Uni-Body, Subframe and Mounting System: Other Mercury Milan I

Body Misalignment Check

Note. All measurements should be made from the bare metal; remove trim and bumper covers as necessary.

1. Repair the badly damaged areas before taking measurements for underbody alignment.
2. To check the underbody alignment, take the measurements between opposite reference points, such as crease lines or weld joints.
3. Monitor the upper body structure for excessive stress or movement while making any corrections to the underbody structure. Remove all the necessary glass to prevent breakage. For additional information, refer to «GLASS, FRAMES AND MECHANISMS»(ref-271080) .

Underbody Misalignment Check

1. The dimensions of the underbody must be restored to provide the correct front and rear wheel alignment geometry.
2. 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.
4. Underbody dimension tolerances are ± 3 mm (0.12 in).
5. To align or square a body, take 2 opposite diagonal measurements between pillars. Take measurements between reference points such as crease lines or weld joints, which are diagonally opposite each other on the 2 pillars being measured.
6. 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.
7. The dimensions shown are symmetrical. UNDERBODY DIMENSIONS Location Dimension 1 1,020 mm (40.1 in) 2 780 mm (30.7 in) 3 738 mm (29.0 in) 4 1,250 mm (49.2 in) 5 394 mm (15.5 in) 6 1,034 mm (40.7 in) 7 3,900 mm (153.54 in)

Subframe - Front

Special Tools Illustration Tool Name Tool Number Ball Joint Separator 204-592 Powertrain Lift Table 014-00765 Adapter for 204-592 204-592/1

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Subframe Bushings - Front

Special Tools Illustration Tool Name Tool Number Handle 205-153 Bushing Remover 204-593 Installer, Wheel Speed Sensor Ring 206-034 Remover/Installer, Front Subframe Bushing 204-362 Remover/Installer, Radius Arm Axle Bushing 204-356

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All bushings

1. Remove the front subframe. For additional information, refer to «Subframe - Front»(ref-271124-S34982594792007110800000) .
2. Assemble the special tools to the groove between the upper and lower bushings and tighten.
3. Remove the lower bushing using a hammer.
4. Turn the subframe over.
5. Assemble the special tools to the upper bushing.
6. Remove the upper bushing using a hammer.
7. Remove the 4 nuts and crossmember from the front subframe.
8. Mark the orientation of the bushings to the subframe.
9. Remove the lower rear bushings using a flat-blade screwdriver, being careful not to damage the subframe.
10. Turn the subframe over.
11. Remove the upper rear bushings using a flat-blade screwdriver, being careful not to damage the subframe.

Subframe Bushings - Rear

Special Tools Illustration Tool Name Tool Number Remover/Installer, Rear Drive Unit Bushing 205-813 Remover/Installer, Differential Bearing 205-485

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All bushings

1. Remove the rear subframe. For additional information, refer to «Subframe - Rear»(ref-271124-S03906116822007110800000) .
2. Remove the rear subframe front lower bushings with a flat-blade screwdriver.
3. Turn the subframe over.
4. Remove the rear subframe front upper bushings with a flat-blade screwdriver.
5. Remove the rear subframe lower bushings with a flat-blade screwdriver.
6. Turn the subframe over.
7. Remove the rear subframe upper bushings with a flat-blade screwdriver.