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

Fiesta 1996 (08.1995-02.2002)

Suspension System - General Information - Suspension System Fiesta 1996 (08/1995-02/2002)
Diagnosis and Testing

CAUTION:
CAUTION:Make sure the tires are inflated to their correct pressures before and after this check is completed.

Vibration, roughness, tramp, shimmy and thump may be caused by excessive tire or wheel runout, worn or cupped tires, or wheel and tire imbalance.

These conditions may also be caused by rough or undulating road surfaces. Driving the vehicle on different types of road surfaces will indicate if the road surfaces are actually causing the conditions.

Do not immediately suspect the tires when attempting to diagnose a vibration concern. Other sources of vibration include:

  • Loose or worn front wheel bearing.
  • Loose or worn suspension or steering components.
  • Excessive front brake disc runout.
  • Loose engine or transaxle supports.
  • Engine driven accessories.

This section covers those vibrations related to the suspension, tires and wheels.

A thumping noise usually means that the tire has flat or soft spots making a noise as they slap the roadways. Tire whine can be distinguished from axle noise because axle noise diminishes or changes according to load or speed. Tire noise remains the same over a range of speeds.

To verify that tire noise is not associated with shake or vibration, over inflate the tires one at a time and check for a change in the sound. The pitch or whine will change as the increased pressure changes the tire frequency.

Check for other types of vibration. REFER to Section  100-04 Noise, Vibration and Harshness.

Inspection and Verification

A vibration diagnostic procedure always begins with a road test. REFER to Section  100-04 Noise, Vibration and Harshness. The road test and customer interview (if available) will provide much of the information needed to find the source of a vibration.

During the road test, drive the vehicle on a road that is smooth and free of undulations. If a vibration is apparent, note and record the following:

  • The speed at which the vibration occurs.
  • What type of vibration occurs in each speed range – mechanical or audible.
  • How the vibration is affected by changes in engine torque, vehicle speed and engine speed.
  • Type of vibration sensitivity – torque sensitive, vehicle speed sensitive, or engine speed sensitive.

If the road test indicates the vibration is related to the tires or wheels, use the Tire Wear Condition Chart to help pinpoint the cause of the concern. If the road test indicates that there is tire whine but no shake or vibration, the noise originates with the contact between the tire and the road surface.

Use the following explanation of terms to help isolate the source of the vibration:

Torque Sensitive

This means that the condition can be improved or worsened by accelerating, decelerating, coasting or maintaining a steady vehicle speed.

Vehicle Speed Sensitive

This means that the vibration always occurs at the same vehicle speed and is not affected by the application of engine torque, engine speed, or transaxle gear.

Engine Speed Sensitive

This means that the vibration occurs at varying vehicle speeds when a different transaxle gear is selected and the engine speed is constant. It can sometimes be isolated by increasing or decreasing engine speed with the transaxle in NEUTRAL or by stall testing with the transaxle in gear. If the condition is engine speed sensitive, the condition is not related to tires.

Front End

NOTE:
NOTE:Do not check or carry out a front suspension alignment without first making the following inspection for front end damage or wear.
  1. Check for specified air pressure in all four tires.
  1. Raise and support the front of the vehicle. REFER to Section  100-02 Jacking and Lifting. Check the front suspension ball joints and mounts for looseness, wear and damage. For additional information refer to Ball Joint - Lower, Inspection in this section. Tighten all loose nuts and bolts to specification. When parts are worn install new parts. REFER to Section  204-01 Front Suspension.
  1. Check the steering gear mountings and tie-rod connections for tightness. Tighten all mountings to specification. If tie-rod ends are worn or bent, install new parts. REFER to Section  211-02 Power Steering.
  1. Remove the front wheels. Check the wheels for out-of-round and bent rims. Balance wheel and tire assemblies on high-speed balancing equipment.
  1. Check action of suspension units and the condition of their attachment. Refer to Suspension Unit Checks. A sticking or binding suspension unit may not allow the vehicle to settle in a normal level position, possibly affecting the front wheel alignment.

Ball Joint – Lower, Inspection

  1. Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  1. Firmly grasp the outer end of the lower suspension 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 ball joint. REFER to Section  204-01 Front Suspension.
  1. If a new ball joint is installed it will be necessary to check and adjust the front wheel alignment. Refer to General Procedures.

Suspension Unit Checks

All vehicles are equipped with low-pressure gas pressurized hydraulic suspension units. These suspension units are not adjustable or refillable.

  1. Oil Leak: A light film of oil (seepage) on the upper portion of the front or rear suspension unit is permissible and is a result of correct suspension unit lubrication. Seepage is a condition in which a thick film of oil may be deposited on the suspension unit outer tube (body) and is normally noticed due to the collection of dust in this area. Suspension units which exhibit this seepage condition are functional units and new parts should not be installed. Leakage is a condition in which the entire suspension unit body is covered with oil and the oil will drip from the suspension unit onto the pavement.

If this condition exists:

  • Make sure that fluid observed is not from sources other than the suspension unit.
  • When the unit is worn or damaged install a new suspension unit.
  1. Vehicle sag: Many new front or rear suspension units are installed in an effort to solve a vehicle sag concern. Suspension units by design are hydraulic damping units only and unlike suspension springs, do not support any suspension loads. Therefore, installing a new suspension unit will not correct a vehicle sag concern.
  1. NOTE: New suspension units do not need to be installed in pairs when only one unit is worn or damaged.

Installing new suspension units in pairs: In the past it was recommended that new suspension units or springs be installed in pairs if one unit became unserviceable. Improved sealing, due to new technology and improved manufacturing quality checks, have added to the functional reliability of suspension units. Installation of new front suspension units or spring assemblies and rear suspension units or springs in pairs is not necessary.

Vehicle Inspection

  1. Check all tires for correct inflation pressure.
  1. Check tire condition to confirm correct front end alignment, tire balance and overall tire condition such as separation or bulges.
  1. Check the vehicle for optional suspension equipment such as heavy-duty handling or trailer tow suspensions. These suspensions will have a firmer ride feeling than standard suspensions.
  1. Check vehicle attitude for evidence of possible overload or sagging. Check luggage compartment area of heavy objects.
  1. Road test the vehicle to confirm customer concern after performing the above steps.

Lift Check

  1. Noise: Noise can be caused by loose suspension or suspension unit attachments. Verify that all attachments for the suspension components are tight. If suspension units have a damaged integral lower mounting bushing, install new units. Check front and rear suspension units for external damage.
  1. Bottom/Hopping: Check condition of the rubber suspension travel stops (front suspension unit jounce bumper). Install new parts if worn or missing. Examine for evidence of previous overload which may have damaged components.
  1. Only install one new unit in place of the worn or damaged suspension unit. Suspension units do not need to be installed in pairs, unless both units are worn or damaged.

Bench Test

The suspension units are gas-pressurized which results in them being fully extended when not restrained. If a suspension unit does not fully extend, it is damaged and a new unit should be installed. Check the overall length. If the suspension unit does not meet the overall length requirements, there is a good indication something internal is out of specification and a new suspension unit should be installed.

With the suspension unit in the normal upright position, compress it and allow it to extend three times to purge the pressure chamber of any gas that may have been introduced during handling.

CAUTION:
CAUTION:If the combination dust shield/jounce bumper has been removed from the suspension unit, care must be taken to avoid excessive bottoming of the rod during the compression stroke to avoid internal damage.

Place the suspension unit right side up in a vise. Hand stroke the suspension unit as fast as possible using as much travel as possible. Action should become smooth and uniform throughout each stroke. Higher resistance on extension than on compression is normal.

The following conditions are abnormal:

  • A lag or skip at reversal of travel near mid-stroke when the suspension unit is correctly aligned and in the installed position.
  • Seizing.
  • Noise, other than a faint swish, such as a clicking upon fast stroke reversal.
  • Excessive fluid leakage.
  • With the rod fully extended, any lateral motion of the rod in relation to outer suspension unit body.

If the suspension unit action remains erratic after purging air, install a new suspension unit. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).

Rear Suspension

At regulator intervals, the following rear suspension checks should be made:

  1. Check for evidence of fluid leaks on rear suspension units. (A light film of fluid is permissible. Verify fluid is not from other sources).
  1. Check the rear suspension unit operation.
  1. Check the condition of the upper and lower rear suspension bushings.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Wander/pull/drift
*
Excessive side to side difference in caster or camber angles.
*
CARRY OUT wheel alignment. Refer to General Procedures in this section.
*
Toe setting out of specification.
*
CARRY OUT wheel alignment. Refer to General Procedures in this section.
*
Vehicle ride height incorrect (front or rear, high or low).
*
CHECK for abnormal loading, spring sag or non-standard springs.
*
Steering gear or tie-rods worn or damaged.
*
CHECK the steering system. REFER to Section  211-00 Steering System - General Information.
*
Worn, damaged or defective tire(s).
*
INSPECT the tires. REFER to Section  204-04 Wheels and Tires.
Hard steering
*
Excessive positive caster angle.
*
CARRY OUT wheel alignment. Refer to General procedures in this section.
*
Vehicle ride height incorrect (front or rear, high or low).
*
CHECK for abnormal loading, spring sag or non-standard springs.
*
Steering gear or tie-rods worn or damaged.
*
CHECK the steering system. REFER to Section  211-00 Steering System - General Information.
*
Front suspension lower arm ball joint worn or damaged.
*
REFER to the Service Procedures in this section.
*
Damaged tires or unbalanced wheels.
*
CHECK the tires. REFER to Section  204-04 Wheels and Tires.
*
Insufficient power steering assist.
*
CHECK the power steering system. REFER to Section  211-02 Power Steering.
Brake pull
*
Unequal tire pressures.
*
INFLATE the tires to the correct pressures. REFER to Section  204-04 Wheels and Tires.
*
Brake system failure.
*
CHECK the brakes. REFER to Section  206-00 Brake System - General Information.
Shimmy or vibration
*
Wheel tire imbalance, damage or excessive runout.
*
CHECK the tires. REFER to Section  204-04 Wheels and Tires.
*
Front wheel driveshaft(s) worn or damaged.
*
CHECK the front wheel halfshafts. REFER to Section  205-04 Front Drive Halfshafts.
*
Steering system damaged or worn.
*
CHECK the steering system. REFER to Section  211-00 Steering System - General Information.
*
Suspension unit assembly loose, worn or damaged.
*
CHECK the suspension unit assemblies. Refer to the procedure in this section.
*
Loose suspension unit assembly mounting.
*
TIGHTEN components to specification. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Damaged or worn front suspension lower arm ball joint.
*
INSTALL a new front suspension lower arm ball joint. REFER to Section  204-01 Front Suspension.
*
Damaged, loose or worn front suspension lower arm mounting bolt bushing.
*
INSTALL a new front suspension lower arm mounting bolt bushing. REFER to Section  204-01 Front Suspension.
*
Damaged or worn stabilizer bar end bushings (if equipped).
*
INSTALL new stabilizer bar end bushings or connecting links. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Damaged, loose or worn rear suspension and bushings.
*
INSTALL new rear suspension and bushings as necessary. REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension.
*
Damaged or worn wheel bearing.
*
INSTALL a new wheel bearing. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
Crabbing
*
Rear suspension damage.
*
REPAIR or INSTALL new rear suspension components as necessary. REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension.
*
Caster angle out of specification.
*
CARRY OUT wheel alignment. Refer to the procedure in this section.
Bump steer
*
Worn, loose or damaged steering gear mounting brackets and bushings.
*
REPAIR or INSTALL new mounting brackets and bushings as necessary. REFER to Section  211-02 Power Steering.
*
Loose, worn or damaged front suspension unit(s).
*
REPAIR or INSTALL new suspension units as necessary. REFER to Section  204-01 Front Suspension.
Front/rear suspension noises
*
Loose, worn or damaged suspension unit mounting components.
*
REPAIR or INSTALL new suspension unit mounting components as necessary. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Worn or damaged wheel bearings.
*
CHECK the wheel bearings. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
Body rolls
*
Worn, missing or damaged front stabilizer bar connecting links or bushings (if equipped).
*
INSTALL new front stabilizer bar connecting links or bushings. REFER to Section  204-01 Front Suspension.
*
Damaged or loose front suspension lower arm mounting bolt bushing.
*
REPAIR or INSTALL a new front suspension lower arm mounting bolt bushing. REFER to Section  204-01 Front Suspension.
*
Loose, damaged or worn suspension unit(s).
*
CHECK the suspension units. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
Body leans
*
Weak or damaged front or rear coil spring.
*
CHECK the coil springs. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Incorrect tire pressures.
*
ADJUST the tire pressures. REFER to Section  204-04 Wheels and Tires.
Poor riding comfort
*
Weak front or rear coil spring.
*
CHECK the coil springs. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Damaged or worn front or rear suspension unit(s).
*
CHECK the suspension units. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
General drive instability
*
Wheel, tire imbalance, damage or excessive runout.
*
CHECK the tires. REFER to Section  204-04 Wheels and Tires.
*
Toe setting out of specification.
*
CARRY OUT wheel alignment. Refer to General Procedures in this section.
*
Steering system damaged or worn.
*
CHECK the steering system. REFER to Section  211-00 Steering System - General Information.
*
Damaged front suspension lower arm ball joint.
*
INSTALL a new front suspension lower arm ball joint. REFER to Section  204-01 Front Suspension.
*
Weak front or rear coil spring.
*
CHECK the coil springs. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Damaged or worn front or rear suspension unit(s).
*
CHECK the suspension units. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).
*
Damaged, loose or worn rear suspension, bushing or bolts.
*
CHECK the rear suspension. REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension.
*
Damaged or worn stabilizer bar end bushings or connecting links (if equipped).
*
INSTALL new stabilizer bar end bushings or connecting links. REFER to Section  204-01 Front Suspension.
Steering wheel does not return correctly
*
Incorrect wheel alignment.
*
CARRY OUT wheel alignment. Refer to General Procedures in this section.
*
Steering system damaged or worn.
*
CHECK the steering system. REFER to Section  211-00 Steering System - General Information.
*
Damaged or stuck front suspension lower arm ball joint.
*
INSTALL a new front suspension lower arm ball joint. REFER to Section  204-01 Front Suspension.
Steering wheel pulls to one side
*
Wheel, tire imbalance, damage or excessive runout.
*
CHECK the tires. REFER to Section  204-04 Wheels and Tires.
*
Brake system damaged or worn.
*
CHECK the brake system. REFER to Section  206-00 Brake System - General Information.
*
Steering system damaged or worn.
*
CHECK the steering system. REFER to Section  211-00 Steering System - General Information.
*
Incorrect wheel alignment.
*
CARRY OUT wheel alignment. Refer to General Procedure in this section.
*
Damaged or stuck front suspension lower arm ball joint.
*
INSTALL a new front suspension lower arm ball joint. REFER to Section  204-01 Front Suspension.
*
Weak front coil spring.
*
CHECK the front coil springs. REFER to Section  204-01 Front Suspension.
*
Damaged or loose front suspension lower arm mounting bolt bushing.
*
REPAIR or INSTALL a new front suspension lower arm mounting bolt bushing. REFER to Section  204-01 Front Suspension.
Abnormal noise from the suspension system
*
Damaged or stuck front suspension lower arm ball joint.
*
INSTALL a new front suspension lower arm ball joint. REFER to Section  204-01 Front Suspension.
*
Damaged, loose or worn front stabilizer bar components (if equipped).
*
REPAIR or INSTALL new stabilizer bar components. REFER to Section  204-01 Front Suspension. (front).
*
Loose front or rear suspension components.
*
REPAIR or INSTALL new suspension components. REFER to Section  204-01 Front Suspension.
*
Damaged or loose front suspension lower arm mounting bolt bushing.
*
REPAIR or INSTALL a new front suspension lower arm mounting bolt bushing. REFER to Section  204-01 Front Suspension.
*
Loose, damaged or worn suspension unit(s).
*
CHECK the suspension units. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear).

Pinpoint Tests

PINPOINT TEST A : DRIFT LEFT OR RIGHT
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR DRIFT LEFT OR RIGHT
WARNING:
WARNING:To avoid personal injury due to the loss of vehicle control, the inspection should be performed by two people to maintain safe driving conditions. One person should drive while the other checks the time. 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.
1
Check the cold tire pressure
  • Drive the vehicle at 88 km/h (55 mph) on a level and straight road. Drive in the center lane of a three lane highway.
  • Be sure that no crosswinds or gusting breezes are present.
  • Drive the vehicle in both (opposing) directions at least twice.
  • If the vehicle changes one complete 12 foot wide lane within seven seconds, it has a drift.

Does the vehicle have drift?
Yes
GO to A2.
No
GO to Pinpoint Test B.
A2: CHECK THE STEERING LINKAGE
1
Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  • Check the steering linkage for indications of excessive wear or damage.

Is there indication of excessive wear or damage?
Yes
INSTALL new or REPAIR worn or damaged components as necessary. TEST the system for normal operation.
No
GO to A3.
A3: CHECK THE WHEEL ALIGNMENT
1
Check the wheel alignment.

Is the steering wheel straight and the alignment within specification?
Yes
GO to A4.
No
ADJUST the alignment as necessary. TEST the system for normal operation.
A4: CHECK THE TIRES
1
Inspect the tires for excessive wear or damage.

Are the tires excessively worn or damaged?
Yes
INSTALL new tires. TEST the system for normal operation.
No
GO to A5.
A5: ROTATE THE TIRES
1
Raise and support vehicle. REFER to Section  100-01 Identification Codes.
  • Rotate the wheels in a cross pattern.

Does the vehicle drift?
Yes
INSPECT the front suspension components for wear or damage. INSTALL new or REPAIR worn or damaged components as necessary. REFER to Section  204-01 Front Suspension. TEST the system for normal operation.
No
INSTALL new tires. TEST the system for normal operation.

PINPOINT TEST B : STEERING WHEEL OFF-CENTER
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: INSPECT THE STEERING COMPONENTS
1
Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  • Inspect the steering components for excessive wear or damage.

Are the steering components excessively worn or damaged?
Yes
INSTALL new or REPAIR worn components. REFER to Section  211-00 Steering System - General Information.
No
GO to B2.
B2: CHECK THE WHEEL ALIGNMENT
1
Check the wheel alignment.

Is the steering wheel centered and the alignment within specification.
Yes
GO to Pinpoint Test C.
No
ADJUST the alignment as necessary. TEST the system for normal operation.

PINPOINT TEST C : TRACKS INCORRECTLY
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE CASTER ANGLE
1
Check the caster angle.

Is the caster angle within specification?
Yes
GO to C2.
No
CHECK all suspension components for wear or damage. INSTALL new or REPAIR worn or damaged components as necessary. REFER to Section  204-01 Front Suspension. (front). REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear). TEST the system for normal operation.
C2: CHECK THE REAR SUSPENSION
1
Measure the vehicle wheel base left-hand and right-hand.
  • Compare the measurements.

Are the measurements the same?
Yes
GO to Pinpoint Test D.
No
INSPECT the rear suspension components for wear or damage. INSTALL new or REPAIR worn or damaged components as necessary. REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. TEST the system for normal operation.

PINPOINT TEST D : ROUGH RIDE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE SUSPENSION UNITS
1
Make sure the tires are at the correct pressure.
  • Inspect the suspension units for oil leaks or damage.

Are the suspension units leaking or damaged?
Yes
INSTALL new suspension units as necessary. REFER to Section  204-01 Front Suspension. TEST the system for normal operation.
No
Verify the customer concern.

PINPOINT TEST E : EXCESSIVE NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: INSPECT THE SUSPENSION
1
Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  • Inspect the suspension unit mounting bolts.

Are the mounting bolts loose or broken?
Yes
TIGHTEN or INSTALL new suspension unit mounting bolts. REFER to Section  204-01 Front Suspension. (front) REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear). TEST the system for normal operation.
No
GO to E2.
E2: INSPECT THE SPRINGS
1
Inspect the springs for damage.

Are the springs damaged?
Yes
INSTALL new springs. REFER to Section  204-01 Front Suspension. (front) REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. (rear). TEST the system for normal operation.
No
GO to E3.
E3: INSPECT THE FRONT SUSPENSION LOWER ARM
1
Inspect the front suspension lower arm bushings for excessive wear or damage.

Are the front suspension lower arm bushings worn or damaged?
Yes
INSTALL new front suspension lower arm bushings. REFER to Section  204-01 Front Suspension. TEST the system for normal operation.
No
GO to E4.
E4: INSPECT THE BALL JOINT
1
Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  • Firmly grasp the outer end of the lower suspension arm and try to move it up and down. Feel for any free movement. There must be no free movement.

Is there any free movement?
Yes
INSTALL a new ball joint. REFER to Section  204-01 Front Suspension.. TEST the system for normal operation.
No
GO to E5.
E5: INSPECT THE FRONT WHEEL BEARINGS
1
Inspect the front wheel bearings.
  • Rock each front wheel by gripping the top and bottom and alternately pushing and pulling in and out. Feel for excessive looseness of the bearings.
  • Spin each front wheel by hand checking for roughness.

Are the bearings loose or rough?
Yes
INSTALL new wheel bearings as necessary. TEST the system for normal operation.
No
Verify the customer concern.
E6: INSPECT THE TIRES
1
Inspect the tires for uneven wear.

Is there uneven wear?
Yes
INSTALL new tires. CHECK the wheel alignment. TEST the system for normal operation.
No
GO to E5.

PINPOINT TEST F : INCORRECT TIRE WEAR
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
F1: INSPECT THE TIRES
1
Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  • Inspect the tires for uneven wear on inner or outer shoulder, or saw tooth pattern.

Is there uneven tire wear?
Yes
INSTALL new tires if badly worn. CHECK wheel alignment. TEST the system for normal operation.
No
GO to F2.
F2: CHECK FOR CUPPED TIRES
1
Inspect the tires for cupping or dishing.

Are the tires cupped or dished?
Yes
INSTALL new tire(s). BALANCE and ROTATE the tires. REFER to Section  204-04 Wheels and Tires. TEST the system for normal operation.
No
Verify the customer concern.

PINPOINT TEST G : VIBRATION
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
G1: INSPECT THE TIRES
1
Raise and support the vehicle. REFER to Section  100-02 Jacking and Lifting.
  • Inspect the tires for damage or excessive wear.

Are the tires damaged or worn?
Yes
INSTALL new tires. TEST the system for normal operation.
No
GO to G2.
G2: INSPECT THE FRONT WHEEL BEARINGS
1
Inspect the front wheel bearings.
  • Rock each front wheel by gripping the top and bottom and alternately pushing and pulling in and out. Feel for excessive looseness of the bearings.
  • Spin each front wheel by hand, checking for roughness.

Are the bearings loose or rough?
Yes
GO to G3.
No
GO to G4.
G3: MEASURE THE FRONT WHEEL BEARING END PLAY
1
Remove the wheel, the front disc brake caliper and brake disc.
  • Position a dial test indicator gauge with mounting bracket against the front wheel hub.
  • Push and pull the wheel hub by hand in the axial direction and check for end play of the wheel hub and front wheel bearing assembly. There must be no end play.

Is the front wheel bearing end play within limits?
Yes
REFER to the Component Tests in this section and CHECK the ball joint. GO to G4.
No
INSTALL a new wheel hub bearing assembly as necessary. TEST the system for normal operation.
G4: INSPECT THE REAR WHEEL BEARINGS
1
Inspect the rear wheel bearings.
  • Rock each rear wheel by gripping the top and bottom, then alternately push/pull the wheel in and out. Feel for excessive looseness of the bearings.
  • Spin each wheel by hand and check for roughness.

Are the bearings loose or rough?
Yes
GO to G5.
No
GO to G6.
G5: MEASURE THE REAR WHEEL BEARING END PLAY
1
Remove the rear wheel
  • Position a dial test indicator gauge with mounting bracket to the rear brake drum.
  • Push and pull the wheel hub by hand in the axial direction and check for rear wheel bearing end play. There must be no end play.

Is the rear wheel bearing end play within limits?
Yes
GO to G6.
No
INSTALL a new wheel bearing as necessary. REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. TEST the system for normal operation.
G6: MEASURE THE WHEEL/TIRE RUNOUT ON THE VEHICLE
1
Measure the wheel and tire runouts on the vehicle using a radial runout gauge. Assembly runout should be less than 1.14 mm radial and lateral.

Is the measurement in specification?
Yes
GO to G12.
No
GO to G7.
G7: MEASURE THE WHEEL/TIRE RUNOUT OFF THE VEHICLE
1
Measure the wheel and tire from any position that exceeds 1.14 mm radial or lateral. Before removing the wheel, mark the wheel stud and the corresponding stud hole so the wheel can be installed in the same position. Remove the wheel and mount on a wheel balancer. Measure the runout. Wheel and tire runout should be less than 1.14 mm radial and lateral.

Is the measurement in specification?
Yes
GO to G10.
No
GO to G8.
G8: MATCH MOUNTING
1
Mark the high runout location on the tire and also on the wheel. Break the wheel and tire down and rotate the tire 180 degrees (half-way around) on the wheel. Inflate the tire and measure the runouts.

Are the wheels and tires match mounted?
Yes
BALANCE the wheel and tire and INSTALL on the vehicle. TEST the system for normal operation.
No
If the high spot is not within 101.6 mm of the first high spot INSTALL a new tyre. If a high spot is within 101.6 mm of the first high spot on the tire, GO to G9.
G9: MEASURE THE WHEEL RUNOUT
1
Remove the tire and mount the wheel on a wheel balancer. Measure the runout on both flanges. Runout should be less than 1.14 mm radial and lateral.

Is there runout correct?
Yes
LOCATE and MARK the low spot on the wheel and INSTALL the tire matching the high spot on the wheel. BALANCE the assembly. TEST the system for normal operation.
No
INSTALL a new wheel. CHECK the runout on the new wheel. If the new wheel is within limits, LOCATE and MARK the low spot. INSTALL the tire, matching the high spot of the tire with the low spot of the wheel. BALANCE the assembly and INSTALL on the vehicle. TEST the system for normal operation.
G10: REAR HUB AND STUD CIRCLE RUNOUT
1
Measure the drum flange face runout (greater than 0.254 mm), stud circle runout (greater than 0.08 mm) and pilot radial runout (greater than 0.05 mm).

Are the measurements correct?
Yes
GO to G11.
No
INSTALL a new rear hub. REFER to Section  204-02A Rear Suspension / 204-02B Rear Suspension. TEST the system for normal operation.
G11: FRONT HUB AND STUD CIRCLE RUNOUT
1
Remove the front wheel.
  • Remove the front brake disc.
  • Measure the stud circle runout (greater than 0.06 mm) and rotor pilot radial runout (greater than 0.05 mm).

Are the measurements correct?
Yes
CHECK the front brake disc runout. REFER to Section  206-00 Brake System - General Information. TEST the system for normal operation.
No
INSTALL a new hub. REFER to Section  204-01 Front Suspension. TEST the system for normal operation.
G12: WHEEL BALANCE
1
Balance all the wheels. Road test the vehicle.

Is a vibration felt?
Yes
REFER to Section  100-04 Noise, Vibration and Harshness.
No
Verify the customer concern.

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