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Ford Mondeo (petrol engines). Manual - part 39

Chapter 10 Suspension and steering systems

Front anti-roll bar and links - removal and refitting . . . . . . . . . . . . . .

Front hub and bearings - inspection and renewal . . . . . . . . . . . . . .

Front suspension lower arm - removal, overhaul and refitting . . . . .

Front suspension lower arm balljoint - renewal . . . . . . . . . . . . . . . .

Front suspension strut - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front suspension strut - removal and refitting . . . . . . . . . . . . . . . . .

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering fluid level check . . . . . . . . . . . . . . . . .

See Chapter 1

Power steering gear (all except left-hand-drive models

with ABS) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Power steering gear (left-hand-drive models with ABS) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power steering gear rubber gaiters - renewal  . . . . . . . . . . . . . . . . . . 32
Power steering hydraulic system - bleeding  . . . . . . . . . . . . . . . . . . . 33
Power steering pump - removal and refitting  . . . . . . . . . . . . . . . . . . 34
Rear anti-roll bar and links (Estate models) - removal and refitting  . 20
Rear anti-roll bar and links (Saloon/Hatchback models) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Rear coil spring (Estate models) - removal and refitting . . . . . . . . . . 21
Rear hub and bearings (Estate models) - inspection and renewal . . 17
Rear hub and bearings (Saloon/Hatchback models) -

inspection and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear shock absorber (Estate models) - removal, testing and refitting . 19
Rear suspension crossmember (Estate models) - removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Rear suspension crossmember (Saloon/Hatchback models) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Rear suspension front lower arm (Estate models) - removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Rear suspension knuckle (Estate models) - removal and refitting . . 18
Rear suspension knuckle (Saloon/Hatchback models) - removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Rear suspension lower arms (Saloon/Hatchback models) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Rear suspension rear lower arm (Estate models) - removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Rear suspension strut (Saloon/Hatchback models) - overhaul . . . . . 12
Rear suspension strut (Saloon/Hatchback models) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Rear suspension tie-bar (Estate models) - removal and refitting . . . 25
Rear suspension tie-bar (Saloon/Hatchback models) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Rear suspension upper arm (Estate models) - removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Steering column - removal, inspection and refitting . . . . . . . . . . . . . 28
Steering column flexible coupling - removal and refitting . . . . . . . . . 29
Steering knuckle and hub assembly - removal and refitting . . . . . . .

Steering, suspension and wheel check . . . . . . . . . . . .

See Chapter 1

Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 27
Track rod end - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tyre condition and tyre pressure checks . . . . . . . . . . .

See Chapter 1

Wheel alignment and steering angles - general information . . . . . . . 36

Front wheel alignment

Toe setting:

Tolerance allowed before resetting required . . . . . . . . . . . . . . . . . . . .

0.5 mm to 3.5 mm toe-out (0°05’ to 0°35’ toe-out)

Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm ± 1.0 mm toe-out (0°20’ ± 0°10’ toe-out)

Rear wheel alignment

Toe setting:

Tolerance allowed before resetting required:

Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 mm toe-in to 0.1 mm toe-out (0°38’ toe-in to 0°02’ toe-out)

Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 mm toe-in to 1.3 mm toe-out (0°27’ toe-in to 0°13’ toe-out)

Adjustment setting (if required):

Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 mm ± 1.2 mm toe-in (0°18’ ± 0°12’ toe-in)

Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.7 mm ± 1.2 mm toe-in (0°07’ ± 0°12’ toe-in)

Roadwheels and tyres

Wheel sizes:

Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 x 5 1/2

Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 x 5 1/2 or 15 x 6

Tyre sizes:

Wheel size 14 x 5 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185/65/14 or 195/60VR/14

Wheel size 15 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205/55VR/15

Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1 Specifications

10•1

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult, suitable
for competent DIY
mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

Specifications

Contents

Torque wrench settings

lbf ft

Front suspension

Front subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 to 150

81 to 111

Lower arm balljoint to lower arm (service replacement, bolted on) . . . .

Lower arm balljoint-to-steering knuckle clamp bolt . . . . . . . . . . . . . . .

48 to 60

35 to 44

Lower arm to subframe:

Stage 1 (used components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 1 (new components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slacken completely

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through further 90°

Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-roll bar link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 43

Suspension strut-to-steering knuckle pinch-bolt . . . . . . . . . . . . . . . . . .

Suspension strut upper mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspension strut thrust bearing retaining nut . . . . . . . . . . . . . . . . . . . . .

Driveshaft/hub retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

340

251

Rear suspension (Saloon/Hatchback)

Crossmember mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 to 138

75 to 102

Front lower arm to knuckle and to crossmember . . . . . . . . . . . . . . . . . .

70 to 98

52 to 72

Rear lower arm to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 to 138

75 to 102

Rear lower arm to crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 to 98

52 to 72

Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 to 26

14 to 19

Anti-roll bar link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 to 40

22 to 30

Suspension strut to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 to 98

52 to 72

Drum brake backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 to 54

33 to 40

Disc brake splash shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hub nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

290

181

Tie-bar and tie-bar bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 to 138

75 to 102

Suspension strut upper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . .

23 to 30

17 to 22

Suspension strut upper nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 43

Rear suspension (Estate)

Same as for Saloon/Hatchback, except for the following.
Crossmember mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Front lower arm to knuckle and to crossmember . . . . . . . . . . . . . . . . . .

120

Upper arm to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Upper arm to crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear lower arm to knuckle and to crossmember . . . . . . . . . . . . . . . . . .

Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-roll bar link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hub assembly-to-knuckle retaining bolts . . . . . . . . . . . . . . . . . . . . . . . .

Tie-bar to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Tie-bar bracket to underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Tie-bar to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shock absorber upper mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shock absorber lower mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Steering

Steering gear mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 to 159

84 to 117

Track rod end to steering knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 to 30

18 to 22

Track rod end locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 to 47

25 to 35

Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 to 55

33 to 41

Flexible coupling-to-pinion shaft clamp bolt . . . . . . . . . . . . . . . . . . . . .

23 to 32

17 to 24

Power steering pipe unions to valve body . . . . . . . . . . . . . . . . . . . . . . .

27 to 35

20 to 26

Steering column-to-coupling clamp bolt . . . . . . . . . . . . . . . . . . . . . . . .

20 to 27

14 to 20

Steering column mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 to 27

14 to 20

Steering pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 to 28

15 to 21

Steering pump pressure line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 to 73

42 to 54

Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10•2 Suspension and steering systems

The independent front suspension is of

MacPherson strut type, incorporating coil
springs, integral telescopic shock absorbers,
and an anti-roll bar. The struts are attached to
steering knuckles at their lower ends, and the
knuckles are in turn attached to the lower
suspension arm by balljoints. The anti-roll bar
is bolted to the rear of the subframe, and is
connected to the front suspension struts by
links (see illustration).

On Saloon/Hatchback models, the

independent rear suspension is of
“Quadralink” type, having four mounting
points on each side of the vehicle. The two
lower arms are attached to the rear
suspension knuckle at their outer ends, and to
the rear crossmember at their inner ends. A
tie-bar, located between the bottom of the
knuckle and the floor, counteracts braking
and acceleration forces on each side (see
illustration).

On Estate models, the independent rear

suspension is of “SLA” (Short and Long Arm)
type. This allows a larger load area, since
there are no suspension points projecting into
the luggage area. There are three side arms
on each side: one forged upper arm, and two

1 General information

Suspension and steering systems 10•3

1.1 Front suspension components

1 MacPherson strut
2 Steering knuckle
3 Lower arm

4 Vertical silent bush on

lower arm

5 Anti-roll bar

6 Front subframe
7 Front subframe rubber bush
8 Rear subframe rubber bush

1.2 Rear suspension components on

Saloon/Hatchback models

1 Wheel housing
2 Upper mounting bracket and coil spring seat
3 Strut
4 Solenoid valve for adaptive damping
5 Rear suspension crossmember
6 Eccentric bolt for rear toe setting
7 Anti-roll bar
8 Link
9 Front lower arm
10 Rear lower arm
11 Knuckle (drum brake models)
12 ABS wheel sensor

(drum brake models)

13 Tie-bar
14 Backplate
15 Hub and bearing assembly
16 Hub nut
17 Grease cap
18 Brake drum
19 Tie-bar mounting bracket
20 Brake disc
21 Splash shield (disc brake models)
22 Brake caliper (disc brake models)
23 Knuckle (disc brake models)
24 ABS wheel sensor (disc brake models)

10•4 Suspension and steering systems

pressed-steel lower side arms. A tie-bar on
each side supports the rear suspension
knuckles. The coil springs are separate from
the shock absorbers (see illustration).

A rear anti-roll bar is fitted to all models. On

SI models, the front and rear shock absorbers
are gas-filled; on other models, they are filled
with fluid. Self-levelling rear shock absorbers
are fitted as standard to Ghia Estate models.

A variable-ratio type rack-and-pinion

steering gear is fitted, together with a
conventional column and telescopic coupling,
incorporating two universal joints. Power-
assisted steering is fitted to all models. A
power steering system fluid cooler is fitted, in
front of the cooling system radiator on the
crossmember (see illustration). On models
with adaptive damping, a steering position
sensor with sensor disc is located above the
upper universal joint.

On models with adaptive damping, it is

possible to select a hard or soft setting for the
front and rear shock absorbers. The system is

computer-controlled; a switch is provided
near the handbrake lever for selection of
“Sport” or “Normal” mode. With this system, a
solenoid valve is fitted to each suspension
strut. When the valve is open, the hydraulic oil
inside the shock absorber is routed through a
bypass channel, making the action “softer”.
When the solenoid valve is closed, the shock
absorber action becomes “harder”. The
system takes into consideration the
roadspeed of the vehicle; at high speeds, the
shock absorbers are automatically set to
“hard”. The adaptive damping computer
module is located in the luggage
compartment, behind the rear seat, and
incorporates a self-test function. Adaptive
damping is not available on Estate models
(see illustrations).

When working on the suspension or

steering, you may come across nuts or bolts
which seem impossible to loosen. These nuts
and bolts on the underside of the vehicle are
continually subjected to water, road grime,

mud, etc, and can become rusted or seized,
making them extremely difficult to remove. In
order to unscrew these stubborn nuts and
bolts without damaging them (or other
components), use lots of penetrating oil, and
allow it to soak in for a while. Using a wire
brush to clean exposed threads will also ease
removal of the nut or bolt, and will help to
prevent damage to the threads. Sometimes, a
sharp blow with a hammer and punch will
break the bond between a nut and bolt, but
care must be taken to prevent the punch from
slipping off and ruining the threads. Heating
the nut or bolt and surrounding area with a
blow lamp sometimes helps too, but this is
not recommended, because of the obvious
dangers associated with fire. Extension bars
or pipes will increase leverage, but never use
one on a ratchet, as the internal mechanism
could be damaged. Actually tightening the nut
or bolt first may help to break it loose. Nuts or
bolts which have required drastic measures to
remove them should always be renewed.

1.5 The power steering system fluid cooler

is located in front of the radiator

1.6A Adaptive damping switch located

near the handbrake lever

1.6B Adaptive damping computer module

located in the luggage compartment

1.3 Rear suspension components on

Estate models

1 Tie-bar bracket
2 Short front lower arm
3 Long front upper arm
4 Shock absorber
5 Crossmember
6 Anti-roll bar
7 Coil spring
8 Rear lower arm
9 Stub axle (part of hub and bearing

assembly)

10 Knuckle
11 Brake caliper (disc brake models)
12 Hub nut
13 Brake drum
14 Splash guard (disc brake models)
15 Brake disc
16 Hub and bearing assembly
17 Backplate (drum brake models)
18 ABS wheel sensor
19 Tie-bar

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