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Front Subframe Front Bushing > < 502-00 Uni-Body, Subframe and Mounting System|Specifications

Mondeo 2001 (10.2000-02.2007)

Uni-Body, Subframe and Mounting System - Subframe Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Alignment Pins, Subframe

205-316 (15-097A)

Wrench, Steering Gear

211-270 (13-028)
General Equipment
Transmission jack
Wooden blocks
Materials
Name
Specification
Washer
E830 819 571 

Removal

All vehicles
  1. NOTE:
    NOTE:Make sure the road wheels are in the straight ahead position.
    Centralize the steering.

  1. Using cable ties, support the radiator on both sides.
  1. Remove the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Remove the engine undershield (if equipped).

  1. Remove the radiator splash shield.

  1. Remove the radiator support bracket on both sides.
    1. Remove the hose bracket (if equipped).
    1. Remove the radiator support bracket.

  1. Detach the stabilizer bar connecting link from the suspension strut on both sides.

  1. Detach the radiator cooling fan wiring harness from the subframe.
Vehicles with direct fuel injection
  1. Disconnect the heated oxygen sensor (HO2S) electrical connectors.
All except vehicles with diesel engine
  1. Disconnect the catalyst monitor sensor electrical connector.

  1. Detach the catalyst monitor sensor wiring harness from the subframe.
Vehicles with 1.8L, 2.0L or diesel engine
  1. Remove the exhaust flexible pipe.
    For additional information, refer to: Exhaust Flexible Pipe (309-00 Exhaust System, Removal and Installation).
Vehicles with 2.5L engine
  1. Remove the dual converter Y-pipe.
    For additional information, refer to: Dual Catalytic Converter Y-Pipe (309-00 Exhaust System, Removal and Installation).
Vehicles with 3.0L engine
  1. Remove the exhaust flexible pipes.
    For additional information, refer to: Exhaust Flexible Pipe (309-00 Exhaust System, Removal and Installation).
Vehicles with high intensity discharge headlamps
  1. Disconnect the headlamp leveling sensor electrical connector.

  1. Detach the headlamp leveling sensor wiring harness from the subframe.
All vehicles
  1. Remove the engine support insulator.

  1. Using two suitable wooden blocks and a suitable transmission jack, support the subframe.

  1. CAUTION:
    CAUTION:To prevent damage to the lower arm hydro-bushing, do not pull down on the lower arm.
    Remove the lower arm ball joint to wheel knuckle pinch bolt and nut on both sides.
Vehicles with electric booster heater
  1. Detach the electric booster heater from the subframe.
All vehicles
  1. Remove the subframe rear retaining bolt and the subframe bracket retaining bolts on both sides.

  1. Remove the subframe front retaining bolt on both sides.

  1. CAUTION:
    CAUTION:To prevent damage to the lower arm hydro-bushing, make sure the subframe is lowered uniformly.
    Using the transmission jack, lower the subframe approximately 150 mm.

  1. Remove the fender splash shield on both sides.

  1. Using the special tool, detach the steering gear from the subframe.
    • Using cable ties, support the steering gear.

  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 on both sides.
    • Remove the heat shield.

  1. Using the transmission jack, lower the subframe uniformly.

  1. NOTE:
    NOTE:If installing a new crossmember, remove the stabilizer bar.
    Remove the stabilizer bar (two bolts each side).

  1. NOTE:
    NOTE:If installing a new crossmember, remove the lower arms.
    Remove the lower arms (two bolts each side).

Installation

All vehicles
  1. NOTE:
    NOTE:If installing a new crossmember, install the lower arms.
    NOTE:
    NOTE:Use new bolts and nuts.
    Install the lower arms.
    1. Install the lower arm front retaining bolt in two stages.

        2. 1. Stage 1: 80 Nm.

        2. Stage 2: 60 degrees.

    1. Install the lower arm rear retaining bolt in two stages.

        2. 1. Stage 1: 90 Nm.

        2. Stage 2: 60 degrees.

  1. NOTE:
    NOTE:If installing a new crossmember, install the stabilizer bar.
    Install the stabilizer bar (two bolts each side).

  1. Using the transmission jack, position the subframe and lift it towards the body until the distance of the subframe to body is approximately 150 mm.

  1. CAUTION:
    CAUTION:Make sure the heat shield is installed to prevent damage to the ball joint.
    Attach the lower arm ball joint to the wheel knuckle on both sides.
    • Install the heat shield.

  1. Using the special tool, attach the steering gear to the subframe.
    • Remove the cable ties.

  1. Install the fender splash shield on both sides.

  1. Using the transmission jack, position the subframe.

  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 both sides.

  1. CAUTION:
    CAUTION:While tightening the subframe retaining bolts, make sure the subframe does not move.
    Install the subframe front retaining bolt on both sides.

  1. Remove the special tool and the washer.
Vehicles with electric booster heater
  1. Attach the electric booster heater to the subframe.
All vehicles
  1. NOTE:
    NOTE:The lower arm pinch bolt must be installed from the rear.
    Install the lower arm ball joint to wheel knuckle pinch bolt and nut on both sides

  1. Install the engine support insulator.
Vehicles with high intensity discharge headlamps
  1. Attach the headlamp leveling sensor wiring harness to the subframe.

  1. Connect the headlamp leveling sensor electrical connector.
Vehicles with 1.8L, 2.0L or diesel engine
  1. Install the exhaust flexible pipe.
    For additional information, refer to: Exhaust Flexible Pipe (309-00 Exhaust System, Removal and Installation).
Vehicles with 2.5L engine
  1. Install the dual converter Y-pipe.
    For additional information, refer to: Dual Catalytic Converter Y-Pipe (309-00 Exhaust System, Removal and Installation).
Vehicles with 3.0L engine
  1. Install the exhaust flexible pipes.
    For additional information, refer to: Exhaust Flexible Pipe (309-00 Exhaust System, Removal and Installation).
All except vehicles with diesel engine
  1. Attach the catalyst monitor sensor wiring harness to the subframe.

  1. Connect the catalyst monitor sensor electrical connector.
Vehicles with direct fuel injection
  1. Connect the heated oxygen sensor (HO2S) electrical connectors.
All vehicles
  1. Attach the radiator cooling fan wiring harness to the subframe.

  1. Install the stabilizer bar connecting link to the suspension strut on both sides.

  1. Install the radiator support bracket on both sides.
    1. Install the radiator support bracket.
    1. Install the hose bracket (if equipped).

  1. Install the radiator splash shield.

  1. Install the engine undershield (if equipped).
  1. Install the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

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

Front Subframe Front Bushing > < 502-00 Uni-Body, Subframe and Mounting System|Specifications