Front Suspension: Removal & Installation Ford Fusion I рестайлинг

REMOVAL

Note. If removing the wheel hub, a new wheel bearing must be installed.

1. Remove the wheel knuckle. For additional information, refer to «Wheel Knuckle»(ref-291927-S12029880032008073000000) .
2. Using the Step Plate, press the wheel hub from the wheel bearing.
3. If necessary, using the Pinion Bearing Cone Remover, press the inner wheel bearing race from the wheel hub.
4. Remove the snap ring.
5. Using the Wheel Hub Cup Remover/Installer, press the wheel bearing from the wheel knuckle.

INSTALLATION

1. Using the Wheel Hub Bearing Cup Installer, press the wheel bearing into the wheel knuckle.
2. Install the snap ring.
3. Using the Step Plate and Wheel Hub Bearing Cup Installer, press the wheel hub into the wheel bearing.
4. Install the wheel knuckle. For additional information, refer to «Wheel Knuckle»(ref-291927-S12029880032008073000000) .

Scheme 7

1. Remove the wheel hub. For additional information, refer to «Wheel Bearing and Wheel Hub»(ref-291927-S18351578422008073000000) .
2. Using a press, remove the wheel stud from the wheel bearing and hub assembly.

1. Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by the original wheel stud.
2. Using a press, install a new wheel stud.
3. Install the wheel hub. For additional information, refer to «Wheel Bearing and Wheel Hub»(ref-291927-S18351578422008073000000) .

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Using a suitable jack, support the front wheel knuckle at the rear lower ball joint.
3. Remove the front lower arm-to-subframe bolt. Discard the bolt. To install, tighten the new bolt to 110 Nm (81 lb-ft), then tighten an additional 90 degrees with the suspension at the bushing fastener tightening position.
4. Remove the damper fork-to-lower arm bolt flag nut and damper. Discard the bolt and flag nut. To install, tighten the new bolt and flag nut to 103 Nm (76 lb-ft) with the suspension at the bushing fastener tightening position.
5. Remove and discard the front lower ball joint nut. To install, tighten the new nut to 200 Nm (148 lb-ft).
6. Using the Ball Joint Separator and Adapter, separate the front lower ball joint from the wheel knuckle and remove the front lower arm.
7. 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. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
2. Remove the 2 lower steering column shaft joint cover bolts and cover.
3. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt. To install, align the index marks and tighten the new bolt to 25 Nm (18 lb-ft).
4. Remove the steering column shaft-to-dash seal.
5. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-291853) article.
6. Remove the 8 screws and position the LH and RH splash shields aside.
7. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
8. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
9. If equipped, remove the bolts and the underbody cover shield. To install, tighten 7 Nm (62 lb-in).
10. Remove and discard the 2 catalytic converter manifold-to-exhaust flexible pipe nuts and separate the exhaust flexible pipe. To install, tighten the new nuts to 40 Nm (30 lb-ft).
11. Using 2 suitable jack stands, support the rear of the subframe assembly.
12. Remove and discard the 4 subframe bracket-to-body bolts, the 2 subframe bracket-to-subframe nuts and washers. Lower the rear of the subframe. To install, tighten the new bolts to 103 Nm (76 lb-ft). To install, tighten the new nuts to 150 Nm (111 lb-ft).
13. Remove and discard the rear lower ball joint nut. To install, tighten the new nut to 200 Nm (148 lb-ft).
14. Using the Ball Joint Separator and Adapter, separate the rear lower ball joint from the wheel knuckle.
15. Remove the rear lower arm-to-subframe bolt and washer and remove the rear lower arm. Discard the bolt and washer. To install, tighten the new bolt to 65 Nm (48 lb-ft), then tighten an additional 90 degrees.
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. Remove and discard the 3 shock absorber upper mount nuts.
2. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-291853) article.
3. If equipped, remove the wheel speed sensor bolt.
4. If equipped, remove the wheel speed sensor harness bolt and position the wheel speed sensor aside.
5. Remove and discard the upper ball joint nut.
6. Using the Steering Arm Remover, separate the upper ball joint from the wheel knuckle.
7. Position the shock absorber and spring assembly toward the wheel knuckle to access the upper arm-to-body bolts.
8. Remove the 2 upper arm-to-body bolts and the upper arm. Discard the bolts.

1. Position the upper arm and install the 2 new upper arm-to-body bolts.
2. Set the upper arm bushing fastener tightening position by aligning the hole in the upper arm with the hole in the body bracket and inserting a 6.35 mm (0.25 in) drill bit through both holes.
3. Tighten the upper arm-to-body bolts to 55 Nm (41 lb-ft) and remove the drill bit.
4. Position the shock and spring assembly and install the 3 new shock upper mount nuts. Tighten to 30 Nm (22 lb-ft).
5. Position the upper ball joint and install a new nut. Tighten to 48 Nm (35 lb-ft).
6. If equipped, position the wheel speed sensor harness and install the bolt. Tighten to 23 Nm (17 lb-ft).
7. If equipped, position the wheel speed sensor and install the bolt. Tighten to 23 Nm (17 lb-ft).
8. Install the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-291853) article.
9. Check and, if necessary, align the front end. For additional information, refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(ref-291854) article.

Scheme 8

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-291853) article.
2. Remove and discard the stabilizer bar link upper nut. To install, tighten the new nut to 40 Nm (30 lb-ft).
3. Remove and discard the stabilizer bar link lower nut and remove the stabilizer bar link. To install, tighten the new nut to 42 Nm (31 lb-ft).
4. 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.

All vehicles

1. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
2. Remove the 2 lower steering column shaft joint cover bolts and cover.
3. Remove the bolt and disconnect the steering column shaft from the steering gear. To install, align the index marks, tighten to 25 Nm (18 lb-ft).
4. Remove the steering column shaft-to-dash seal.
5. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
6. Remove the 8 screws and position the LH and RH splash shields aside.
7. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
8. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
9. If equipped, remove the bolts and the underbody cover shield. To install, tighten 7 Nm (62 lb-in).
10. Remove and discard the 2 tie-rod end cotter pins and nuts. To install, tighten the new nuts to 48 Nm (35 lb-ft). Install a new cotter pin.
11. Using the Tie-Rod End Remover, separate the 2 tie-rod ends from both wheel knuckles.
12. Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust flexible pipe. To install, tighten the new nuts to 40 Nm (30 lb-ft).
13. Index the rear driveshaft-to-Power Transfer Unit (PTU). Remove the 4 bolts and position the driveshaft aside. To install, tighten to 70 Nm (52 lb-ft).
14. Remove RH steering gear-to-subframe bolt. To install, tighten to 107 Nm (79 lb-ft).
15. Remove the 2 LH steering gear-to-subframe bolts and position the steering gear to access the stabilizer bar LH bracket front nut. To install, tighten to 107 Nm (79 lb-ft).
16. Remove and discard the 4 stabilizer bar bracket nuts and remove the 2 stabilizer bar brackets. To install, tighten the new bracket nuts to 48 Nm (35 lb-ft).
17. Remove the 2 stabilizer bar bushings.
18. 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.

All vehicles

1. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
2. Remove the 2 lower steering column shaft joint cover nuts and cover.
3. Remove the bolt and disconnect the steering column shaft from the steering gear. To install, align the index marks, tighten to 25 Nm (18 lb-ft).
4. Remove the steering column shaft-to-dash seal.
5. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-291853) article.
6. Remove the 8 screws and position the LH and RH splash shields aside.
7. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
8. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
9. If equipped, remove the bolts and the underbody cover shield. To install, tighten 7 Nm (62 lb-in).
10. Remove and discard the 2 tie-rod end cotter pins and nuts. To install, tighten the new nuts to 48 Nm (35 lb-ft) and install new cotter pins.
11. Using the Tie-Rod End Remover, separate the tie-rod ends from both wheel knuckles.
12. Remove and discard the 2 stabilizer bar link lower nuts and disconnect both stabilizer bar links from the stabilizer bar. To install, tighten the new nuts to 42 Nm (31 lb-ft).
13. Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust flexible pipe. To install, tighten the new nuts to 40 Nm (30 lb-ft).
14. Index the rear driveshaft-to-Power Transfer Unit (PTU). Remove the 4 bolts and position the driveshaft aside. To install, tighten the new bolts to 70 Nm (52 lb-ft).
15. Using 2 suitable jackstands, support the rear of the subframe assembly.
16. Remove and discard the 4 subframe bracket-to-body bolts, the 2 subframe bracket-to-subframe nuts and lower the rear of the subframe. To install, tighten the new bolts to 103 Nm (76 lb-ft). To install, tighten the new nuts to 150 Nm (111 lb-ft).
17. Remove the RH steering gear-to-subframe bolt. To install, tighten to 107 Nm (79 lb-ft).
18. Remove the 2 LH steering gear-to-subframe bolts and position the steering gear to access the stabilizer bar LH bracket front nut. To install, tighten to 107 Nm (79 lb-ft).
19. Remove and discard the 4 stabilizer bar bracket nuts and remove the 2 stabilizer bar brackets. To install, tighten the new bracket nuts to 48 Nm (35 lb-ft).
20. Remove the 2 stabilizer bar bushings.
21. Remove the stabilizer bar through the LH wheel opening.
22. 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. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-291853) article.
2. If equipped, remove the wheel speed sensor bolt.
3. If equipped, remove the wheel speed sensor harness bolt and position the wheel speed sensor aside.
4. Remove and discard the halfshaft nut.
5. Remove the bolts and position the caliper and anchor plate assembly aside. Support the caliper and anchor plate assembly using mechanic's wire.
6. Remove the 2 brake disc bolts and the brake disc.
7. Using the Front Hub Remover, separate the halfshaft from the wheel hub.
8. Remove and discard the upper ball joint nut.
9. Using the Steering Arm Remover, separate the upper ball joint from the wheel knuckle.
10. Remove and discard the tie-rod end cotter pin and nut.
11. Using the Tie-Rod End Remover, separate the tie-rod end from the wheel knuckle.
12. Remove and discard the 2 lower ball joint nuts.
13. Using the Ball Joint Separator and Adapter, separate the 2 lower ball joints from the wheel knuckle and remove the wheel knuckle.

1. Position the wheel knuckle and install the 2 new lower ball joint nuts. Tighten to 200 Nm (148 lb-ft).
2. Position the tie-rod end and install the new nut and cotter pin. Tighten to 48 Nm (35 lb-ft).
3. Position the upper ball joint and install the new nut. Tighten to 48 Nm (35 lb-ft).
4. If equipped, position the wheel speed sensor and install the bolt. Tighten to 23 Nm (17 lb-ft).
5. If equipped, install the wheel speed sensor harness bolt. Tighten to 23 Nm (17 lb-ft).
6. Position the brake caliper and anchor plate assembly and install the 2 bolts. Tighten to 90 Nm (66 lb-ft).
7. Install the brake disc and the 2 brake disc bolts. Tighten to 20 Nm (177 lb-in).
8. Using the Halfshaft Installer, install the halfshaft into the wheel hub.
9. Install the halfshaft nut. Tighten to 255 Nm (189 lb-ft).

Scheme 9

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 and discard the 3 shock absorber upper mount nuts. To install, tighten the new nuts to 30 Nm (22 lb-ft).
2. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-291853) article.
3. Remove the brake tube bracket bolt and position the brake line aside. To install, tighten to 23 Nm (17 lb-ft).
4. If equipped, remove the wheel speed sensor bolt. To install, tighten to 23 Nm (17 lb-ft).
5. If equipped, remove the wheel speed sensor harness bolt and position the wheel speed sensor aside. To install, tighten to 23 Nm (17 lb-ft).
6. Using a suitable jack, support the wheel knuckle at the lower ball joints.
7. Remove and discard the stabilizer bar link upper nut. To install, tighten the new nut to 40 Nm (30 lb-ft).
8. Remove the damper fork-to-front lower arm bolt, flag nut and damper. Discard the bolt and flag nut. To install, tighten the new bolt and flag nut to 103 Nm (76 lb-ft) with the suspension at the bushing fastener tightening position.
9. Remove and discard the shock absorber-to-damper fork bolt and separate the damper fork from the shock absorber and spring assembly. To install, tighten the new bolt to 48 Nm (35 lb-ft).
10. Lower the wheel knuckle and remove the shock absorber and spring assembly.
11. To install, reverse the removal procedure.
12. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to «Shock Absorber and Spring Assembly»(ref-291927-S39283413152008073000000) .

Scheme 10