ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

Rear Axle Crossmember - Vehicles With: Ball Joint Stabilizer Bar Link-Fuel Additive Tank > < Front Axle Crossmember Rear Bushing
Uni-Body, Subframe and Mounting System - Rear Axle Crossmember—Vehicles With: Fuel Additive Tank/Solid Stabilizer Bar Link Focus 2004.75 (07/2004-)
Removal and Installation

Securing strap
Transmission jacks
  1. Remove the spring on both sides. For additional information, refer to: Spring (204-02, Removal and Installation).
  1. Remove the evaporative emission canister (if equipped). For additional information, refer to: Evaporative Emission Canister (303-13, Removal and Installation).
  1. Remove the headlamp leveling rear sensor (if equipped). For additional information, refer to: Headlamp Leveling Rear Sensor (417-01, Removal and Installation).

  1. CAUTION:
    CAUTION:Suspend the fuel additive tank to prevent load being placed on the fuel pipes.
    Detach the fuel additive tank from the rear axle crossmember.

  1. Detach the fuel additive tank filler pipe retaining clip from the rear axle crossmember.

  1. Detach the headlamp leveling rear sensor wiring harness from the rear axle crossmember (if equipped).

  1. Detach the headlamp leveling rear sensor wiring harness from the rear axle crossmember and disconnect the electrical connector (if equipped).

8. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Evaporative emission canister heat shield to rear axle crossmember stud (if equipped)
2
-
Evaporative emission canister heat shield to rear axle crossmember retaining bolt (if equipped)

 
Item
Part Number
Description
3
-
Stabilizer bar clamp retaining bolts

 
Item
Part Number
Description
6
-
Front lower arm
See Removal Detail

 
Item
Part Number
Description
8
-
Upper arm
9
-
Rear lower arm adjustment cam nut
See Removal Detail
See Installation Detail
10
-
Rear lower arm to wheel knuckle retaining bolt
11
-
Rear lower arm
See Installation Detail

 
Item
Part Number
Description

 
Item
Part Number
Description
14
-
Rear axle crossmember
See Installation Detail

9. To install, reverse the removal procedure.

  1. Check the toe setting and adjust as necessary. For additional information, refer to: (204-00 Suspension System - General Information)
    Specifications (Specifications),
    Rear Toe Adjustment (General Procedures).

  1. NOTE:
    NOTE:Final tightening of the rear lower arm adjustment cam nut must be carried out when the vehicle weight is on the road wheels.
    Tighten the rear lower arm adjustment cam nut on both sides.

Removal Details

Item 5 : Front lower arm retaining bolts

  1. Fabricate two 20 mm wide by 113 mm long spacers.

  1. CAUTION:
    CAUTION:Both sides of the suspension must be set to the design height setting.
    Using two transmission jacks and wooden blocks, raise the suspension to the design height setting on both sides.
    • Position the transmission jack and the wooden block as shown (left-hand side shown).

  1. NOTE:
    NOTE:The spacer must be positioned exactly as shown.
    Install the spacer on both sides.
    1. Remove the bump stop.
    1. Install the spacer between the rear lower arm and the rear axle crossmember making sure that the spacer is in a vertical plane.

Item 6 : Front lower arm

CAUTION:
CAUTION:The front lower arms are marked FRONT. Make a note of the position of the front lower arms to aid installation.

Item 7 : Upper arm retaining bolts

NOTE:
NOTE:Make a note of the position of the upper arms to aid installation.

Item 9 : Rear lower arm adjustment cam nut

  1. Mark the position of the rear lower arm adjustment cam to the rear axle crossmember on both sides.

Item 12 : Exhaust hanger insulator

NOTE:
NOTE:Support the exhaust muffler and tailpipe assembly.

Item 13 : Rear axle crossmember retaining bolts

  1. Using a transmission jack, support the rear axle crossmember.
  1. WARNING:
    WARNING:Make sure that the rear axle crossmember is secured to the transmission jack. Failure to follow this instruction may result in personal injury.
    Using a securing strap, secure the rear axle crossmember to the transmission jack.

Installation Details

Item 14 : Rear axle crossmember

  1. Using a transmission jack, support the rear axle crossmember.
  1. WARNING:
    WARNING:Make sure that the rear axle crossmember is secured to the transmission jack. Failure to follow this instruction may result in personal injury.
    Using a securing strap, secure the rear axle crossmember to the transmission jack.

  1. Locate the rear axle crossmember.

Item 13 : Rear axle crossmember retaining bolts

  1. Install the rear axle crossmember retaining bolts on both sides.
  1. Remove the securing strap.
  1. Lower and remove the transmission jack.

Item 11 : Rear lower arm

  1. CAUTION:
    CAUTION:Both sides of the suspension must be set to the design height setting.
    Using two transmission jacks and wooden blocks, raise the suspension to the design height setting on both sides.
    • Position the transmission jack and the wooden block as shown (left-hand side shown).

  1. NOTE:
    NOTE:The spacer must be positioned exactly as shown.
    Install the spacer on both sides.
    • Install the spacer between the rear lower arm and the rear axle crossmember making sure that the spacer is in a vertical plane.

Item 9 : Rear lower arm adjustment cam nut

  1. NOTE:
    NOTE:Do not fully tighten the rear lower arm adjustment cam nut at this stage.
    NOTE:
    NOTE:Align the mark on the rear lower arm adjustment cam to the mark on the rear axle crossmember.
    Install the rear lower arm adjustment cam nut on both sides.

Item 4 : Stabilizer bar

  1. Lower the suspension from the design height setting on both sides.
    1. Remove the spacer.
    1. Install the bump stop.
  1. Position the stabilizer bar.

Rear Axle Crossmember - Vehicles With: Ball Joint Stabilizer Bar Link-Fuel Additive Tank > < Front Axle Crossmember Rear Bushing