Front Suspension: Removal & Installation Ford Flex I

Removal and Installation

Note. Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

Scheme 23

1. Remove the wheel knuckle. For additional information, refer to «WHEEL KNUCKLE»(ref-372768-S14036726542010093000000) .
2. Remove and discard the 4 wheel bearing and wheel hub bolts, then separate the wheel bearing and wheel hub from the wheel knuckle. To install, tighten the new bolts to 133 Nm (98 lb-ft) in the sequence shown in illustration.
3. NOTE: The wheel knuckle bore must be clean enough to allow the wheel bearing and wheel hub to seat completely by hand. Do not press or draw the wheel hub and bearing into place or damage to the bearing may occur. Clean and inspect the knuckle bearing bore. If the wheel knuckle is cracked, install a new wheel knuckle.
4. NOTE: Make sure the wheel hub-to-wheel knuckle mating surfaces are clean and free of any adhesive. Failure to clean the adhesive from both surfaces may cause bearing damage. Using a clean shop towel, clean the wheel hub-to-knuckle mating surfaces.
5. To install, reverse the removal procedure. Lubricate the hub-to-brake disc surface with anti-seize lubricant before installing the brake disc.

Removal

1. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Make sure the steering wheel is in the unlocked position. Remove the brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
2. Using the C-Frame and Screw Installer/Remover, remove the wheel stud.

Scheme 24

Scheme 25

1. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Position the wheel stud in the flange, making sure the serrations on the stud line up with the serrations in the flange. Install the washers and a reversed wheel nut.
2. NOTE: Do not use power tools to install the wheel stud or damage to the flange may occur. Tighten the wheel nut until the stud is seated against the hub flange.
3. Remove the wheel nut and the washers. Discard the wheel nut.
4. Install the brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .

Note. Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

1. Remove the wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
2. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Using a crowfoot wrench, remove and discard the lower ball joint nut. To install, tighten to 200 Nm (148 lb-ft).
3. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal may occur. Push the lower arm downward until the ball joint is clear of the wheel knuckle.
4. Remove and discard the lower arm forward bolt. To install, tighten the new bolt to 185 Nm (136 lb-ft).
5. Remove and discard the lower arm rearward nuts and bolts. To install, tighten the new nuts to 99 Nm (73 lb-ft). Install the new lower arm rearward bolts from the bottom of the lower arm bushing with the nuts on top.
6. If necessary, remove the lower arm rearward bushing. For additional information, refer to «LOWER ARM BUSHING»(ref-372768-S20193496702010093000000) .
7. NOTE: The lower arm forward bolt must be tightened with the weight of the vehicle on the wheels and tires or damage to the bushings may occur.

To install, reverse the removal procedure.

1. Remove the lower arm. For additional information, refer to «LOWER ARM»(ref-372768-S18294597232010093000000) .
2. Index-mark the bushing-to-lower arm position for reference during the installation procedure.
3. NOTE: The Drive Pinion Bearing Cone Remover is used to secure the lower arm bushing while separating the bushing from the lower arm.

Using the Drive Pinion Bearing Cone Remover, a suitable press and adapters, remove the lower arm bushing.

Scheme 26

Scheme 27

Scheme 28

1. NOTE: The Drive Pinion Bearing Cone Remover is used to clamp and hold the lower arm while installing the bushing. Install the Drive Pinion Bearing Cone Remover onto the lower arm.
2. Transfer the index mark to the new lower arm bushing.
3. NOTE: The Drive Pinion Bearing Cone Remover is used to clamp and hold the lower arm while installing the bushing. Align the index marks and using the Drive Pinion Bearing Cone Remover, a suitable press and adapters, install a new lower arm bushing.
4. Install the lower arm. For additional information, refer to «LOWER ARM»(ref-372768-S18294597232010093000000) .

Note. Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

Note. Make sure the steering wheel is in the unlocked position.

Note. The stabilizer bushing and bracket are part of the stabilizer bar assembly. The stabilizer bar will not turn easily in the bushing.

All vehicles

Scheme 29

Scheme 30

Scheme 31

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector and unclip the connector from the subframe. All-Wheel Drive (AWD) vehicles
3. Remove the exhaust Y-pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) . All vehicles
4. NOTE: Do not use power tools to remove the stabilizer bar link nut. Damage to the stabilizer link ball joint or boot may occur. NOTE: To remove the stabilizer bar link nut, first loosen the nut, then use the hex-holding feature to prevent the ball joint from turning while removing the stabilizer bar link nut. Remove and discard the stabilizer bar link lower nuts. To install, tighten the new nuts to 150 Nm (111 lb-ft).
5. NOTE: No special tools are necessary to separate the tie rod from the front knuckle; use a mallet to loosen the joint. Remove and discard both tie-rod end nuts and separate the tie-rod ends from the knuckles. To install, tighten the new nuts to 150 Nm (111 lb-ft).
6. NOTE: Install the new lower arm rearward bolts from the bottom of the lower arm bushing with the nuts on top. Remove and discard the 4 lower arm rearward nuts and bolts. To install, tighten the new bolts to 99 Nm (73 lb-ft).
7. Remove and discard the 2 lower arm forward bolts. Position both lower arms aside. To install, tighten the new bolts to 185 Nm (136 lb-ft).
8. Using a suitable screw-type jackstand, support the rear of the subframe.
9. Remove the 2 steering gear nuts and bolts. Vehicles with Electronic Power Assist Steering (EPAS) To install, tighten the nuts to 165 Nm (122 lb-ft). Vehicles with Hydraulic Power Assist Steering (HPAS) To install, tighten the new nuts to 117 Nm (86 lb-ft).
10. Remove and discard the 4 subframe bracket bolts. To install, tighten the new bolts to 55 Nm (41 lb-ft).
11. Remove and discard the subframe forward bolts. To install, tighten the new bolts to 200 Nm (148 lb-ft).
12. Remove and discard the subframe rearward bolts. Vehicles with EPAS To install, tighten the new bolts to 150 Nm (111 lb-ft). Vehicle with HPAS To install, tighten the new bolts to 175 Nm (130 lb-ft).
13. Lower the rear of the subframe approximately 51 mm (2 in).
14. Remove and discard the LH and RH stabilizer bar bracket bolts. To install, tighten the new bolts to 55 Nm (41 lb-ft).
15. Remove the stabilizer bar by guiding it between the subframe and the steering gear toward the RH side of the vehicle.
16. To install, reverse the removal procedure.

Note. Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) . NOTE: Do not use power tools to remove the stabilizer bar link nuts. Damage to the stabilizer bar link ball joints or boots may occur. NOTE: To remove the stabilizer bar link nuts, first loosen the nuts, then use the hex-holding feature to prevent the stabilizer bar link ball joints from turning while removing the stabilizer bar link nuts.
2. Remove and discard the stabilizer bar link lower nut. To install, tighten the new nut to 150 Nm (111 lb-ft).
3. Remove and discard the stabilizer bar link upper nut. To install, tighten the new nut to 150 Nm (111 lb-ft).
4. Remove the stabilizer bar link.
5. NOTE: To install the nuts, use the hex-holding feature to prevent the stabilizer link ball joints from turning while installing the nuts until snug. Finally, tighten the nuts using a socket and a torque wrench. To install, reverse the removal procedure.

Note. Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

Scheme 32

Scheme 33

1. Remove the wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
2. NOTE: Do not discard the wheel hub nut at this time. Remove the wheel hub nut.
3. Remove the brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
4. NOTE: No special tools are necessary to separate the tie rod from the front knuckle; use a mallet to loosen the joint. Remove and discard the tie-rod end nut, then separate the tie rod from the wheel knuckle.
5. Remove the bolt and the wheel speed sensor from the wheel knuckle. Position the wheel speed sensor aside.
6. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Using a crowfoot wrench, remove and discard the lower ball joint nut.
7. Push the lower arm downward until the ball joint is clear of the wheel knuckle.
8. NOTE: Do not allow the halfshaft to move outboard. Overextension of the tripod Constant Velocity (CV) joint may result in separation of internal parts, causing failure of the halfshaft. Using the Front Wheel Hub Remover, press the halfshaft from the wheel bearing and hub. Support the halfshaft in a level position.
9. Remove and discard the strut-to-wheel knuckle nut and flagbolt.
10. Remove the wheel knuckle. If necessary, remove the wheel hub and bearing. For additional information, refer to «WHEEL BEARING AND WHEEL HUB»(ref-372768-S42601492792010093000000) .

Installation

1. Position the wheel knuckle and install a new strut-to-wheel knuckle nut and flagbolt. Tighten to 175 Nm (129 lb-ft).
2. While supporting the halfshaft in a level position, install the halfshaft into the wheel bearing and hub.
3. NOTE: Use care not to damage the ball joint seal while installing the ball joint stud into the wheel knuckle. Push the lower arm downward and install the ball joint stud into the wheel knuckle.
4. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nut. Using a crowfoot wrench, install the new lower ball joint nut. Tighten to 200 Nm (148 lb-ft).
5. Position the wheel speed sensor and install the bolt. Tighten to 15 Nm (133 lb-in).
6. Position the tie-rod end stud into the wheel knuckle and install a new tie-rod end nut. Tighten to 150 Nm (111 lb-ft).
7. Install the brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
8. NOTE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Using the previously removed hub nut, seat the halfshaft. Tighten to 350 Nm (258 lb-ft). Remove and discard the hub nut.
9. NOTE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur. NOTE: Apply the brake to keep the halfshaft from rotating. Install a new hub nut. Tighten to 350 Nm (258 lb-ft).
10. Install the wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .

Note. Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

Note. Make sure the steering wheel is in the unlocked position.

1. Loosen the upper strut mount nuts.
2. Remove the wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
3. NOTE: Do not discard the wheel hub nut at this time. Remove the wheel hub nut.
4. Remove the brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
5. NOTE: No special tools are necessary to separate the tie rod from the front knuckle; use a mallet to loosen the joint. Remove and discard the tie-rod end nut, then separate the tie rod from the wheel knuckle.
6. Remove and discard the stabilizer bar link upper nut.
7. Detach the wheel speed sensor harness from the strut.
8. Remove the bolt and the wheel speed sensor from the wheel knuckle. Position the wheel speed sensor aside.
9. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Using a crowfoot wrench, remove and discard the lower ball joint nut.
10. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal may occur. Push the lower arm downward until the ball joint is clear of the wheel knuckle.
11. NOTE: Do not allow the halfshaft to move outboard. Overextension of the tripod Constant Velocity (CV) joint may result in separation of internal parts, causing failure of the halfshaft. Using the Front Wheel Hub Remover, press the halfshaft from the wheel bearing and hub. Support the halfshaft in a level position.
12. Remove and discard the 4 upper strut mount nuts.
13. Remove the wheel knuckle and the strut and spring as an assembly.
14. Remove and discard the strut-to-wheel knuckle nut and flagbolt.
15. Separate the strut and spring assembly from the wheel knuckle.

1. Position the wheel knuckle onto the strut and spring and install a new strut-to-wheel knuckle nut and flagbolt. Tighten the nut to 175 Nm (129 lb-ft).
2. Install the wheel knuckle and the strut and spring as an assembly.
3. Loosely install the 4 new upper strut mount nuts.
4. While supporting the halfshaft in a level position, install the halfshaft into the wheel bearing and hub.
5. NOTE: Use care not to damage the ball joint seal while installing the ball joint stud into the wheel knuckle. Push the lower arm downward and install the ball joint stud into the wheel knuckle.
6. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nut. Using a crowfoot wrench, install the new lower ball joint nut. Tighten to 200 Nm (148 lb-ft).
7. Position the wheel speed sensor and install the bolt. Tighten to 15 Nm (133 lb-in).
8. Attach the wheel speed sensor harness to the strut.
9. Install the new stabilizer bar link upper nut. Tighten to 150 Nm (111 lb-ft).
10. Position the tie-rod end stud into the wheel knuckle and install a new tie-rod end nut. Tighten to 150 Nm (111 lb-ft).
11. Install the brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
12. NOTE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Using the previously removed hub nut, seat the halfshaft. Tighten to 350 Nm (258 lb-ft). Remove and discard the hub nut.
13. NOTE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur. NOTE: Apply the brake to keep the halfshaft from rotating. Install a new hub nut. Tighten to 350 Nm (258 lb-ft).
14. Install the wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
15. Tighten the 4 upper strut mount nuts to 30 Nm (22 lb-ft).