Uni-Body, Subframe and Mounting System Ford Five Hundred I

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Frame Assembly

The front subframe is bolted to the body and

1. aids in structural support.
2. provides the mounting surface for the steering gear, the front suspension lower arms, the front engine support brackets, the transmission support insulator and the stabilizer bar.
3. front subframe bushings are serviceable.

The rear subframe is bolted to the body and

1. aids in structural support.
2. provides the mounting surface for the rear suspension upper control arms, rear suspension lower control arms and (if equipped) a mounting location for the rear differential.

Body Misalignment Check

Note. All measurements should be made from the bare metal; remove the trim and bumper covers as necessary.

Note. The subframe is not meant to be straightened. If structural damage occurs to the subframe, a new subframe should be installed.

1. Repair the badly damaged areas before taking measurements for underbody alignment.
2. To check the underbody alignment, take the measurements between opposite reference points, such as crease lines or weld joints.
3. Monitor the upper body structure for excessive stress or movement while making any corrections to the underbody structure. Remove all the necessary glass to prevent breakage. For additional information, refer to «GLASS, FRAMES AND MECHANISMS»(/ford/five-hundred/i-2004-2007/remont/windows/#window-and-glass) .

Underbody Misalignment Check

Note. To make sure of accurate measurements, remove all trim from the reference points to expose bare metal.

Note. The subframe is not meant to be straightened. If structural damage occurs to the subframe, a new subframe should be installed.

1. To align or square a body, take 2 opposite diagonal measurements between pillars. Take measurements between reference points such as crease lines or weld joints, which are diagonally opposite each other on the 2 pillars being measured.
2. When repairing a vehicle with damage on both sides, take horizontal and vertical measurements from an intact vehicle and transfer the dimensions to the damaged vehicle. Alignment can be made by diagonal measurements taken from points on the 2 pillars.
3. The dimensions of the underbody must be restored, in repairing major body damage, to provide correct front and rear wheel geometry. Once the frame and suspension members are aligned other repair operations can be carried out.

Special Tool(s)

SPECIAL TOOLS DESCRIPTION Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent Engine Lifting Bracket Set 303-1140 Support Bar, Engine 303-290A Adapters for 303-290A 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12

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1. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the air cleaner outlet pipe and air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Remove the cowl vent screen. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
4. Remove the upper roll restrictor bolt. To install, tighten to 48 Nm (35 lb-ft).
5. Remove the 4 upper cross brace bolts and remove the brace. To install, tighten to 55 Nm (41 lb-ft).
6. Remove the 3 power steering high pressure line routing bolts.
7. Remove the positive crankcase ventilation (PCV) pipe.
8. Remove the transfer case bracket. To install, tighten to 55 Nm (41 lb-ft).
9. Install the lower half of the special tool to the engine block.
10. Install the upper half of the special tool.
11. Install the special tools to the LH (front) cylinder head.
12. Install the special tools to the RH (rear) cylinder head.
13. Install the special tools to support the engine assembly.
14. Install the special tools to the LH (front) cylinder head.
15. Install the special tools to the RH (rear) cylinder head.
16. Install the special tools to the lifting hook near the exhaust gas recirculation (EGR) valve.
17. Remove the front tires and wheels. For additional information, refer to «WHEELS & TIRES»(/ford/five-hundred/i-2004-2007/remont/wheel-tire-system/#wheels-tires) .
18. Remove the engine exhaust Y-pipe.
19. Disconnect the 2 coolant hose routing clamps.
20. Remove the lower roll restrictor bolt and nut. To install, tighten to 40 Nm (30 lb-ft).
21. Remove the lower ball joint nuts and separate the lower ball joints from the steering knuckles. To install, tighten to 115 Nm (85 lb-ft).
22. Remove the stabilizer bar upper nuts and disconnect the stabilizer bar from the front strut brackets. To install, tighten to 55 Nm (41 lb-ft).
23. Remove the 3 power steering line routing bolts. To install, tighten to 5 Nm (44 lb-in).
24. Remove the power steering line routing bolt at the rear of the subframe. To install, tighten to 12 Nm (9 lb-ft).
25. Release the intermediate shaft boot bearing clamp from the intermediate shaft boot. Using a suitable tool, open the intermediate shaft boot bearing clamp and release the boot from the intermediate shaft. Retain the intermediate shaft boot bearing clamp in the open position.
26. Remove the intermediate shaft-to-steering gear bolt. To install, tighten to 25 Nm (18 lb-ft).
27. Separate the intermediate shaft from the steering gear. During installation, verify that the steering column boot bearing is correctly seated within the retention groove in the boot by verifying that the white outer bearing race is not visibly protruding from the groove.
28. Disconnect the power steering gear from the front subframe. Support the power steering gear to the underbody of the vehicle with mechanic's wire. Remove the power steering gear-to-subframe bolts and nuts. To install, tighten to 117 Nm (86 lb-ft).
29. Remove the 2 transmission mount bolts. To install, tighten to 90 Nm (66 lb-ft).
30. Remove the front engine mount nut. To install, tighten to 70 Nm (52 lb-ft).
31. Remove the rear engine mount nut. To install, tighten to 70 Nm (52 lb-ft).
32. Disconnect the oxygen sensor electrical connector and position away from the front subframe.
33. Remove the 3 RH fender insert-to-front subframe pin-type retainers.
34. Remove the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
35. Position a lifting table.
36. Remove the 4 front subframe bracket bolts. To install, tighten to 55 Nm (41 lb-ft).
37. Remove the 4 front subframe bolts. To install, tighten the front subframe front bolts to 200 Nm (148 lb-ft). To install, tighten the front subframe rear bolts to 150 Nm (111 lb-ft).
38. Remove the front subframe.
39. Transfer components as necessary.
40. To install, reverse the removal procedure.
41. Check the front end alignment and adjust as necessary. For additional information, refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) .

SPECIAL TOOLS DESCRIPTION Front Subframe Bushing Remover/Installer 204-362

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1. Remove the front subframe. For additional information, refer to «SUBFRAME - FRONT»(/ford/five-hundred/i-2004-2007/remont/frames-subframes-crossmembers/#uni-body-subframe-and-mounting-system) .
2. Assemble the special tools to the front subframe.
3. Press out the subframe bushing.

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1. Assemble the special tools to the front subframe with the new subframe bushing.
2. Align the subframe bushing to the front subframe. Align the subframe bushing so that the voids are oriented in the fore-aft position.
3. Press the new subframe bushing into the front subframe.
4. Install the front subframe. For additional information, refer to «SUBFRAME - FRONT»(/ford/five-hundred/i-2004-2007/remont/frames-subframes-crossmembers/#uni-body-subframe-and-mounting-system) .

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1. Measure and record the vehicle ride height. For additional information, refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) .
2. Remove the rear wheels. For additional information, refer to «WHEELS & TIRES»(/ford/five-hundred/i-2004-2007/remont/wheel-tire-system/#wheels-tires) .
3. With a wax pencil, mark the relational alignment of the rear subframe to the underbody at the mounting locations.
4. Remove the catalytic converter, muffler and tailpipe assembly. Remove the 2 catalytic converter nuts. To install, tighten to 40 Nm (30 lb-ft). Disconnect the muffler and tailpipe assembly from the isolators. Remove the assembly.
5. Remove the 6 driveshaft bolts. To install, tighten to 25 Nm (18 lb-ft).
6. Loosen the trailing link-to-subframe bolts. To install, tighten to 105 Nm (77 lb-ft).
7. Support and raise the knuckle with a suitable jack. Raise the knuckle until the tilt angle of the trailing link is horizontal to the body.
8. Remove the trailing link-to-knuckle bolts. To install, tighten to 105 Nm (77 lb-ft).
9. Position the trailing link aside.
10. Remove the rear shock-to-lower control arm bolts. To install, tighten the rear shock-to-lower control arm bolts - AWD to 142 Nm (105 lb-ft). To install, tighten the rear shock-to-lower control arm bolts - FWD to 110 Nm (81 lb-ft).
11. Disconnect the rear wheel speed sensor electrical connectors.
12. Remove the rear axle assembly. For additional information, refer to «REAR DRIVE AXLE/DIFFERENTIAL»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .
13. Release the park brake cable tension. For additional information, refer to «PARKING BRAKE & ACTUATION»(/ford/five-hundred/i-2004-2007/remont/parking-brake-system/#parking-brake-system-actuation) .
14. Disconnect the intermediate park brake cable from the front park brake cable.
15. Disconnect the intermediate cable from the body bracket.
16. Remove the park brake cable-to-body bracket. To install, tighten to 12 Nm (9 lb-ft).
17. Disconnect the rear park brake cables at the equalizer.
18. Disconnect the rear park brake cables from the park brake levers at the rear calipers.
19. Disconnect the rear park brake cables from the park brake brackets.
20. Remove the rear brake caliper pins. To install, tighten to 35 Nm (26 lb-ft).
21. Remove the rear calipers and the rear caliper brackets and attach aside to the body with mechanic's wire. It is not necessary to disconnect the hydraulic brake lines.
22. Remove the 4 rear subframe bracket bolts. To install, tighten to 63 Nm (46 lb-ft).
23. Position a lifting table.
24. Remove the 4 rear subframe bolts. To install, tighten to 115 Nm (85 lb-ft).
25. Remove the 2 rear subframe brackets.
26. Remove the rear subframe assembly.
27. Transfer components as necessary.
28. To install, reverse the removal procedure. For installation, align the subframe to the body following the alignment specification. Check and, if necessary, adjust the rear toe. For additional information, refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) .

See also:
• GLASS, FRAMES AND MECHANISMS
• BATTERY, MOUNTING AND CABLES
• INTAKE AIR DISTRIBUTION & FILTERING
• FRONT END BODY PANELS
• WHEELS & TIRES
• FRONT DRIVE HALFSHAFTS
• SUSPENSION SYSTEM-GENERAL INFORMATION
• REAR DRIVE AXLE/DIFFERENTIAL
• PARKING BRAKE & ACTUATION
• SUBFRAME - FRONT