Front Suspension: Removal & Installation Ford Kuga II

Removal

Note. Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

Note. Removal steps in this procedure may contain installation details.

Scheme 4

1. NOTE: Disconnect the battery ground cable anytime the steering gear is being serviced or damage to the steering gear internal power relay may occur resulting in steering gear replacement. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
2. Steering wheel in straight ahead position.
3. WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Torque: 21 lb.ft (28 Nm)
4. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
5. If equipped.
6. If equipped. On both sides. Torque: 18 lb.ft (25 Nm)
7. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. On both sides. Torque: 35 lb.ft (48 Nm)
8. NOTE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or damage to the wheel knuckle may result. NOTE: Use care when installing the tie rod separator or damage to the outer tie-rod end boot may occur. On both sides. Use the General Equipment: Tie Rod End Remover Torque: 35 lb.ft (48 Nm)
9. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the exhaust flexible pipe.
10. Torque: 18 lb.ft (25 Nm)
11. Torque: 63 lb.ft (86 Nm)
12. NOTE: Index mark the subframe positioning for reference during the installation procedure. Use the General Equipment: Transmission Jack
13. Callouts 1. Torque: 177 lb.in (20 Nm) 2. Torque: 177 lb.in (20 Nm) 3. Torque: Stage 1: 103 lb.ft (140 Nm) Stage 2: 180° 4. Torque: 85 lb.ft (115 Nm) 5. Dimension: 4 in (100 mm)
14. Discard the specified component. Follow local disposal regulations. Torque: Stage 1: 85 lb.ft (115 Nm) Stage 2: 90°
15. NOTE: If replacing the stabilizer bar or stabilizer bar bushings, note the position of the stabilizer bar bushing brackets. The protrusion on both bushings must be facing the RH side of the vehicle for correct installation. Use the General Equipment: Transmission Jack

Installation

1. To install, reverse the removal procedure.
2. NOTE: While tightening the subframe bolts, make sure the front subframe does not move. NOTE: Before tightening the subframe bolts, align the subframe using the special tool and the reference marks made during removal. Use Special Service Tool: 502-002 (T94P-2100-AH) Alignment Pins, Subframe .
3. Refer to: «FRONT TOE ADJUSTMENT»(ref-658847-S39501925392014092900000) .

Note. Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

1. NOTE: Removal steps in this procedure may contain installation details. Refer to: «FRONT STABILIZER BAR»(ref-658870-S31733540732014092900000) .
2. NOTE: Note the position of the component before removal.

Scheme 5

1. Callouts NOTE: If replacing the stabilizer bar or the stabilizer bar bushings, note the position of the stabilizer bar bushing brackets. The bushing locator on the clamp offset must face inboard. NOTE: Make sure that the component is clean, free of foreign material and lubricant. 1. Metal strip. 2. NOTE: Make sure that the component is installed to the position noted before removal. NOTE: The bushing locator bump on both bushings must face the RH side of the vehicle. Use the General Equipment: Vise
2. Refer to: «FRONT STABILIZER BAR»(ref-658870-S31733540732014092900000) .

Note. Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

Note. Removal steps in this procedure may contain installation details.

1. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
2. Callouts NOTE: Do not hold the stabilizer bar link boot with any tool or damage to the boot may occur. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. NOTE: When installing the stabilizer link to the stabilizer bar, make sure the stabilizer bar is perpendicular to the stabilizer link when tightening the link nut or the link nut may not seat properly. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. 1. Torque: 46 lb.ft (63 Nm) 2. Torque: 46 lb.ft (63 Nm)

1. To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

Scheme 6

1. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
2. Callouts NOTE: Do not use power tools to remove or install the stabilizer bar link nuts or damage to the stabilizer bar link ball joints or boots may occur. NOTE: Do not hold the stabilizer bar link boot with any tool or damage to the boot may occur. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. Torque: 1. 97 lb.in (11 Nm) 2. 35 lb.ft (48 Nm)
3. Refer to: «WHEEL KNUCKLE»(ref-658870-S35449293662014092900000) .
4. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
5. Torque: 26 lb.ft (35 Nm)

1. To install, reverse the removal procedure.
2. For additional information on the disassembly and assembly of the strut and spring assembly. Refer to: «FRONT STRUT AND SPRING ASSEMBLY»(ref-658870-S19773116232014092900000) .
3. Refer to: «FRONT CAMBER AND CASTER ADJUSTMENT»(ref-658847-S02830863262014092900000) .

1. NOTE: If removing the wheel hub, a new wheel bearing must be installed. Refer to: «WHEEL KNUCKLE»(ref-658870-S35449293662014092900000) .
2. NOTE: After the wheel hub is removed from the wheel knuckle, the wheel bearing must be discarded. Use Special Service Tool: 205-153 (T80T-4000-W) Handle , 204-023 (T73T-1217-A) Installer, Wheel Hub Bearing Cup , 205-D064 (D84L-1123-A) Puller, Bearing . Use the General Equipment: Hydraulic Press
3. NOTE: The Bearing Puller and Bushing Remover/Installer must be used to prevent damage to the hub. If the hub is damaged, a new hub must be installed. NOTE: Do not use heat to remove the bearing inner ring or damage to the bearing may occur. NOTE: This step may not be necessary if the wheel bearing inner race remains on the wheel bearing after removing the wheel hub. Use Special Service Tool: 204-180 (T93P-5493-A) Remover/Installer, Bushing , 205-D064 (D84L-1123-A) Puller, Bearing . Use the General Equipment: Hydraulic Press
4. Use Special Service Tool: 205-153 (T80T-4000-W) Handle , 205-480 Installer, Drive Pinion Inner Bearing Cup , 205-538 Remover, Axle Bushing . Use the General Equipment: Hydraulic Press

Scheme 7

1. NOTE: Make sure the wheel bearing is installed into the wheel knuckle with the wheel speed sensor ring (black in color) toward the inner face of the wheel knuckle. NOTE: Once the wheel bearing is installed, make sure the wheel speed sensor ring on the bearing and the sensor hole on the wheel knuckle are clean or damage to the wheel speed sensor or sensor ring may occur. Use Special Service Tool: 205-153 (T80T-4000-W) Handle , 205-480 Installer, Drive Pinion Inner Bearing Cup , 205-538 Remover, Axle Bushing . Use the General Equipment: Hydraulic Press
2. NOTE: Make sure the wheel speed sensor hole in the wheel knuckle is not blocked by the circlip. The sensor hole must be positioned between the ends of the circlip.
3. Use Special Service Tool: 205-153 (T80T-4000-W) Handle , 205-140 (T80T-4000-F) Installer, Drive Pinion Bearing Cup , 205-138 (T80T-4000-D) Installer, Drive Pinion Bearing Cup . Use the General Equipment: Hydraulic Press
4. Refer to: «WHEEL KNUCKLE»(ref-658870-S35449293662014092900000) .

Note. Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

Scheme 8

Scheme 9

1. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
2. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
3. If equipped.
4. NOTE: Do not use a prying device to open the slot in the knuckle to separate the lower ball joint from the knuckle assembly. Damage to the knuckle assembly may occur. NOTE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening. NOTE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may occur.

Scheme 10

Scheme 11

Scheme 12

1. NOTE: Do not tighten the nuts and bolts at this time. Finger tight at this stage.
2. Torque: 61 lb.ft (83 Nm)
3. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
4. Callouts 1. Finger tight. 2. Torque : Stage 1: 85 lb.ft (115 Nm) Stage 2: 90° 3. Torque : Stage 1: 85 lb.ft (115 Nm) Stage 2: 90°
5. Use the General Equipment: Vehicle/Axle Stands
6. NOTE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight of the vehicle resting on the wheels and tires, otherwise incorrect clamp load and bushing damage may occur. Torque: Stage 1: 59 lb.ft (80 Nm) Stage 2: 360°
7. Callouts Torque : 1. 18 lb.ft (25 Nm) 2. 35 lb.ft (48 Nm)
8. If equipped.
9. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
10. Refer to: «FRONT TOE ADJUSTMENT»(ref-658847-S39501925392014092900000) .

1. Torque : Stage 1: 59 lb.ft (80 Nm) Stage 2: 180°
2. Use Special Service Tool: 204-161 (T97P-1175-A) Installer, Halfshaft .
3. Refer to: «BRAKE DISC SHIELD»(ref-658874-S13614776952014092900000) .
4. Torque: 42 lb.in (4.8 Nm)
5. Torque: 61 lb.ft (83 Nm)
6. Torque: 35 lb.ft (48 Nm)
7. 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: Install and tighten the new wheel hub nut to specification in a continuous rotation. Always install a new wheel hub nut after loosening or when not tightened to specification in a continuous rotation or damage to the components may occur. NOTE: Apply the brake to keep the halfshaft from rotating. Torque: Stage 1: 59 lb.ft (80 Nm) Stage 2: 90°
8. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
9. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
10. Refer to: «FRONT TOE ADJUSTMENT»(ref-658847-S39501925392014092900000) .

1. NOTE: Wheel studs are not serviceable separately. Wheel bearing and wheel hub assembly must be replaced. Refer to: «FRONT WHEEL BEARING AND WHEEL HUB»(ref-658870-S31408701872014092900000) .

1. NOTE: Wheel studs are not serviceable separately. Wheel bearing and wheel hub assembly must be replaced. Refer to: «FRONT WHEEL BEARING AND WHEEL HUB»(ref-658870-S31408701872014092900000) .