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General Procedures > < 204-00 Suspension System - General Information|Specifications

Transit 2000.5 (01.2000-05.2006)

Suspension System - General Information - Suspension System Transit 2000.5 (01/2000-05/2006)
Diagnosis and Testing

Special Tool(s)

Alignment Pins, Subframe

205-316 (15-097A)

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical
  • Tire pressure(s)
  • Wheels and tires
  • Wheel knuckles
  • Tie-rod ends
  • Front suspension lower arm ball joints
  • Front suspension lower arm bushings
  • Front strut and spring assemblies
  • Front and rear stabilizer bar and connecting links
  • Rear springs
  • Rear shock absorbers
  • Rear suspension beam axle and bushings
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
Drift left or right
*
Vehicle attitude incorrect (front or rear is high or low).
*
CHECK for abnormal loading, spring sag or non-standard springs.
*
Steering gear or linkage worn or damaged.
*
CHECK the steering system.
REFER to: Steering System (211-00 Steering System - General Information, Diagnosis and Testing).
*
Brake system.
*
CHECK the brake system.
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
*
Incorrect wheel alignment.
*
ADJUST the wheel alignment. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Incorrect front crossmember alignment.
*
Using the special tool, CHECK the front crossmember alignment.
*
Worn front wheel bearings.
*
CHECK the wheel bearings.
REFER to: Wheel Bearing Inspection (204-00 Suspension System - General Information, General Procedures).
*
Wheels and tires.
*
GO to Pinpoint Test A.
Steering wheel off-center
*
Vehicle attitude incorrect (front or rear is high or low).
*
CHECK for abnormal loading, spring sag or non-standard springs.
*
Steering gear or linkage worn or damaged.
*
CHECK the steering system.
REFER to: Steering System (211-00 Steering System - General Information, Diagnosis and Testing).
*
Lower arm ball joint.
*
CARRY OUT the Ball Joint Component Test in this section.
*
Incorrect wheel alignment.
*
ADJUST the wheel alignment. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
Tracks incorrectly
*
Incorrect front suspension toe castor or camber angles.
*
CHECK the wheel alignment. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
INSTALL new suspension components as necessary.
*
Front or rear suspension damage.
*
CHECK and INSTALL new suspension components as necessary.
Rough ride
*
Front strut and spring assemblies.
*
CARRY OUT the Strut or Shock Absorber Testing component test in this procedure.
*
CHECK and INSTALL new suspension components as necessary.
REFER to: Front Strut and Spring Assembly (204-01 Front Suspension, Disassembly and Assembly).
*
Front or rear stabilizer bar, connecting links or bushings.
*
CHECK and INSTALL new suspension components as necessary. REFER to:
Front Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link (204-01 Front Suspension, Removal and Installation),
Front Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link (204-01 Front Suspension, Removal and Installation),
Rear Stabilizer Bar (204-02 Rear Suspension, Removal and Installation).
*
Front suspension lower arm bushings.
*
INSTALL new lower arm bushings.
REFER to: Lower Arm Bushing (204-01 Front Suspension, Removal and Installation).
*
Rear suspension bushings.
*
CHECK and INSTALL new components as necessary.
*
Rear shock absorbers.
*
CARRY OUT the Strut or Shock Absorber Testing component test in this procedure.
*
CHECK and INSTALL new suspension components as necessary.
Excessive noise
*
Front strut and spring assembly or rear shock absorber and spring upper mounting bolts or nuts loose or broken.
*
GO to Pinpoint Test B.
*
Shock absorbers leaking
*
GO to Pinpoint Test B.
*
Shock absorber performance incorrect
*
GO to Pinpoint Test B.
*
Stabilizer bar components
*
GO to Pinpoint Test B.
*
Strut and spring assembly and springs
*
GO to Pinpoint Test B.
*
Springs moving on spring upper or lower seats
*
GO to Pinpoint Test B.
*
Suspension bushings
*
GO to Pinpoint Test B.
*
Lower arm ball joint
*
GO to Pinpoint Test B.
*
Worn front wheel bearings
*
GO to Pinpoint Test B.
*
Wheels and tires
*
GO to Pinpoint Test B.
Incorrect tire wear
*
Front or rear suspension damage.
*
CHECK and INSTALL new suspension components as necessary.
*
Incorrect wheel alignment.
*
CHECK the wheel alignment. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
Vibration
*
Damaged or worn front wheel bearings.
*
CHECK the front wheel bearings.
REFER to: Wheel Bearing Inspection (204-00 Suspension System - General Information, General Procedures).
*
Wheels and tires.
*
CHECK the tires. BALANCE or INSTALL new tires as necessary.
*
Incorrect wheel alignment.
*
ADJUST the wheel alignment. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Steering gear or linkage worn or damaged.
*
CHECK the steering system.
REFER to: Steering System (211-00 Steering System - General Information, Diagnosis and Testing).
*
Front strut and spring assemblies.
*
CARRY OUT the Strut or Shock Absorber Testing component test in this procedure.
*
CHECK and INSTALL new suspension components as necessary. REFER to: (204-01 Front Suspension)
Driver Side Strut and Spring Assembly (Removal and Installation),
Passenger Side Strut and Spring Assembly (Removal and Installation).
*
Damaged front suspension lower arm(s).
*
INSTALL a new lower arm(s).
REFER to: Lower Arm (204-01 Front Suspension, Removal and Installation).

Pinpoint Tests

PINPOINT TEST A : DRIFT LEFT OR RIGHT
WARNING:
WARNING:To avoid personal injury due to the loss of vehicle control, the inspection should be carried out by two people to maintain safe driving conditions. Adequate grip should always be maintained on the steering wheel. Failure to follow these instructions may result in personal injury.
NOTE:
NOTE:The following conditions must be met when evaluating the vehicle.
NOTE:
NOTE:The tire swapping procedures are for bi-directional rotating tires only.
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
  • Swap the front left-hand wheel and tire assembly with the front right-hand wheel and tire assembly.
  • Road test the vehicle.

Does the vehicle drift?
Yes
GO to A2.
No
The concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
1
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
  • Swap the rear left-hand wheel and tire assembly with the rear right-hand wheel and tire assembly.
  • Road test the vehicle.

Does the vehicle drift?
Yes
GO to A3.
No
The concern has been corrected.
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
1
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
  • Swap the front left-hand wheel and tire assembly with the rear left-hand wheel and tire assembly.
  • Road test the vehicle.

Does the vehicle drift?
Yes
GO to A4.
No
The concern has been corrected.
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
1
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
  • Swap the front right-hand wheel and tire assembly with the rear right-hand wheel and tire assembly.
  • Road test the vehicle.

Does the vehicle drift?
Yes
GO to A5.
No
The concern has been corrected.
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
1
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
  • Swap the front left-hand wheel and tire assembly with the rear right-hand wheel and tire assembly.
  • Road test the vehicle.

Does the vehicle drift?
Yes
GO to A6.
No
The concern has been corrected.
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
1
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
  • Swap the front right-hand wheel and tire assembly with the rear left-hand wheel and tire assembly.
  • Road test the vehicle.

Does the vehicle drift?
Yes
GO to A7.
No
The concern has been corrected.
A7: INSTALL NEW TIRES
NOTE:
NOTE:Install new tires only once.
1
Install new tires to the four road wheels.
  • Road test the vehicle.

Does the vehicle drift?
Yes
Verify possible sources. Refer to the Symptom Chart.
No
The concern has been corrected.

PINPOINT TEST B : EXCESSIVE NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS AND NUTS
1
Inspect the strut and spring assembly and shock absorber mounting bolts and nuts.

Are the mounting bolts or nuts loose or broken?
Yes
TIGHTEN or INSTALL new mounting bolts and nuts. REFER to:
Specifications (204-01 Front Suspension, Specifications),
Specifications (204-02 Rear Suspension, Specifications).
No
GO to B2.
B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS
NOTE:
NOTE:Make sure that the oil is not from another source.
1
Inspect the strut and spring assemblies and shock absorbers for signs of oil weepage or leaks. Refer to weepage and leakage conditions in the Strut or Shock Absorber Testing component test in this procedure.

Are the struts or shock absorbers leaking?
Yes
INSTALL new struts or shock absorbers as necessary. REFER to: (204-01 Front Suspension)
Driver Side Strut and Spring Assembly (Removal and Installation),
Passenger Side Strut and Spring Assembly (Removal and Installation).
No
GO to B3.
B3: INSPECT THE SPRINGS AND STABILIZER BAR(S)
1
Inspect the springs and stabilizer bar(s) for damage.

Are the springs or stabilizer bar(s) damaged?
Yes
INSTALL new springs or stabilzer bar(s). REFER to:
Front Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link (204-01 Front Suspension, Removal and Installation),
Front Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link (204-01 Front Suspension, Removal and Installation),
Driver Side Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation),
Passenger Side Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation),
Rear Stabilizer Bar (204-02 Rear Suspension, Removal and Installation),
Spring (204-02 Rear Suspension, Removal and Installation).
No
GO to B4.
B4: INSPECT THE SUSPENSION BUSHINGS
1
Inspect the suspension bushings for excessive wear or damage.

Are the bushings worn or damaged?
Yes
INSTALL new components as necessary. REFER to:
Front Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link (204-01 Front Suspension, Removal and Installation),
Front Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link (204-01 Front Suspension, Removal and Installation),
Lower Arm Bushing (204-01 Front Suspension, Removal and Installation),
Driver Side Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation),
Passenger Side Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation),
Rear Stabilizer Bar (204-02 Rear Suspension, Removal and Installation).
No
GO to B5.
B5: INSPECT THE SUSPENSION LOWER ARM BALL JOINTS
1
Carry out the Ball Joint Inspection component test in this procedure.

Is the lower arm ball joint or gaiter damaged?
Yes
INSTALL a new lower arm.
REFER to: Lower Arm (204-01 Front Suspension, Removal and Installation).
No
GO to B6.
B6: INSPECT THE WHEEL BEARINGS
1
Check the wheel bearings.
REFER to: Wheel Bearing Inspection (204-00 Suspension System - General Information, General Procedures).

Are the wheel bearings damaged?
Yes
INSTALL a new wheel bearing(s). REFER to: Front Wheel Bearing (204-01 Front Suspension, Removal and Installation).
No
GO to B7.
B7: INSPECT THE WHEELS AND TIRES
1
Check the tires for uneven wear.

Is there uneven tire wear?
Yes
REFER to the symptom chart.
No
GO to B8.
B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING INTERFACE
1
Loosen the strut and spring assemblies and rear spring mounting bolts and nuts. Tighten the mounting bolts and nuts. REFER to:
Specifications (204-01 Front Suspension, Specifications),
Specifications (204-02 Rear Suspension, Specifications).
  • Carry out a road test.
    REFER to: Road/Roller Testing (100-00 General Information, Description and Operation).

Is the concern still evident?
Yes
GO to B9.
No
Vehicle condition corrected.
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES, REAR SPRING AND SHOCK ABSORBER COMPONENTS
1
Check that the spring is correctly located on the spring seat and has not moved.
2
Disassemble the strut and spring and assembly and inspect the individual components.
REFER to: Front Strut and Spring Assembly (204-01 Front Suspension, Disassembly and Assembly).
3
Inspect the shock absorber top mount for wear or damage.
4
Carry out the Strut or Shock Absorber Testing component test in this procedure.

Are any of the strut and spring assemblies or shock absorber components damaged?
Yes
INSTALL new components as necessary. REFER to:
Driver Side Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation),
Passenger Side Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation),
Spring (204-02 Rear Suspension, Removal and Installation).
No
REINSTALL the strut and spring assemblies, rear spring or shock absorbers. GO to B10.
B10: CARRY OUT A ROAD TEST
1
Carry out a road test.
REFER to: Road/Roller Testing (100-00 General Information, Description and Operation).

Is the concern still evident?
Yes
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).
No
Vehicle condition corrected.

Component Tests

Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)

Jacking (Description and Operation),
Lifting (Description and Operation).

Ball Joint Inspection

  1. Firmly grasp the outer end of the suspension lower arm and try to move it up and down, watching and feeling for any movement. Free movement will usually be accompanied by an audible "click". There should be no free movement.
  1. If there is any free movement, install a new lower arm ball joint. REFER to: (204-01 Front Suspension)
    Lower Arm Ball Joint - RWD (Removal and Installation),
    Lower Arm Ball Joint - FWD (Removal and Installation).
  1. If a new lower arm ball joint is installed it will be necessary to check and adjust the front wheel alignment. REFER to:
    Specifications (204-01 Front Suspension, Specifications),
    Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).

Strut or Shock Absorber Inspection

NOTE:
NOTE:Inspect the struts or shock absorber for signs of oil weepage or leaks. Make sure that the oil is not from another source.

    Weepage:

  • deposits a thin film of oil on the strut and spring assembly or shock absorber.
  • is normally noticed due to a collection of dust on the strut and spring assembly or shock absorber.
  • occurs during the normal running-in period of 4800 - 8050 km. After this period no new signs of oil should be visible.
  • does not require new struts or shock absorbers to be installed.

    Leakage:

  • covers the entire strut and spring assembly or shock absorber with oil.
  • will drip oil onto the surrounding suspension components.
  • requires new struts or shock absorbers to be installed.

Strut or Shock Absorber Testing

NOTE:
NOTE:Struts or shock absorbers must be tested in the vertical position.
  1. Remove both strut and spring assemblies or shock absorbers. The piston rods should extend.
    • Disassemble the strut and spring assemblies.
      REFER to: Front Strut and Spring Assembly (204-01 Front Suspension, Disassembly and Assembly).
  1. Compress the piston rods. Both piston rods should offer the same resistance when compressing.
  1. Compress and release the piston rods. The piston rods should extent equally.
  1. Compress and pull the piston rod in the vertical position. Feel if the resistance force at the point of direction change-over is perceptible without a lag. If a lag is perceptible it is an indication of damper valve damage and new struts or shock absorbers must be installed. REFER to: (204-01 Front Suspension)
    Driver Side Strut and Spring Assembly (Removal and Installation),
    Passenger Side Strut and Spring Assembly (Removal and Installation).

General Procedures > < 204-00 Suspension System - General Information|Specifications