter of the wheel and the steering shaft has beenminimized. This change results in a smaller steering axis offset. This in turn results in a smaller steering lever arm and the transferential steering

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torques are minimized in line with the change tothe steering lever arm.

With the McPherson spindle, the upper pivot pointof the steering shaft is the suspension strut bearing

and the bottom pivot point is on the wheel knuckle.The distance between the center of the wheel andthe steering shaft is 50-70 mm.

With the Revo spindle, the upper and lower pivotpoints of the steering shaft are directly on the wheelknuckle. The distance between the center of thewheel and the steering shaft is 30 mm.

E113369

1

2

3

DescriptionItem

Roller bearing1

Wheel knuckle2

Needle bearing3

The wheel knuckle of the Revo spindle ispositioned as follows:

• Roller bearing, top

• Needle bearing, bottom

NOTE: The wheel bearings have one magneticside (dark grey) and one non-magnetic side (lightgrey). When installing the wheel bearings, it mustbe ensured that the non-magnetic side is pointingoutwards. Otherwise, the ABS (anti-lock brakesystem) function is disrupted.

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Front Suspension

REFER to Section 204-00 [Suspension System -General Information].

G17395en


DIAGNOSIS AND TESTING


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Wheel Hub(14 371 0)

Special Tool(s)

Remover/Installer, Wheel

Hub/Wheel Bearing204-348

E42977

Protector, Axle Shaft205-332

15108

1. Remove the wheel knuckle.

For additional information, refer to: WheelKnuckle (204-01 Front Suspension,Removal and Installation).

2. Remove the components in the order indicated in the following illustration(s) andtable(s).

E39195

1

DescriptionItem

Wheel hubSee Removal DetailSee Installation Detail

1

3. To install, reverse the removal procedure.

Removal Details

Item 1 Wheel hub

1. Using a hydraulic press and the specialtools, remove the wheel hub.

E44828

204-348

205-332

Installation Details

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Item 1 Wheel hub

1. Using a hydraulic press and the specialtools, install the wheel hub.

TIE44829

204-348

204-348

204-348

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Wheel Hub — 2.5L Duratec-RS (224kW/305PS) - VI5(14 371 0)

Removal

1. Refer to: Front Wheel Bearing - 2.5LDuratec-RS (224kW/305PS) - VI5 (204-01Front Suspension, Removal and Installation).

Installation


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Lower Arm(14 706 0)

Special Tool(s)

Protector, Ball Joint Gaiter

204-349

E42949

General Equipment

Ball joint separator

CAUTION: Make sure the strut and springassembly does not move in a forwards or

rearwards direction, to prevent damage tothe top mount center cup.

1. Remove the wheel and tire.

For additional information, refer to: Wheeland Tire (204-04 Wheels and Tires, Removaland Installation).

2. Remove the engine undershield.

• Rotate the locking tangs counterclockwise.

E40677

3. Detach the headlamp leveling front sensor bracket from the right-hand lower arm andsecure it to one side (if equipped).

TIE44651

8 Nm


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E39200

21

DescriptionItem

Lower arm ball jointSee Removal DetailSee Installation Detail

1

Lower armSee Removal DetailSee Installation Detail

2


6. Check the toe setting and adjust asnecessary.

For additional information, refer to:Specifications (204-00 Suspension System- General Information, Specifications)

/ Front Toe Adjustment (204-00 SuspensionSystem - General Information, GeneralProcedures).

Removal Details

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Item 1 Lower arm ball joint

1. Using the special tool to prevent the ball jointfrom rotating, remove and discard the lower arm ball joint retaining nut.

TIE39073

2.CAUTION: Make sure the special tool is

installed with the curved surface facingupwards to prevent damage to the ball jointseal.

Install the special tool.

TIE44354

3. Using a suitable ball joint separator , detachthe lower arm from the wheel knuckle.

TIE44353

Item 2 Lower arm

1. Remove the lower arm front retaining bolt.

TIE0036674

2. Remove the lower arm rear clamp retainingbolts.

TIE0036676


Item 2 Lower arm

1. NOTE: Do not fully tighten the lower arm rear clamp retaining bolts at this stage.

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Install the lower arm rear clamp retainingbolts.

TIE0036676

2. NOTE: Do not fully tighten the lower arm

front retaining bolt at this stage.

Install the lower arm front retaining bolt.

TIE0036674

3.CAUTION: While tightening the rear clamp

retaining bolts, make sure the lower armdoes not move.

NOTE: Make sure the lower arm rear clamp andthe crossmember are correctly aligned.

Tighten the lower arm rear clamp retainingbolts.

TIE0036677

115 Nm

4. Tighten the lower arm front retaining bolt.

TIE0036675

175 Nm


1. WARNING: Install a new lower arm ball joint retaining nut. Failure to follow thisinstruction may result in personal injury.

Using the special tool to prevent the ball jointfrom rotating, install the lower arm ball jointretaining nut.

TIE39074

70 Nm

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Lower Arm — 2.5L Duratec-RS (224kW/305PS) - VI5(14 706 0;

14 707 0; 14 709 0)

Special Tool(s)

204-605Separator, Lower Arm BallJoint

E63772

204-609Protection Cap, Ball JointGaiter

E75372

Removal

NOTE: Removal steps in this procedure maycontain installation details.

1. Refer to: Wheel and Tire (204-04 Wheels and

Tires, Removal and Installation).

2.

E40677

3. If equipped.

E75215

4. Torque: 83 Nm

E112595

5. Special Tool(s): 204-605

E97732

204-605

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E81908

204-609

7. Torque:• Stage 1: 100 Nm

• Stage 2: Loosen: 90°• Stage 3: 125 Nm

1.

2. Torque: 125 Nm

E115186

1

2

Installation


2. Check the toe setting and adjust as necessary.

Refer to: Specifications (204-00 SuspensionSystem - General Information, Specifications).

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Front Stabilizer Bar

Special Tool(s)


204-349

E42949

Alignment Pins, Subframe205-316 (15-097A)

15097A

Separator, Ball Joint211-020

13006

General Equipment


Securing strap

Transmission jack

CAUTION: Make sure the strut and springassembly does not move in a forwards or rearwards direction, to prevent damage tothe top mount center cup.

All vehicles

1. NOTE: Make sure the road wheels are in thestraight ahead position.

Centralize the steering wheel and lock it inposition.

TIE38834

2. Detach the steering column from the steeringgear pinion.

• Discard the bolt.

TIE0027063

3. Remove the front wheels and tires.


4. Remove the engine undershield.

E40677

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TIE44651

8 Nm

6. CAUTION: Over bending of the exhaustflexible pipe may cause damage resulting infailure.

Support the exhaust flexible pipe with asuitable support wrap or a suitable splint.

TIE0002772

7.CAUTION: Take care when removing the

exhaust hanger insulators to preventdamage.

Detach the exhaust flexible pipe from thefront axle crossmember exhaust hanger insulators.

TIE39009

All except vehicles with diesel engine

8.CAUTION: Using suitable cable ties,

support the rear muffler and exhaust tailpipeassembly to prevent damage to the exhausthanger insulators.

Detach the exhaust flexible pipe from therear muffler flange.

• Discard the gasket and nuts.

E50598

48 Nm

Vehicles with diesel engine9.

CAUTION: Using suitable cable ties,support the rear muffler and exhaust tailpipeassembly to prevent damage to the exhausthanger insulators.

Detach the exhaust flexible pipe from therear muffler flange (2.0L Duratorq-TDCi (DW)Diesel shown).

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• Discard the gasket and nuts.

TIE40628

51 Nm


E39001

3

48 Nm 148 Nm2

DescriptionItem

Tie-rod end retaining nutSee Removal DetailSee Installation Detail

1

Stabilizer bar link retaining nutSee Removal DetailSee Installation Detail

2

Lower arm ball joint retaining nutSee Removal DetailSee Installation Detail

3

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TIE45173

80 Nm 4

5

DescriptionItem

Engine support insulator front retainingbolt

4

Front axle crossmember See Removal DetailSee Installation Detail

5

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E40394

7

48 Nm 6

8

48 Nm 6

DescriptionItem

Stabilizer bar clamp retaining bolts6

Stabilizer bar clamps7

Stabilizer bar See Removal DetailSee Installation Detail

8


12.WARNING: Install a new steering column

to steering gear pinion bolt. Failure to

follow this instruction may result inpersonal injury.

NOTE: Make sure the road wheels are in thestraight ahead position.

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Attach the steering column to the steeringgear pinion.

TIE0027064

28 Nm

13. Check the front toe setting and adjust asnecessary.

For additional information, refer to:Specifications (204-00 Suspension

System - General Information,Specifications) / Front Toe Adjustment (204-00 Suspension

System - General Information, GeneralProcedures).

Removal Details

Item 1 Tie-rod end retaining nut

1.CAUTION: Leave the tie-rod end retaining

nut in place to protect the ball joint stud.

NOTE: Use a 5 mm Allen key to prevent the ball joint stud from rotating.

Loosen the tie-rod end retaining nut on bothsides.

TIE0026775

2.CAUTION: Protect the ball joint seal using

a soft cloth to prevent damage.

Using the special tool, detach the tie-rod endfrom the wheel knuckle on both sides.

• Discard the tie-rod end retaining nut.

E52983

211-020

Item 2 Stabilizer bar link retaining nut

1. NOTE: Use a 5 mm Allen key to prevent theball joint stud from rotating.

Detach the stabilizer bar link from thestabilizer bar on both sides.

Item 3 Lower arm ball joint retaining nut

1. Using the special tool to prevent the ball jointfrom rotating, remove the lower arm ball jointretaining nut on both sides.

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• Discard the lower arm ball joint retaining nut.

TIE39073

2.CAUTION: Make sure that the special tool

is installed with the curved surface facingupwards to prevent damage to the ball jointseal.


TIE44354

3. Using a suitable ball joint separator, detachthe lower arm from the wheel knuckle onboth sides.

TIE44353

Item 5 Front axle crossmember

1. Using a transmission jack and a woodenblock, support the front axle crossmember.

2. Using a suitable securing strap, secure thefront axle crossmember to the transmission

jack.

3. Remove the front axle crossmember bracket

retaining bolts on both sides.

TIE44500

4. Remove the front axle crossmember retaining bolts (transmission jack shownremoved for clarity).

TIE39071

5.CAUTION: To prevent damage to the

power steering lines, only lower thecrossmember sufficiently to allow thestabilizer bar to be removed.

Lower the front axle crossmember.

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Item 8 Stabilizer bar

1. Remove the stabilizer bar bushings.

TIE0046824


Item 8 Stabilizer bar

1.CAUTION: The stabilizer bar bushings

must be located correctly on the flats of thestabilizer bar with no lubricant.

Install the stabilizer bar bushings.

TIE0046825

2. Position the stabilizer bar on the front axlecrossmember.

Item 5 Front axle crossmember 1. Using a transmission jack and the special

tool, position and align the front axlecrossmember.

1. Insert the alignment pins through the frontaxle crossmember alignment holes.

2. Slide the locking plates into the groove of thespecial tool and tighten the alignment pinsleeve.

3. Raise the front axle crossmember engagingthe alignment pins into the front axlecrossmember alignment holes.

TIE0000859

1

3

2205-316

2.CAUTION: While tightening the front axle

crossmember retaining bolts, make sure thefront axle crossmember does not move.

Install the front axle crossmember retainingbolts (transmission jack shown removed for clarity).

TIE39072

115 Nm

275 Nm

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3. Install the front axle crossmember bracketretaining bolts on both sides.

TIE44501

70 Nm

4. Remove the securing strap.

5. Lower and remove the transmission jack andthe wooden block.

Item 3 Lower arm ball joint retaining nut

1.WARNING: Install a new lower arm ball

joint retaining nut. Failure to follow thisinstruction may result in personal injury.

Using the special tool to prevent the ball jointfrom rotating, install the lower arm ball jointretaining nut on both sides.

TIE39074

70 Nm

Item 2 Stabilizer bar link retaining nut

1. NOTE: Use a 5 mm Allen key to prevent theball joint stud from rotating.

Attach the stabilizer bar link to the stabilizer bar on both sides.

Item 1 Tie-rod end retaining nut

1. NOTE: Use a 5 mm Allen key to prevent the

ball joint stud from rotating.

Attach the tie-rod end to the wheel knuckleon both sides.

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Front Stabilizer Bar — 2.5L Duratec-RS (224kW/305PS) -

VI5(14 752 0)

Special Tool(s)

205-316A Alignment Pins, Subframe

15097A

211-020Separator, Ball Joint

13006

General Equipment

Cable Ties

Transmission Jack

Vise

Removal


1. Refer to: Wheel and Tire (204-04 Wheels andTires, Removal and Installation).

2.

E40677

3. If equipped.

Torque: 11 Nm

E75215

4. CAUTION: Make sure that the ball jointball does not rotate.

On both sides.Torque: 110 Nm

E112596


Torque: 48 Nm

E112598

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211-020E112599

7. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.

E98334

8.

E98346

9. Torque:• Stage 1: 35 Nm• Stage 2: Loosen: 360°• Stage 3: 85 Nm

1.

E89385

10. General Equipment: Cable TiesTorque:• Stage 1: 40 Nm• Stage 2: 60°

E98557

11. General Equipment: Transmission Jack

E99060

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12. Remove the following items:

1. Torque: 70 Nm

2.

Torque:• Stage 1: 140 Nm• Stage 2: 180°

3. Torque: 125 Nm

E115435

1 1

2 2

3

35 mm

4

13. Torque: 48 Nm

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E115436

x 4

1

23

14.

E115437

75 mm

NOTE: This step is only necessary when installing

a new component.

15. NOTE: Note the position of the componentsbefore removal.

On both sides.

General Equipment: Vise

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E115443

Installation


NOTE: This step is only necessary when installinga new component.

2. NOTE: Make sure that the component is clean,

free of foreign material and lubricant.

NOTE: Make sure that the component isinstalled to the position noted before removal.

1. Metal strip

General Equipment: Vise

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E115444

1

3. Special Tool(s): 205-316A

E116296

205-316A

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4. Refer to: Front Toe Adjustment (204-00Suspension System - General Information,General Procedures).

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Lower Arm Ball Joint(14 735 0)

Special Tool(s)


204-349

E42949

General Equipment


Electric hand drill





TIE44651

8 Nm


E40735

1

DescriptionItem


1


5. Check the toe setting and adjust asnecessary.

For additional information, refer to:Specifications (204-00 Suspension System- General Information, Specifications)

/ Front Toe Adjustment (204-00 SuspensionSystem - General Information, GeneralProcedures).

Removal Details

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TIE39073

2.CAUTION: Make sure that the special tool

is installed with the curved surface facingupwards to prevent damage to the ball jointseal.


TIE44354

3. Using a suitable ball joint separator, detachthe lower arm from the wheel knuckle.

TIE44353

4. Remove the lower arm ball joint.

• Using a suitable electric hand drill removethe rivets.

TIE0036826


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1. Using suitable M10 nuts and M10 x 30 mmbolts, install a new lower arm ball joint.

TIE0036827

70 Nm




TIE39074

70 Nm

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Wheel Knuckle

Special Tool(s)

Lever, Wheel Knuckle

204-159 (14-039)

14039

Protector, Ball Joint Gaiter 204-349

E42949

Separator, Ball Joint211-020

13006

General Equipment


CAUTION: Make sure the strut and springassembly does not move in a forwards or

rearwards direction, to prevent damage tothe top mount center cup.

1. Remove the wheel & tire.



TIE44651

8 Nm


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E40389

10

9 Nm3

2

1 8

9 Nm 6

9

4

7

5

45 m

DescriptionItem

Brake caliper and anchor plateSee Removal DetailSee Installation Detail

1

Brake discSee Removal Detail

2

Wheel speed sensor retaining bolt3

Wheel hub retaining bolt4

Tie-rod endSee Removal DetailSee Installation Detail

5

DescriptionItem

Lower arm ball joint heat shield6


7

Wheel knuckle to strut and springassembly pinch boltSee Installation Detail

8

Strut and spring assemblySee Removal Detail9

Wheel knuckle10

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Removal Details

Item 1 Brake caliper and anchor plate

1.CAUTION: Suspend the brake caliper and

anchor plate to prevent load being placedon the brake hose.

Detach the brake caliper and anchor plateassembly from the wheel knuckle.

TIE0030230

Item 2 Brake disc

1. Remove the brake disc.

• Remove and discard the retaining washer (if equipped)

E0032118

Item 5 Tie-rod end

1.CAUTION: Leave the tie-rod end retaining

nut in place to protect the ball joint stud.

NOTE: Use a 5 mm Allen key to prevent the ball joint stud from rotating.

Loosen the tie-rod end retaining nut.

TIE0026775

2.CAUTION: Protect the ball joint seal using

a soft cloth to prevent damage.

Using the special tool, detach the tie-rod endfrom the wheel knuckle.

1. Release the tie-rod end.

2. Remove and discard the tie-rod end retainingnut.

TIE0026773

211-020 1

2

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TIE39073

2.CAUTION: Make sure the special tool is

installed with the curved surface facingupwards to prevent damage to the ball jointseal.


TIE44354

3. Using a suitable ball joint separator, detachthe lower arm from the wheel knuckle.

TIE44353

4. CAUTIONS:

Support the halfshaft. The inner constantvelocity (CV) joint must not be bent morethan 23 degrees. The outer CV joint must notbe bent more than 45 degrees.

Do not apply excessive force to the strutand spring assembly. Do not pull the strutand spring assembly outwards by more than28 mm.

NOTE: Make sure the halfshaft is still fully engagedin the tripode housing.

Detach the halfshaft from the wheel hub.

• Pull the strut and spring assembly outwardsapproximately 28 mm.

Item 9 Strut and spring assembly

1. Using the special tool, detach the strut andspring assembly from the wheel knuckle.

TIE0000944

204-159


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Item 8 Wheel knuckle to strut and spring

assembly pinch bolt

1.CAUTION: The wheel knuckle to strut and

spring assembly pinch bolt must be installed

from the front of the wheel knuckle.

Attach the strut and spring assembly to thewheel knuckle.

TIE0005688

90 Nm


1. CAUTIONS:

Support the halfshaft. The inner constantvelocity (CV) joint must not be bent morethan 23 degrees. The outer CV joint must not

be bent more than 45 degrees.

Do not apply excessive force to the strutand spring assembly. Do not pull the strutand spring assembly outwards by more than28 mm.

Attach the halfshaft to the wheel hub.

• Pull the strut and spring assembly outwardsapproximately 28 mm.




TIE39074

70 Nm

Item 5 Tie-rod end

1.WARNING: Install a new tie-rod end

retaining nut. Failure to follow thisinstruction may result in personal injury.

NOTE: Use a 5 mm Allen key to prevent the ball joint from rotating.

Attach the tie-rod end to the wheel knuckle.

TIE41742

48 Nm

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Item 1 Brake caliper and anchor plate

1. Attach the brake caliper and anchor plate tothe wheel knuckle.

TIE0036772

115 Nm

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Wheel Knuckle — 2.5L Duratec-RS (224kW/305PS) -

VI5(14 343 0)

Special Tool(s)

204-159Lever, Wheel Knuckle

14039


E63772


E75372

205-071-01 Adapter for 205-071 (ThrustPad)

15026A01

211-020Separator, Ball Joint

13006

General Equipment

Puller

Removal



2. Torque:• Stage 1: 45 Nm• Stage 2: 90°

E112606

3. Special Tool(s): 205-071-01General Equipment: Puller

205-071-01205-071-01

E101038

4. WARNINGS:

Make sure that no load is placed on thebrake hose.

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Make sure that the brake hose is nottwisted and is correctly located.

Torque: 200 Nm

E115549

5. If equipped.

E75215


Torque: 110 Nm

E112596

7. Torque: 83 Nm

E112595


E97732

204-605


E81908

204-609

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10. NOTE: This step is only necessary wheninstalling a new component.

E112605

11. CAUTION: Make sure that the ball joint

ball does not rotate.

Torque: 48 Nm

E112598


211-020E112599

13. Refer to: Front Wheel Speed Sensor (206-09 Anti-Lock Control, Removal and Installation).


E112597


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E112604

4

1

2

3

204-159

16. NOTE: This step is only necessary wheninstalling a new component.

Refer to: Front Wheel Bearing - 2.5LDuratec-RS (224kW/305PS) - VI5 (204-01Front Suspension, Removal and Installation).

Installation


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Strut and Spring Assembly

Special Tool(s)

Lever, Wheel Knuckle

204-159

14039


1. Remove the engine upper cover.2. Remove the cowl panel grille.

For additional information, refer to: CowlPanel Grille (501-02 Front End Body Panels,Removal and Installation).

3. Remove the bulkhead extension panel.

1. Remove the retaining screws and washers.

2. Detach the panel from the retaining clips.

E50990

1

2

4. Detach the strut and spring assembly topmount brace from the bulkhead (left-handside shown).

TIE0036727

25 Nm

5.CAUTION: Make sure that new bolts are

installed.

Remove the strut and spring assembly topmount brace (left-hand side shown).

• Loosely install the strut and spring assemblytop mount bolts.

E42604

32 Nm




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E40390

5

2

4

3

1

DescriptionItem

Stabilizer bar link to strut and springassembly retaining nutSee Removal DetailSee Installation Detail

1

Brake hose2

Wheel knuckle to strut and springassembly pinch boltSee Removal DetailSee Installation Detail

3

DescriptionItem

Strut and spring assembly top mountretaining boltsSee Removal DetailSee Installation Detail

4

Strut and spring assembly5


Removal Details

Item 1 Stabilizer bar link to strut and spring

assembly retaining nut

NOTE: Use a 5 mm Allen key to prevent the ball joint from rotating.

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assembly pinch bolt

1. Using the special tool, detach the strut andspring assembly from the wheel knuckle.

TIE0000944

204-159

Item 4 Strut and spring assembly top mount

retaining bolts

CAUTION: With the aid of another technician, support the strut and spring

assembly.


Item 4 Strut and spring assembly top mount

retaining bolts

1.CAUTION: With the aid of another

technician, support the strut and springassembly.

Install the strut and spring assembly topmount bolts.

1. Use old bolts.

E126084

32 Nm

1

1


assembly pinch bolt

1.WARNING: Install a new wheel knuckle

to strut and spring assembly pinch bolt.Failure to follow this instruction may resultin personal injury.

CAUTION: The wheel knuckle to strut andspring assembly pinch bolt must be

installed from the front of the wheelknuckle.

Attach the strut and spring assembly to thewheel knuckle.

TIE0005688

90 Nm

Item 1 Stabilizer bar link to strut and springassembly retaining nut

1. NOTE: Use a 5 mm Allen key to prevent theball joint from rotating.

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Install the stabilizer bar link to strut andspring assembly retaining nut.

TIE0021919

48 Nm

2. Remove the strut and spring assembly top

mount bolts.

TIE44530

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Front Strut and Spring Assembly — 2.5L Duratec-RS

(224kW/305PS) - VI5(14 781 0; 14 782 0)

Special Tool(s)

204-159Lever, Wheel Knuckle

14039


E63772


E75372

General Equipment

Tire Lever

Removal


1. Refer to: Cowl Panel Grille (501-02 Front EndBody Panels, Removal and Installation).


3. If equipped.Torque: 11 Nm

E75215


Torque: 110 Nm

E112596

5. Torque: 83 Nm

E112595

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E97732

204-605


E81908

204-609

8. General Equipment: Tire Lever 1.

E115072

1


E112597

10.

E115536


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E115537

204-159

1

2

3

12. WARNING: This step requires the aid of another technician.

Torque: 35 Nm

x3x3

E113538

Installation


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Front Wheel Bearing — 2.5L Duratec-RS (224kW/305PS) -

VI5(14 411 0; 14 411 4; 14 412 0; 14 414 4; 14 416 4)

Special Tool(s)

204-348/3Remover/Installer, WheelHub/Wheel Bearing

E87735

204-348/3

204-348-01A Adapter for 204-348

E106983

204-595Remover/Installer, WheelHub/Wheel Bearing

E62064

204-752Remover/Installer FrontWheel Bearing

E103305

General Equipment

Hydraulic Press

Removal


1. Refer to: Wheel Knuckle - 2.5L Duratec-RS(224kW/305PS) - VI5 (204-01 FrontSuspension, Removal and Installation).

2. Special Tool(s): 204-752, 204-348/3General Equipment: Hydraulic Press

E113797

204-752

204-348/3

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Installation

1. Special Tool(s): 204-348-01A, 204-348/3,204-595General Equipment: Hydraulic Press

E113798

204-348/3

204-348-01A

204-595-07

2. Refer to: Wheel Knuckle - 2.5L Duratec-RS(224kW/305PS) - VI5 (204-01 FrontSuspension, Removal and Installation).

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Front Stabilizer Bar Bushing — 2.5L Duratec-RS (224kW/305PS)

- VI5(14 754 0; 14 754 4)

Removal

1. Refer to: Front Stabilizer Bar - 2.5L Duratec-RS(224kW/305PS) - VI5 (204-01 FrontSuspension, Removal and Installation).

Installation


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Front Stabilizer Bar Ball Joint — 2.5L Duratec-RS (224kW/305PS)

- VI5(14 758 0)

Special Tool(s)

204-288ARemover/Installer, Ball Joint

E115081


E63772


E75372

205-066-01 Adapter for 205-066

1503301

211-198Remover, Power SteeringPump Pulley

ES13021

303-038-01 Adapter for 303-038

21008A01

General Equipment

Tire Lever

Removal




Torque: 110 Nm

E112596

3. If equipped.Torque: 11 Nm

E75215

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4. Torque: 83 Nm

E112595


E97732

204-605


E81908

204-609

7. General Equipment: Tire Lever 1.

E115072

1

8. Special Tool(s): 204-288A

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E112602

204-288/A 204-288A/1

Installation

1. To install, reverse the removal procedure.2.

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E115149

1 2

3. Special Tool(s): 204-288A, 205-066-01,211-198, 303-038-01

G1163892en




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2011.00 Focus 8/2010












E112603

204-288A/1211-198205-066-01 204-288/A 303-038-01

G1163892en




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Strut and Spring Assembly

Special Tool(s)

Compressor, Coil Spring

204-167 (14-042)

14042

Adapters for 204-167204-167-01 (14-042-01)

1404201

WARNING: The spring is under extremetension; care must be taken at all times.

Failure to follow this instruction may resultin personal injury.

1. Disassemble the components in the order indicated in the following illustration(s) andtable(s).

E38791

6

3

2

4

5

50 Nm1

DescriptionItem DescriptionItem

Th t b i d i t bl3


DISASSEMBLY AND ASSEMBLY


TO MODEL INDEX








Documents

Front Suspension .pdf