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Uni-Body System, Subframe System and Mounting System: Removal & Installation Ford Focus I facelift

Frames, Subframes & Crossmembers 1 illustration ~693 words

REMOVAL

  1. Center the steering wheel, remove the ignition key and lock the steering in position.
  2. Disconnect the steering column shaft from the steering column coupling shaft. Discard the bolt.
  3. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-278246) article.
  4. Remove the lower radiator air deflector. For additional information, refer to «FRONT END BODY PANELS»(ref-278268) article.
  5. Loosen the tie-rod end nut on both sides.
  6. Using the special tool, disconnect the tie-rod end from the wheel knuckle on both sides. Remove and discard the tie-rod end nuts.
  7. Remove the stabilizer bar link nuts on both sides.
  8. Remove the engine support insulator-to-transaxle center bolt.
  9. Remove the power steering line retainer bolt from the steering gear.
  10. Remove the power steering lines bolt, rotate the power steering line clamp clockwise, and disconnect the 2 power steering lines from the power steering gear. Allow the remaining oil to drain into a suitable container. Discard the O-ring seals.
  11. Using a suitable support table, support the front subframe.
  12. Disconnect the lower arm ball joint from the wheel knuckle on both sides. Remove the 2 lower arm ball joint heat shields.
  13. Remove the 6 subframe bolts.
  14. Remove the front subframe.

INSTALLATION

  1. Using a suitable support table, position and align the front subframe, insert the alignment pins through the front subframe alignment holes and the washers, slide the locking plates on top of the washers and into the groove of the tool and tighten the alignment pin sleeve. Raise the front subframe engaging the alignment pins into the chassis aligning holes.
  2. Loosely install the 4 subframe lower bolts. Tighten to 175 Nm (129 lb-ft).
  3. Remove the crossmember alignment pins.
  4. Install the 2 subframe upper bolts. Tighten to 103 Nm (76 lb-ft).
  5. Remove the support table.
  6. Install the 2 heat shields (1 each side).
  7. Position the lower arm ball joint to the wheel knuckle on both sides and install the bolts and nuts. Tighten to 63 Nm (46 lb-ft).
  8. Using the special tool, install new O-ring seals (high pressure hose pin, 3F886-AA, return hose pin 3F886-BA) onto the power steering lines.
  9. Connect the power steering lines to the power steering gear, rotate the power steering line clamp counterclockwise and install the bolt. Tighten to 18 Nm (13 lb-ft).
  10. Install the power steering line retainer bolt.
  11. Install the engine support insulator-to-transaxle center bolt. Tighten to 50 Nm (37 lb-ft).
  12. Install the 2 stabilizer bar links and the nuts. Tighten to 55 Nm (41 lb-ft).
  13. Install the 2 tie-rod ends and the nuts. Tighten to 35 Nm (26 lb-ft).
  14. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-278246) article.
  15. Install the lower radiator air deflector. For additional information, refer to «FRONT END BODY PANELS»(ref-278268) article.
  16. Connect the steering column shaft to the steering column coupling shaft and install the bolt. Tighten to 28 Nm (21 lb-ft).
  17. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-278262) article.
  18. Check the front end alignment and adjust as necessary. For additional information, refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(ref-278247) article.

Subframe - Rear

Note. 3/4/5 door shown, wagon similar.

Scheme 1

Scheme 1: Subframe - Rear
Scheme 1: Subframe - Rear
ItemPart NumberDescription
1W709634Crossmember bolt (6 required)
25K067Crossmember
3W500744Front lower arm inboard bolt (2 required)
4W500744Upper arm inboard bolt (2 required)

REMOVAL & INSTALLATION

CAUTIONSuspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes 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 both rear springs. For additional information, refer to «REAR SUSPENSION»(ref-278261) article.
  2. Remove both rear lower control arms. For additional information, refer to «REAR SUSPENSION»(ref-278261) article.
  3. Remove the stabilizer bar. For additional information, refer to «REAR SUSPENSION»(ref-278261) article.
  4. Remove and discard the front lower arm inboard bolts. To install, tighten to 115 Nm (85 lb-ft).
  5. Remove and discard the upper arm inboard bolts. To install, tighten to 115 Nm (85 lb-ft).
  6. Support the wheel knuckle and trailing arm assembly using a tie strap or other suitable holding device.
  7. Using a suitable jack stand, support the exhaust system.
  8. Detach the exhaust system from the crossmember exhaust hanger isolator.
  9. Using a suitable jack, support the crossmember.
  10. Remove the 6 crossmember bolts. To install, tighten to 103 (76 lb-ft).
  11. Lower the jack and remove the crossmember.
  12. To install, reverse the removal procedure.
  13. Check and, if necessary, adjust the rear toe. For additional information, refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(ref-278247) article.

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