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Disassembly and Assembly > < Wheel Knuckle

Mondeo 2001 (10.2000-02.2007)

Front Suspension - Front Strut and Spring Assembly Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Lever, Wheel Knuckle

204-159 (14-039)

Alignment Pins, Subframe

205-316 (15-097A)
General Equipment
Transmission jack

Removal

All vehicles
  1. Remove the wheel and tire. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Detach the brake hose support bracket from the suspension strut.

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

  1. CAUTION:
    CAUTION:Suspend the brake caliper and anchor plate to prevent load being placed on the brake hose.
    Detach the brake caliper and anchor plate from the wheel knuckle.
Vehicles with diesel engine
  1. Remove the engine undershield.
All vehicles
  1. Detach the splash shield from the subframe.

  1. NOTE:
    NOTE:Only one side of the subframe needs to be lowered to detach the lower arm ball joint from the wheel knuckle.
    Using a suitable transmission jack, support the side of the subframe to be lowered.

  1. Remove the subframe rear retaining bolt and the subframe rear bracket retaining bolts, on the side the strut and spring assembly is being removed (right-hand side shown).
  1. Loosen the subframe rear retaining bolt and the subframe rear bracket retaining bolts, on the opposite side, by five turns.

  1. Remove the subframe front retaining bolt, on the side the strut and spring assembly is being removed (right-hand side shown).
  1. Loosen the subframe front retaining bolt, on the opposite side, by five turns.

  1. Lower the subframe.

  1. CAUTION:
    CAUTION:To prevent damage to the lower arm hydro-bushing, make sure the subframe is lowered before detaching the lower arm ball joint from the wheel knuckle.
    Remove the lower arm ball joint to wheel knuckle pinch bolt and nut.

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

  1. Remove the wheel knuckle to suspension strut pinch bolt.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    Using the special tool, detach the wheel knuckle from the suspension strut.

  1. Remove the strut and spring assembly top mount brace cover.

  1. CAUTION:
    CAUTION:With the aid of another technician, support the strut and spring assembly.
    Remove the strut and spring assembly.

Installation

All vehicles
  1. NOTE:
    NOTE:Make sure the arrow and the white line on the top mount are pointing to the front of the vehicle.
    Install the strut and spring assembly.

  1. Tighten the strut and spring assembly top mount retaining nuts.

  1. Install the strut and spring assembly top mount brace cover.

  1. Attach the wheel knuckle to the suspension strut.

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

  1. CAUTION:
    CAUTION:The lower arm pinch bolt must be installed from the rear of the wheel knuckle.
    Attach the lower arm ball joint to the wheel knuckle.

  1. Using the special tool and a suitable washer, align the subframe.
    1. Insert the washer, with inside diameter 22 mm, outside diameter 44 mm and height 5 mm, into the subframe above the lower alignment hole.
    1. Insert the alignment pin through the subframe 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. CAUTION:
    CAUTION:While tightening the subframe retaining bolts, make sure the subframe does not move.
    Install the subframe rear retaining bolt and the subframe bracket retaining bolts, on the side the strut and spring assembly was installed (right-hand side shown).

  1. Tighten the subframe rear retaining bolt and the subframe bracket retaining bolts, on the opposite side (left-hand side shown).

  1. CAUTION:
    CAUTION:While tightening the subframe retaining bolts, make sure the subframe does not move.
    Install the subframe front retaining bolt, on the side the strut and spring assembly was installed (right-hand side shown).

  1. Tighten the subframe front retaining bolt, on the opposite side (left-hand side shown).
    • Lower and remove the transmission jack.

  1. Remove the special tools.

  1. Attach the splash shield to the subframe.
Vehicles with diesel engine
  1. Install the engine undershield.
All vehicles
  1. Attach the brake caliper and anchor plate to the wheel knuckle.

  1. NOTE:
    NOTE:Use a 5 mm Allen key to prevent the ball joint from rotating.
    Attach the stabilizer bar connecting link to the suspension strut.

  1. Attach the brake hose support bracket to the suspension strut.
  1. Install the wheel and tire. For additional information, refer to Section  204-04 Wheels and Tires.
  1. Check the toe setting and adjust as necessary. For additional information, refer to Section  204-00 Suspension System - General Information.

Disassembly and Assembly > < Wheel Knuckle