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502-02 Full Frame and Body Mounting > < Frame Assembly

Focus 1999 (08.1998-12.2004)

Uni-Body, Subframe and Mounting System - Crossmember Focus 1999 (08/1998-12/2004)
Removal and Installation

Special Tool(s)

Alignment Pins, Subframe

205-316 (15-097A)

Separator, Ball Joint

211-020 (13-006)
General Equipment
Transmission jack
5 mm Allen key

Removal

All vehicles
  1. NOTE:
    NOTE:Make sure the road wheels are in the straight ahead position.
    Centralize the steering and lock it in position.
Vehicles built up to 12/1998
  1. Disconnect the steering column shaft from the steering gear pinion extension.
    1. Loosen the upper retaining bolt.
    1. Remove the lower retaining bolt.
    1. Push the sleeve up.
Vehicles built 12/1998 onwards
  1. Disconnect the steering column shaft from the steering gear pinion extension.
    • Discard the bolt.
All vehicles
  1. Drain the power steering fluid.
    • Remove the reservoir.
    • Allow the fluid to drain into a suitable container.
  1. Remove the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. CAUTION:
    CAUTION:Leave the tie-rod end retaining nuts in place to protect the ball joint studs.
    Loosen the tie-rod end retaining nut on both sides.

  1. CAUTION:
    CAUTION:Using a soft cloth, protect the ball joint seal to prevent damage.
    Using the special tool, detach the tie-rod end from the wheel knuckle on both sides.
    • Remove and discard the tie-rod end retaining nuts.

  1. NOTE:
    NOTE:Using a 5 mm Allen Key, prevent the ball joint from rotating.
    Detach the stabilizer bar connecting link from the stabilizer bar on both sides.

  1. CAUTION:
    CAUTION:Using a soft cloth, protect the ball joint seal to prevent damage.
    Detach the lower arm ball joint from the wheel knuckle on both sides.
    • Remove the heat shields.

  1. Remove the engine support insulator to transaxle center retaining bolt.

  1. Remove the steering gear heat shield (two bolts).

  1. Detach the power steering line from the clamp.

  1. Detach the power steering line from the power steering gear.
    1. Remove the retaining bolt.
    1. Rotate the power steering line clamp clockwise.
    • Allow the oil to drain into a suitable container.
  1. Using a suitable transmission jack, support the crossmember.

  1. Remove the crossmember retaining bolts (support removed for clarity).

  1. Remove the crossmember.

Installation

All vehicles
  1. CAUTION:
    CAUTION:Make sure the crossmember ball bearing washers are installed correctly.
    Using a suitable transmission jack and the special tool, position and align the crossmember.
    1. Insert the alignment pins through the crossmember alignment holes and the washers.
    1. Slide the locking plates on top of the washers and into the groove of the tool and tighten the alignment pin sleeve
    1. Raise the crossmember engaging the alignment pins into the chassis aligning holes.

  1. CAUTION:
    CAUTION:While tightening the crossmember retaining bolts, make sure the crossmember does not move.
    Install the crossmember retaining bolts (support removed for clarity).
  1. Lower and remove the transmission jack.
  1. Remove the crossmember alignment pins.

  1. NOTE:
    NOTE:Check the O-ring seals for perishing, splits or cuts.
    Install new O-ring seals as necessary.

  1. Attach the power steering lines to the power steering gear.
    • Rotate the power steering line clamp counterclockwise.

  1. Attach the power steering line to the clamp.

  1. Install the steering gear heat shield (two bolts).

  1. Install the engine support insulator to transaxle center retaining bolt.

  1. CAUTION:
    CAUTION:Make sure the heat shield is installed to prevent damage to the ball joint.
    Install the heat shield on both sides.

  1. Attach the lower arm ball joint to the wheel knuckle on both sides.

  1. NOTE:
    NOTE:Using a 5 mm Allen key, prevent the ball joint from rotating.
    Attach the stabilizer bar connecting link to the stabilizer bar on both sides.

  1. NOTE:
    NOTE:Install new retaining nuts.
    Attach the tie-rod ends to the wheel knuckle on both sides.
  1. Install the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
Vehicles built up to 12/1998
  1. CAUTION:
    CAUTION:Make sure the road wheels are in straight ahead position.
    Connect the steering column shaft to the steering gear pinion extension.
Vehicles built 12/1998 onwards
  1. WARNING:
    WARNING:Install a new retaining bolt. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Make sure the road wheels are in straight ahead position.
    Connect the steering column shaft to the steering gear pinion extension.
All vehicles
  1. Fill and bleed the power steering system.
    For additional information, refer to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures) /
    Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).

502-02 Full Frame and Body Mounting > < Frame Assembly