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Home/Ford/Econoline E150/Ford Econoline E150 (1997-2012)/Repair manual/Suspension Front/Suspension System - General Information: Diagnosis
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Suspension System - General Information: Diagnosis Ford Econoline E150

Suspension Front 14 illustrations ~1501 words

Inspection and Verification

  1. Road test. Verify the customer's concern by performing a road test on a smooth road. If any vibrations are apparent, refer to «NOISE, VIBRATION & HARSHNESS»(ref-221745) .
  2. Inspect tires. Check the tire pressure with all normal loads in the vehicle and the tires cold. For additional information, refer to the vehicle certification (VC) label. Verify that all tires are sized to specification. Inspect the tires for incorrect wear and damage.
  3. Inspect chassis and underbody. Remove any excessive accumulation of mud, dirt or road deposits from the chassis and underbody.
  4. Inspect for aftermarket equipment. Check for aftermarket changes to the steering, suspension, wheel and tire components (such as competition, heavy duty, etc.). The specifications shown in this manual do not apply to vehicles equipped with aftermarket equipment. VISUAL INSPECTION CHART Mechanical Front wheel bearing(s) Loose or damaged front or rear suspension components Loose, damaged or missing suspension fastener(s) Loose or damaged shackle(s) Incorrect spring usage Damaged or sagging spring(s) Damaged or leaking shock absorber(s) Worn or damaged suspension bushing(s) Loose, worn or damaged steering system components Damaged axle components
  5. If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before proceeding to the next step.
  6. If the fault is not visually evident, determine the symptom. GO to «SYMPTOM CHART»(ref-234565-S41366241552006061100000) .

Symptom Chart

ConditionPossible SourcesAction
DogtrackingExcessive rear thrust angle.CHECK the wheel alignment. ADJUST as necessary.
Front or rear suspension components.INSPECT the front and rear suspension systems. REPAIR or INSTALL new as necessary. Refer to FRONT SUSPENSION or REAR .
Drive axle damaged.REPAIR as necessary. Refer to the appropriate driveline article for the procedure.
Drift/pullUnequal tire pressure. Unevenly loaded or overloaded vehicle. Tire forces. Excessive side-to-side difference in caster or camber.ADJUST tire pressure. NOTIFY the customer of incorrect vehicle loading. GO to PINPOINT TEST A .
Steering components. Brake drag.Refer to STEERING SYSTEM-GENERAL INFORMATION . refer to BRAKE SYSTEM-GENERAL INFORMATION .
Front bottoming or riding lowSagging spring(s).CHECK the ride height. INSTALL new front spring(s) as necessary. Refer to FRONT SUSPENSION .
Incorrect spring(s).NOTE the part number on the spring(s). NOTE the spring code on the vehicle certification (VC) label. Refer to IDENTIFICATION CODES to convert the spring code to a part number. VERIFY that the part numbers match. INSTALL new spring(s) with the correct part number if necessary. Refer to FRONT SUSPENSION .
Front suspension bumper(s).INSTALL new as necessary. Refer to FRONT SUSPENSION .
Incorrect tire wearIncorrect tire pressure (rapid center rib or inner and outer edge wear).ADJUST tire pressure. REFER to the VC label.
Excessive front or rear toe (rapid inner or outer edge wear).CHECK the wheel alignment. ADJUST as necessary.
Excessive negative or positive camber (rapid inner or outer edge wear).CHECK the wheel alignment. ADJUST as necessary.
Tires out of balance (tires cupped or dished).BALANCE tires.
Rear spring squeakRear spring(s).INSTALL new rear spring anti-squeak inserts.
Shackle bushing(s).INSTALL new as necessary.
Rough rideShock absorber(s).INSTALL new shock absorbers as necessary.
Weak or sagging spring(s).INSTALL new as necessary. Refer to FRONT SUSPENSION or REAR .
Incorrect spring(s).NOTE the part number on the spring(s). NOTE the spring code on the vehicle certification (VC) label. Refer to IDENTIFICATION CODES to convert the spring code to a part number. VERIFY that the part numbers match. INSTALL new spring(s) with the correct part number if necessary. Refer to FRONT SUSPENSION or REAR .
Shimmy or wheel trampLoose wheel nut(s).TIGHTEN to specification. Refer to WHEELS AND TIRES .
Loose front suspension fasteners. Front wheel bearing adjustment. Wheel or tire concerns. Springs.TIGHTEN to specification. Refer to FRONT SUSPENSION . REFER to WHEEL BEARING INSPECTION . Refer to WHEELS AND TIRES . INSTALL new as necessary. Refer to FRONT SUSPENSION or REAR .
Incorrect spring(s).NOTE the part number on the spring(s). NOTE the spring code on the vehicle certification (VC) label. Refer to IDENTIFICATION CODES to convert the spring code to a part number. VERIFY that the part numbers match. INSTALL new spring(s) with the correct part number if necessary. Refer to FRONT SUSPENSION or REAR .
Loose, worn or damaged ball joints.GO to the BALL JOINT INSPECTION component test.
Loose, worn or damage steering components.Refer to STEERING SYSTEM-GENERAL INFORMATION .
Front wheel alignment.CHECK the wheel alignment. ADJUST as necessary.
Sticky steering, poor returnabilityBall joints.GO to the BALL JOINT INSPECTION component test.
Steering components. Front wheel alignment.Refer to STEERING SYSTEM-GENERAL INFORMATION . CHECK the wheel alignment. ADJUST as necessary.
Steering wheel off-centerUnequal front or rear toe settings (side-to-side). Steering components.CHECK the wheel alignment. ADJUST as necessary. refer to STEERING SYSTEM-GENERAL INFORMATION .
Sway or rollOverloaded, unevenly or incorrectly loaded vehicle. Loose wheel nut(s).NOTIFY the customer of incorrect vehicle loading. TIGHTEN to specification. Refer to WHEELS AND TIRES .
Shock absorber(s).INSTALL new shock absorbers as necessary.
Loose stabilizer assembly.TIGHTEN to specification. Refer to FRONT SUSPENSION or REAR .
Worn stabilizer assembly bushing(s).INSTALL new as necessary. Refer to FRONT SUSPENSION or REAR .
Weak spring(s).INSTALL new as necessary. Refer to FRONT SUSPENSION or REAR .
Incorrect spring(s).NOTE the part number on the spring(s). NOTE the spring code on the vehicle certification (VC) label. Refer to IDENTIFICATION CODES to convert the spring code to a part number. VERIFY that the part numbers match. INSTALL new spring(s) with the correct part number if necessary. Refer to FRONT SUSPENSION or REAR .
Vehicle leans to one sideUnevenly loaded or overloaded vehicle. Front or rear suspension components.NOTIFY the customer of incorrect vehicle loading. INSPECT the front and rear suspension systems. REPAIR or INSTALL new as necessary. Refer to FRONT SUSPENSION or REAR .
Sagging spring(s).INSTALL new spring(s) or components as necessary. Refer to FRONT SUSPENSION or REAR .
Incorrect spring(s).NOTE the part number on the spring(s). NOTE the spring code on the vehicle certification (VC) label. Refer to IDENTIFICATION CODES to convert the spring code to a part number. VERIFY that the part numbers match. INSTALL new spring(s) with the correct part number if necessary. Refer to FRONT SUSPENSION or REAR .
Incorrect ride height. Lateral tilt out of specification.CHECK the ride height. CORRECT the ride height as necessary.
Vibration/noiseTires and wheel concerns. Wheel bearings. Wheel hubs. Brake components. Suspension components. Steering components.Refer to NOISE, VIBRATION & HARSHNESS .
WanderUnevenly loaded or overloaded vehicle. Ball joint(s).NOTIFY the customer of improper vehicle loading. GO to the BALL JOINT INSPECTION component test.
Loose, worn or damaged front wheel bearing(s). Loose, worn or damaged suspension component(s). Loose suspension fasteners.REFER to WHEEL BEARING INSPECTION . INSTALL new as necessary. Refer to FRONT SUSPENSION . TIGHTEN to specification. Refer to FRONT SUSPENSION .
Steering components. Wheel alignment (excessive total front toe out).Refer to STEERING SYSTEM-GENERAL INFORMATION . CHECK the wheel alignment. ADJUST as necessary.

SYMPTOM CHART

PINPOINT TEST A: DRIFT LEFT OR RIGHT

  1. A1 CHECK FOR TIRE PULL Rotate the front wheel and tire assemblies side-to-side. Refer to «WHEELS AND TIRES»(ref-234566) . Carry out a road test on a smooth road. Does the vehicle drift/pull? Yes : If vehicle pulls in opposite direction, GO to A2. If vehicle pulls in original direction, GO to A3 . No :Concern has been corrected.
  2. A2 ROTATE WHEEL AND TIRE ASSEMBLIES FRONT-TO-REAR Rotate the front wheel and tire assemblies front-to-rear. Refer to «WHEELS AND TIRES»(ref-234566) . Carry out a road test on a smooth road. Does the vehicle drift/pull? Yes : GO to A3. No :Concern has been corrected.
  3. A3 CHECK WHEEL ALIGNMENT NOTE: The vehicle will tend to pull toward the side with the least positive caster and the most positive camber. Using a suitable alignment system, measure the wheel alignment settings. Refer to «GENERAL SPECIFICATIONS»(ref-234565-S01583852072006061100000) . Does the vehicle have a side-to-side caster or camber split? Yes : ADJUST alignment angles to eliminate the split. DO NOT exceed specifications. TEST the system for normal operation. No :ADJUST alignment angles to add a caster split. DO NOT exceed specifications. TEST the system for normal operation.

Ball Joint Inspection

  1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. For additional information, refer to «NOISE, VIBRATION & HARSHNESS»(ref-221745) .
  2. Raise and support the vehicle by the frame or by the axle beams.
  3. Inspect the ball joint and ball joint boot for damage. If the ball joint or ball joint boot is damaged, install a new ball joint. For additional information, refer to «FRONT SUSPENSION»(ref-235434) . NOTE: Carry out Steps 4- 6 to inspect the lower ball joint. Carry out Steps 7 - 9 to inspect the upper ball joint.
  4. Inspect the ball joint for relative movement by alternately pulling outward and pushing inward on the wheel and tire assembly at the 12 o'clock and 6 o'clock positions, by hand. Note any relative movement between the wheel knuckle and the axle at the lower ball joint. If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. If relative movement is found, continue with Step 5.
  5. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the axle and the wheel knuckle at the lower ball joint.
  6. Measure the ball joint deflection while an assistant alternately pulls outward and pushes inward on the wheel and tire assembly at the 12 o'clock and 6 o'clock positions, by hand. If the deflection exceeds the specification, a new lower ball joint must be installed. For additional information, refer to «FRONT SUSPENSION»(ref-235434) . If the deflection meets the specification, continue with the procedure.
  7. Inspect the ball joint for relative movement by alternately pulling outward and pushing inward on the wheel and tire assembly at the 12 o'clock and 6 o'clock positions, by hand. Note any relative movement between the wheel knuckle and the axle at the upper ball joint. If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. If relative movement is found, continue with Step 8.
  8. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the axle and the wheel knuckle at the upper ball joint.
  9. Measure the ball joint deflection while an assistant alternately pulls outward and pushes inward on the wheel and tire assembly at the 12 o'clock and 6 o'clock positions, by hand. If the deflection exceeds the specification, a new upper ball joint must be installed. For additional information, refer to «FRONT SUSPENSION»(ref-235434) . If the deflection meets the specification, no further action is required.

Scheme 7

Scheme 7: Wheel Bearing Inspection
Scheme 7: Wheel Bearing Inspection

Scheme 8

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Scheme 9

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Scheme 11

Scheme 11
Scheme 11
  1. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
  2. Grasp the tire at the top and bottom and move the wheel inward and outward. If the wheel hub is loose on the spindle, carry out steps 4 through 8 .
  3. Remove the grease cap, cotter pin and the retainer nut.
  4. Rotate the brake disc hub while adjusting front wheel bearing end play. Tighten the spindle nut.
  5. Loosen the spindle nut two turns.
  6. Tighten the spindle nut while rotating the brake disc counterclockwise.
  7. Loosen the spindle nut.
  8. Tighten the spindle nut.
  9. If looseness still exits or the brake disc does not rotate freely, remove and inspect the wheel bearings. For additional information, refer to «FRONT SUSPENSION»(ref-235434) .

Scheme 12

Scheme 12: Camber and Caster Adjustment
Scheme 12: Camber and Caster Adjustment

Scheme 13

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Scheme 15
Scheme 15
  1. Using an alignment rack and manufacturer's instructions, measure the caster and camber. For additional information, refer to «ALIGNMENT SPECIFICATIONS»(ref-234565-S16839975422006061100000) for optimal alignment settings. Note any difference between the actual measurements and the specification. This information will be used to select the correct service adjuster.
  2. Remove the front wheel(s). For additional information, refer to «WHEELS AND TIRES»(ref-234566) .
  3. Check the type and orientation of the installed adjuster. Production adjusters have a round flange, a side tab and the amounts of caster and camber stamped in the top of the adjuster. The first number is the amount of caster; the second number is the amount of camber in degrees if the adjuster is installed in the right-hand axle position. If the adjuster is in the left-hand axle, the caster number is the opposite sign of the number shown. For example, a positive amount in the right-hand axle is a negative amount in the left axle, and a negative amount in the right-hand is a positive in the left-hand position. Service adjusters have a hex flange, no side tab and the adjustment amount of the caster and camber stamped into the top.
  4. Select a new service adjuster and its orientation in the axle to obtain the optimum caster/camber. Refer to the «CAMBER/CASTER SERVICE ADJUSTER»(ref-234565-S08523409052006061100000) . This chart shows the alignment changes that will occur if the vehicle was originally built with 0-degree adjusters Note that the caster change or camber change required to obtain the optimum settings must be added to amounts of caster/camber in the old or production adjuster. Use this example as a guide. If caster must be reduced 1 degree and camber increased +0.75 degree at the LH wheel, and the existing adjuster has +0.25-degree caster as installed, select the 1-degree service adjuster and orient the slot 225 degrees from the straight-ahead position. In all cases, select the adjuster and orientation that will bring the alignment closest to the optimal settings.
  5. Remove the pinch bolt and if necessary, use a suitable puller to remove the adjuster from the axle.
  6. Install the new service adjuster. Orient the slot as noted in Step 5 . Position the new adjuster as specified in the chart. Install the pinch bolt.
  7. Install the front wheel. For additional information, refer to «WHEELS AND TIRES»(ref-234566) .
  8. Check the alignment. If not at optimal caster/camber specification, additional adjustment of the rotational orientation of the adjuster is required.
  9. Once optimal caster/camber has been achieved, reset the toe and clear vision to optimal settings.

Scheme 16

Scheme 16: Toe Adjustment
Scheme 16: Toe Adjustment

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Scheme 20
Scheme 20
  1. Start the engine and center the steering wheel.
  2. Turn the engine off, and hold the steering wheel in the "straight forward" position using a suitable holding device.
  3. Loosen the nuts. Clean and lubricate the steering linkage and tie rod end threads.
  4. Rotate the adjusting sleeves to obtain the correct toe setting.
  5. Position the RH adjusting sleeve clamp opening downward within 45 degrees of vertical. Tighten the nuts.
  6. Position the LH adjusting sleeve clamp opening upward within 45 degrees of vertical. Tighten the nuts.
  7. Recheck the toe settings and adjust if necessary.

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