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Ford Focus RS Workshop Service and Auto Repair Manuals

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Wheel Knuckle - 2.0L Duratec-RS (Zetec) > < Lower Arm - 2.0L Duratec-RS (Zetec)

Front Suspension Stabilizer Bar - 20L Duratec-RS (Zetec) Removal and Installation

Front Suspension - Stabilizer Bar—2.0L Duratec-RS (Zetec) Focus RS 2003 (09/2002-)
Removal and Installation

Special Tool(s)

Alignment Pins, Subframe

205-316 (15-097A)

Separator, Ball Joint

211-020 (13-006)
General Equipment
Transmission Jack

Removal
  1. NOTE:
    NOTE:Make sure the road wheels are in the straight-ahead position.
    Centralize the steering and lock it in position.

  1. Disconnect the steering column shaft from the steering gear pinion extension.
    • Discard the bolt.
  1. Remove the front wheels and tires.
    For additional information, refer to: Wheel and Tire - 2.0L Duratec-RS (Zetec) (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 nuts.

  1. CAUTION:
    CAUTION:Protect the ball joint seal using a soft cloth to prevent damage.
    Using the special tool, detach the tie-rod ends from the wheel knuckles.
    1. Release the tie-rod ends.
    1. Remove and discard the tie-rod end retaining nuts.

  1. NOTE:
    NOTE:Use a 5 mm Allen key to prevent the ball joint from rotating.
    Detach the stabilizer bar connecting links from the stabilizer bar.

  1. CAUTION:
    CAUTION:Protect the ball joint seal using a soft cloth to prevent damage.
    Detach the lower arm ball joints from the wheel knuckles.
    • Remove the heat shields.

  1. Remove the engine rear support insulator to transaxle center bolt.
  1. Using a suitable transmission jack, support the crossmember.

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

  1. CAUTION:
    CAUTION:To prevent damage to the power steering lines, only lower the crossmember sufficently to allow the stabilizer bar to be removed.
    Lower the crossmember.

  1. Remove the stabilizer bar.
    • Remove the bolts.
    • Remove the clamps.

  1. Remove the stabilizer bar bushings.

Installation
  1. CAUTION:
    CAUTION:The stabilizer bar bushings must be located correctly on the flats of the stabilizer bar with no lubricant.
    Install the stabilizer bar bushings on both sides.

  1. Set the stabilizer bar to the design height setting.
    1. Locate the bushing against the spacer on both sides.
    1. Support the stabilizer bar to specification on both sides.

  1. Install the stabilizer bar clamps.
    1. Apply water to the clamps to aid installation.
    1. Press the clamps onto the bushings.

  1. Install the stabilizer bar clamp rear retaining bolts.

  1. NOTE:
    NOTE:Do not fully tighten the stabilizer bar front retaining bolts at this stage.
    Install the stabilizer bar clamp front retaining bolts.

  1. Tighten the stabilizer bar clamp retaining bolts on both sides.
    • Tighten the bolts in two stages:
    • Stage 1: Tighten bolts 1 through 2 to 50 Nm.
    • Stage 2: Tighten bolts 1 through 2 to 70 Nm.
  1. Remove the stabilizer bar supports.

  1. CAUTION:
    CAUTION:Make sure the crossmember ball bearing washers are installed correctly.
    Using the special tool, align the crossmember.
    1. Insert the alignment pins through the crossmember alignment holes and the washer.
    1. Slide the locking plates on top of the washer 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.
  1. Lower and remove the transmission jack.
  1. Remove the subframe alignment pins.

  1. Install the engine rear support insulator center bolt.

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

  1. Attach the lower arm ball joint to the wheel knuckle.

  1. Attach the stabilizer bar connecting links to the stabilizer bar.

  1. WARNING:
    WARNING:Install new tie-rod end retaining nuts. Failure to follow this instruction may result in personal injury.
    Attach the tie-rod ends to the wheel knuckles.
  1. CAUTION:
    CAUTION:Make sure the wheel hubs are in the straight-ahead position, before lowering the vehicle.
    Install the front wheels and tires.
    For additional information, refer to: Wheel and Tire - 2.0L Duratec-RS (Zetec) (204-04 Wheels and Tires, Removal and Installation).

  1. WARNING:
    WARNING:Install a new pinch bolt. Failure to follow this instruction may result in personal injury.
    Connect the steering column shaft to the steering gear pinion extension.

Wheel Knuckle - 2.0L Duratec-RS (Zetec) > < Lower Arm - 2.0L Duratec-RS (Zetec)