Front Suspension - 2wd Ford Explorer Sport Trac I

DESCRIPTION

Front suspension is torsion bar, short and long arm type. The suspension consists of torsion bars, upper and lower control arms with integral ball joints and bushings, adjustment cams, shock absorbers, spindles and stabilizer bar. (Scheme 7)

Scheme 7

Lower & Upper Ball Joint

Before inspecting ball joints, ensure wheel bearings are adjusted properly. See WHEEL BEARING ADJUSTMENT . Raise and support vehicle. Move lower edge of tire in and out while observing movement between spindle and lower control arm. If movement exceeds 1/32" (.8 mm), replace the lower ball joint. To check upper ball joint, move upper edge of tire in and out. If movement between spindle and upper control arm exceeds 1/32" (.8 mm), replace upper control arm assembly.

RIDE HEIGHT

Drive vehicle onto runway lift. Jounce vehicle to normalize front and rear suspension static ride height. Measure ride height. (Scheme 8) Subtract measurement "A" from measurement "B". The difference is the ride height. On original suspension components, ride height should be 3.58-4.37" (90-111 mm). Ride height on NEW suspension components should be 4.33-4.56" (110-116 mm). Adjust ride height by turning torsion bar adjustment bolt. Tighten torsion bar adjusting bolt to raise height. Loosen torsion bar adjusting bolt to lower height.

Scheme 8

WHEEL ALIGNMENT

Note. See approprite SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

WHEEL BEARING ADJUSTMENT

Raise the vehicle until the tire is off the floor. Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. If the tire and wheel hub is loose on the wheel spindle or does not rotate freely, perform the following procedure.

1. Remove wheel cover and grease cap. Remove cotter pin and retainer. Loosen adjusting nut three turns.
2. While rotating wheel, tighten adjusting nut to 17-24 ft. lbs. (23-34 N.m). Back off adjusting nut 1/2 turn (180 degrees). Tighten adjusting nut to 17 INCH lbs. (2.0-2.3 N.m). Install lock cap and NEW cotter pin.
3. Place retainer on adjusting nut. Align nut with cotter pin hole in spindle. If retainer will not align, remove retainer and reposition on adjusting nut. DO NOT turn adjusting nut to align cotter pin holes.
4. Install cotter pin. Check front wheel rotation. If wheel rotates properly, install grease cap and wheel cover.
5. If rotation is noisy or rough, remove, inspect and lubricate bearings. Before driving vehicle, pump brake pedal several times to restore normal pedal position.

Removal

1. Raise and support vehicle. Remove wheel and tire assembly. Remove brake caliper, and wire to underbody. Remove grease cap from hub/rotor. Remove cotter pin, retainer, adjusting nut and washer from spindle. Remove outer wheel bearing. Remove hub/rotor from spindle. Remove grease seal from hub/rotor. (Scheme 9)
2. Remove bearing cone and roller from hub/rotor. Clean and inspect inner and outer bearing cups for scratches, pits, excessive wear or damage. If inner or outer bearing cups are worn or damaged, use Front Hub Remover/Replacer (T81P-1104-C) and Bearing Cup Puller (T77F-1102-A) to remove bearing cups.

Installation

1. Clean grease and dirt from components. If inner and outer bearing cups were removed, install bearing cups using Driver Handle (T80T-4000-W) and Bearing Cup Replacer (T73T-1202-A). Ensure cups are fully seated. Pack bearing cone and roller assembly with Premium Long Life Grease (XG-1-C or K).
2. Place bearing cone and roller assembly into inner bearing cup. Apply grease between lips of new grease seal. Install seal using Hub Seal Replacer (T83T-1175-B) and driver handle. Install hub/rotor onto spindle. Install wheel bearing, washer and adjusting nut.
3. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENT»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__wheel-bearing-adjustment) under ADJUSTMENTS & INSPECTION. Install retainer, NEW cotter pin and grease cap.
4. To complete installation, reverse removal procedure. Tighten remaining bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) . Before driving vehicle, pump brake pedal several times to restore normal pedal position.

Scheme 9

1. Place steering wheel and steering system in the centered position. Raise vehicle on hoist. Remove wheel and tire assembly. Disconnect stabilizer bar link from lower control arm. (Scheme 10) Support lower control arm. Remove 2 shock absorber-to-lower control arm nuts. Remove shock absorber upper retaining nut, washer and insulator. Compress shock absorber, and remove from vehicle. CAUTION: Do not use a hammer to separate the ball joint from the spindle or damage to the spindle will result.
2. Place safety stands under jacking pads, and lower hoist while maintaining working room. Remove torsion bar. See «TORSION BAR»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd). Loosen front and rear lower control arm pivot bolts. Remove the lower ball joint cotter pin. Remove the lower ball joint castellated nut. Using Pitman Arm Puller (T64P-3590-F), separate the front suspension lower arm from the front spindle.
3. Separate the lower ball joint from the spindle. Remove front and rear lower control arm pivot bolts, and remove lower control arm from vehicle. Inspect lower ball joints and boot seals.
4. Remove the snap ring from the ball joint. Discard the snap ring. Using a suitable ball joint remover tool, remove the ball joint. Clean and inspect the control arm ball joint bore for damage before installing a new ball joint.

1. Make sure the new ball joint snap ring is fully seated. Position lower control arm in crossmember, and install pivot bolts. Install nuts on pivot bolts, and tighten until snug. Install torsion bar. See «TORSION BAR»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd) . Raise lower control arm to position lower ball joint into spindle. Install NEW lower ball joint-to-spindle nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) .
2. Install NEW cotter pin toward engine compartment. Ensure head of cotter pin is facing tire. Ensure fingers of cotter pin are bent at a right angle to secure. Place shock absorber into position. Install insulator, washer and nut onto stud. Install 2 lower shock absorber retaining nuts, tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) . Install wheel and tire assembly. Lower vehicle to normal ride height.
3. Connect stabilizer bar link-to-lower control arm. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) . Check ride height. See «RIDE HEIGHT»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__ride-height) under ADJUSTMENTS & INSPECTION. Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 10

Raise and support vehicle. Support lower control arm. Remove upper shock nut, washer and insulator. Remove 2 lower shock retaining nuts. Compress shock and remove shock from vehicle.

To install, reverse removal procedure. Inspect upper nut, washer and insulator for damage and/or wear. Replace if necessary. Tighten retaining nuts to specification. See TORQUE SPECIFICATIONS .

Note. Anytime the steering linkage must be disconnected from the spindle, center the steering wheel and linkage.

1. Place steering wheel and steering system in the centered position. Raise vehicle on hoist. Remove wheel and tire assembly. Remove brake caliper, brake rotor and shield from spindle. (Scheme 9) Remove the Anti-Lock Brake System (ABS) sensor and wire from spindle. Remove cotter pin and tie rod end-to-spindle nut. Separate tie rod end from spindle using Pitman Arm Puller (T64P-3590-F).
2. Support lower control arm with floor jack. Remove cotter pin and loosen spindle-to-lower ball joint nut. Using pitman arm puller, separate lower ball joint from spindle. Remove puller and spindle-to-lower ball joint nut. Raise floor jack until lower ball joint is separated from spindle.
3. Remove upper ball joint-to-spindle pinch bolt. Remove spindle from vehicle. Inspect upper and lower ball joints and seals for damage. Upper and lower ball joints are an integral part of upper and lower control arm assemblies.

1. Position spindle onto upper and lower ball joints. Install upper ball joint-to-spindle pinch bolt. Install lower ball joint nut. Install NEW cotter pin toward engine compartment. Ensure head of cotter pin is facing tire. Ensure fingers of cotter pin are bent at a right angle to secure. Connect tie rod end-to-spindle. Install tie rod end-to-spindle nut.
2. Install NEW cotter pin toward engine compartment. Ensure head of cotter pin is facing tire. Ensure fingers of cotter pin are bent at a right angle to secure. Install brake rotor shield, hub/rotor and brake caliper. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) .
3. Install wheel and tire assembly and lower vehicle. Check ride height. See «RIDE HEIGHT»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__ride-height) under ADJUSTMENTS & INSPECTION. Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Raise and support vehicle. Remove nut, washer and bushings attaching stabilizer bar links-to-lower control arms. Separate stabilizer bar links from lower control arms. Remove stabilizer bar mounting bracket bolts. Remove stabilizer bar. Remove and replace stabilizer bar insulators (if necessary).

To install, reverse removal procedure. Lower vehicle to normal ride height before tightening stabilizer bar link-to-lower control arm nuts. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

1. Raise vehicle on hoist. Remove bolts attaching torsion bar protector-to-frame. (Scheme 12) Remove torsion bar protector. Measure and record adjustment bolt protruding length. (Scheme 11)
2. Using Torsion Bar Installer/Remover (T95T-5310-A), raise torsion bar adjuster until adjuster lifts off of adjustment bolt. Remove adjustment bolt and nut from torsion bar, noting number of turns required to remove bolt for installation. Loosen the torsion bar installer/remover until the tension is removed from the torsion bar. Mark the torsion bar and the adjuster for proper installation. Remove torsion bar insulator. Pull and remove torsion bar from lower control arm.

Scheme 11

1. Slide torsion bar into lower control arm. Position torsion bar adjuster, and slide torsion bar into torsion bar adjuster. Align torsion bar-to-torsion bar adjuster marks. Install torsion bar insulator. Raise adjuster using torsion bar installer/remover until NEW adjustment bolt and nut can be install. Coat adjusting bolt with a dry adhesive whenever it is backed off or removed. Install torsion bar adjusting nut and bolt.
2. Tighten torsion bar adjusting bolt same number of turns recorded during removal. Ensure adjusting bolt protruding length is same as originally measured. Remove torsion bar installer/remover. Install torsion bar protector and tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) . Lower vehicle. Check ride height. See «RIDE HEIGHT»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__ride-height) under ADJUSTMENTS & INSPECTION. Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 12

UPPER CONTROL ARM

Note. Upper ball joints and bushings are an integral part of the upper control arm, and are replaced only as an assembly.

1. Place steering wheel and steering system in the centered position. Raise vehicle on hoist, and support lower control arm. Remove wheel and tire assembly. Secure spindle from tilting, and remove upper ball joint-to-spindle pinch bolt. Separate upper ball joint from spindle.
2. Remove the two nuts from upper control arm pivot bolts. Remove the two bolts along with adjusting cams. (Scheme 13) Remove the front suspension upper arm

1. Position the front suspension upper arm. Install the pivot bolts and adjusting cams. Install pivot bolt nuts. Install the pinch bolt and nut attaching upper control arm to spindle. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__torque-specifications) .
2. Remove jackstand from under lower control arm. Install wheel and tire assembly. Lower vehicle. Check ride height. See «RIDE HEIGHT»(/ford/explorer-sport-trac/i-2000-2005/remont/suspension-front/#front-suspension-2wd__ride-height) under ADJUSTMENTS & INSPECTION. Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 13

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• WHEEL BEARING ADJUSTMENT
• TORQUE SPECIFICATIONS
• TORSION BAR
• RIDE HEIGHT