Uni-Body System, Subframe System and Mounting System: Other Ford Focus II

Body Misalignment Check

1. To align or square up a body, take 2 opposite diagonal measurements between the front, center or rear pillars. Take the measurements between reference points, such as crease lines or weld joints, which are diagonally opposite each other on the 2 pillars being measured. Since all measurements should be made from the bare metal, remove all interior trim or chassis components from the points being checked. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-255442) .
2. Align each section proportionately, until the proper dimensions are obtained. If body alignment is questionable, refer to «UNDERBODY MISALIGNMENT CHECK»(ref-255403-S39076472512007053100000) .
3. Due to the design and construction of the unibody vehicle, it is important to monitor the upper body structure while making any corrections to the underbody structure.
4. Roughly straighten badly damaged areas before taking measurements for squaring up the unibody body. Remove the glass to prevent breakage. For additional information, refer to «GLASS FRAMES AND MECHANISMS»(ref-255396) . In severe cases, reinforcement brackets and other inner construction parts may have to be removed or cut to permit restoration of the outer shell and pillars without excessive strain on the parts.
5. In case of severe or sharp bends, it may be necessary to use heat. Never heat the area to more than 670°C (1,238°F). Always use temperature-indicating crayons when applying heat to any part.

Underbody Misalignment Check

1. The dimensions of the underbody must be restored to provide the correct front and rear wheel alignment geometry.
2. All the dimensions are measured between the centers of the existing holes in the underbody unless otherwise specified.
3. Inspect all underbody structural members for cracks, twists or bends. Check all welded connections for cracks. Inspect the support brackets for looseness. Carry out any necessary repairs or install new components as necessary.

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Subframe - Front

SPECIAL TOOL(S) Remover, Tie-Rod End 211-001 (TOOL-3290-D) Alignment Pins, Subframe 502-002 (T94P-2100-AH) Installer Set, Teflon® Seal 211-D027 (D90P-3S17-A) or equivalent

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Note. The front bumper cover and the RH/LH brake assemblies have been removed for clarity.

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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-255382) .
4. Remove the lower radiator air deflector. For additional information, refer to «FRONT END BODY PANELS»(ref-255420) .
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.

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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-255382) .
15. Install the lower radiator air deflector. For additional information, refer to «FRONT END BODY PANELS»(ref-255420) .
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-255398) .
18. Check the front end alignment and adjust as necessary. For additional information, refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(ref-255383) .

Subframe - Rear

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

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