204-01-1 Front Suspension 204-01-1

SECTION 204-01 Front Suspension

VEHICLE APPLICATION:2008.50 Mondeo
CONTENTS PAGE

DESCRIPTION AND OPERATION

Front Suspension................................................................................................................ 204-01-2
Vehicles with standard suspension..................................................................................... 204-01-2
Vehicles with dynamic suspension..................................................................................... 204-01-3

REMOVAL AND INSTALLATION

Front Wheel Bearing....................................................................................... (14 411 0) 204-01-4
Wheel Knuckle................................................................................................ (14 343 0) 204-01-5
Lower Arm...................................................................................................... (14 706 0) 204-01-9
Front Stabilizer Bar......................................................................................... (14 752 0) 204-01-11
Front Stabilizer Bar Link..................................................................................................... 204-01-16
Front Stabilizer Bar Bushing........................................................................... (14 754 0) 204-01-17
Shock Absorber and Spring Assembly............................................................................... 204-01-18

DISASSEMBLY AND ASSEMBLY

Shock Absorber and Spring Assembly............................................................................... 204-01-21
204-01-2 Front Suspension 204-01-2
DESCRIPTION AND OPERATION

Front Suspension

Vehicles with standard suspension

10

1
9
8

6 7
3

4 5

E91024

Item Description Item Description

1 Shock absorber and spring assembly 8 Vibration damper (if equipped)
2 Wheel knuckle 9 Stabilizer bar clamp and bushing assembly
3 Wheel hub 10 Stabilizer bar link
4 Heat shield
5 Lower arm Item 9 : Stabilizer Bar Clamp
6 Stabilizer bar The stabilizer bar clamp retaining bolts are dual
7 Front subframe purpose. They also act as the lower arm rear
retaining bolts.

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204-01-3 Front Suspension 204-01-3
DESCRIPTION AND OPERATION
Vehicles with dynamic suspension

11

1 10
9
8

3
6 7

4 5
E91025

force which depends on the velocity of the vehicle

Item Description
and an electrical current applied to the continuous
1 Shock absorber and spring assembly damping control shock absorber. The electronic
stability program (ESP) sensors, acceleration
2 Wheel knuckle
sensors and displacement sensors provide
3 Wheel hub information to the dynamic suspension electronic
control unit (ECU), which detects the state of
4 Heat shield heave, roll, pitch, cornering and acceleration of the
5 Lower arm vehicle. The ECU then calculates the best damping
characteristics for each wheel within 2 ms. The
6 Stabilizer bar ECU sends an individual electrical current to each
7 Front subframe shock absorber to control the amount of damping
required.
8 Vibration damper (if equipped)
9 Stabilizer bar clamp and bushing assembly
10 Stabilizer bar link
11 Shock absorber wiring harness

Item 1 : Shock absorber and spring

assembly

Continuous damping control shock absorbers

provide dynamic front suspension. A continuous
damping control shock absorber creates a damping

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204-01-4 Front Suspension 204-01-4
REMOVAL AND INSTALLATION

Front Wheel Bearing(14 411 0)

Special Tool(s)
2. Special Tool(s): 204-348, 205-332
204-348
Remover/Installer, Wheel
Hub/Wheel Bearing 205-332

E42977

204-348/3
204-348/3
Remover/Installer, Wheel
Hub/Wheel Bearing 204-348
E44828

E87735
Installation
204-348-01 1. CAUTION: The smaller diameter of the
204-348-01 tool 205-074 must be upermost. Check
Adapter for 204-348
the installation of the wheel bearing.
Wheel bearing must be fully home.
1. Wheel bearing.
E87734 Special Tool(s): 204-348, 204-348-01,
205-074, 204-348/3
2. Wheel knuckle.
205-074
Installer, Differential Bearing
Cone 2

15035

205-332
Protector, Axle Shaft
1

E75466

15108
2. To install, reverse the removal procedure.

Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Remove the wheel knuckle.
Refer to: Wheel Knuckle (204-01 Front
Suspension, Removal and Installation).

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204-01-5 Front Suspension 204-01-5
REMOVAL AND INSTALLATION

Wheel Knuckle(14 343 0)

Special Tool(s) 2. Remove the wheel and tire.
204-159 Refer to: Wheel and Tire (204-04 Wheels and
Lever, Wheel Knuckle Tires, Removal and Installation).

Vehicles with high intensity discharge

headlamps
14039
3.

204-605
Separator, Lower arm-ball
joint

E63772

204-607
Remover, Ball joint
E75215

Vehicles with dynamic suspension

E63420
4.

204-609
Protection Cap, Ball Joint
Gaiter

E75372

Removal
E67356

NOTE: Removal steps in this procedure may

contain installation details. All vehicles
1. Loosen the wheel hub bolt. 5. Torque: 60 Nm

TIE0012381
E67357

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204-01-6 Front Suspension 204-01-6
REMOVAL AND INSTALLATION
6. CAUTION: Make sure that the ball joint 8. WARNING: Make sure that no load is
ball does not rotate. placed on the brake hose.
Loosen the tie-rod end nut. 1. Loosen the nut two turns.
Torque: 100 Nm
2. Torque: 200 Nm

TIE0026775
2

7. WARNING: Make sure that a new nut is E76838

installed.
9. Special Tool(s): 204-607
CAUTIONS:
Use suitable packing material to prevent
damage to the component.
204-607
Make sure that the ball joint ball does
not rotate.
2. Torque: 80 Nm

1
2

1
E75216

2
10. Torque: 200 Nm

E83824

E89307

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204-01-7 Front Suspension 204-01-7
REMOVAL AND INSTALLATION
11. 14. Special Tool(s): 204-609

204-609

E81908
E67589

12. Torque: 10 Nm 15. CAUTION: If the outer constant velocity

(CV) joint boot is damaged a new
halfshaft must be installed.
Torque:
• Stage 1: 45 Nm
• Stage 2: 80°

E67359

13. Special Tool(s): 204-605

E69360

16. Torque: 110 Nm

204-605

E81907

TIM1401098

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204-01-8 Front Suspension 204-01-8
REMOVAL AND INSTALLATION
17. Special Tool(s): 204-159

204-159

TIE0000944

Installation
1. To install, reverse the removal procedure.

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204-01-9 Front Suspension 204-01-9
REMOVAL AND INSTALLATION

Lower Arm(14 706 0)

Special Tool(s) 3. CAUTION: Make sure that the ball joint
ball does not rotate.
204-605
Separator, Lower arm-ball Torque: 70 Nm
joint

E63772

204-607
Remover, Ball joint

E91648
E63420

4. 1. Loosen: 2 turn(s)
204-609 2. WARNING: Make sure that no load is
Protection Cap, Ball Joint placed on the brake hose.
Gaiter
Torque: 200 Nm

E75372

Removal
1
NOTE: Removal steps in this procedure may
contain installation details.
2
1. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation). E76838

2.
5. 1. Special Tool(s): 204-607
2. Torque: 100 Nm

204-607

1
2
E75215

E75216

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204-01-10 Front Suspension 204-01-10
REMOVAL AND INSTALLATION
6. Special Tool(s): 204-605 2. Check the toe setting and adjust as necessary.
Refer to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures).

204-605

E81907

7. Special Tool(s): 204-609

204-609

E81908

8. • CAUTION: Make sure that new bolts

are installed.
Torque:
• Stage 1: 140 Nm
• Stage 2: 45°

E67384

Installation
1. To install, reverse the removal procedure.

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204-01-11 Front Suspension 204-01-11
REMOVAL AND INSTALLATION

Front Stabilizer Bar(14 752 0)

Special Tool(s) 4.
205-316A
Alignment Pins, Subframe

15097B

General Equipment
Transmission jack
Hydraulic press E68962

Removal 5. CAUTION: Make sure that the ball joint

ball does not rotate.
1. CAUTION: Make sure that the steering On both sides.
wheel lock is engaged.
NOTE: Make sure that the road wheels are in
the straight ahead position.

TIE0008508

6. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent.
TIE38834

2. Remove the wheel and tire on both sides.

Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.

TIE0002772

E65299

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204-01-12 Front Suspension 204-01-12
REMOVAL AND INSTALLATION
7. 10. Support the steering gear when lowering the
subframe.
General Equipment: Transmission jack

E66156

8. E70066

11.

1 1

E79176
2
9. E66163

12. WARNING: This step requires the aid of

another technician.
Lower the front subframe to gain access to the
stabilizer bar bolts.

E66162

E66164

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204-01-13 Front Suspension 204-01-13
REMOVAL AND INSTALLATION
13. Remove the stabilizer bar nuts on both sides. On both sides.
Do not remove the stabilizer bar bolts at this General Equipment: Hydraulic press
stage.

E69763
E67366

3. Install new nuts and bolts, on both sides.

14. NOTE: Note the position of each component Torque: 175 Nm
before removal.

1 3

2 4

E70213
E68087

4. 1. Insert the washer, with inside diameter 22

Installation mm, outside diameter 44 mm and height 5
mm, into the front subframe above the
1. Install the stabilizer bar bushings with no alignment hole.
lubricant. 2. Insert the alignment pin through the front
subframe alignment holes and the washer.
Special Tool(s): 205-316A
3. Slide the locking plates on top of the washer
and into the groove of the special tool and
tighten the alignment pin sleeve.

1
E67369
2

2. NOTE: Make sure that the clamp is installed to

the same orientation as when removed.
205-316A
NOTE: Apply water to the stabilizer bar clamp
to assist installation. E0021863

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204-01-14 Front Suspension 204-01-14
REMOVAL AND INSTALLATION
5. CAUTION: Make sure that new bolts are 8. Torque: 85 Nm
installed.
Torque:
• Stage 1: 150 Nm
• Stage 2: 90°

E79176

9.

E66164

6. 1. Torque: 30 Nm
2. CAUTION: Make sure that new bolts
are installed.
Torque:
• Stage 1: 150 Nm
• Stage 2: 90°

1 1 E66156

10. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent.

2
E66163

7. CAUTION: Make sure that new bolts are

installed.
Torque: 120 Nm
TIE0002772

11. CAUTION: Make sure that the ball joint

ball does not rotate.

E66162

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204-01-15 Front Suspension 204-01-15
REMOVAL AND INSTALLATION
On both sides.
Torque: 75 Nm

TIE0008508

12.

E68962

13.

E65299

14. Install the wheel and tire on both sides.

Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
15. Check the toe setting and adjust as necessary
on both sides.
Refer to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures).

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204-01-16 Front Suspension 204-01-16
REMOVAL AND INSTALLATION

Front Stabilizer Bar Link

Removal

1. Remove the wheel and tire.

Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. CAUTION: Make sure that the ball joint
ball does not rotate.
1. Torque: 70 Nm
2. Torque: 60 Nm

E67372

Installation
1. To install, reverse the removal procedure.

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204-01-17 Front Suspension 204-01-17
REMOVAL AND INSTALLATION

Front Stabilizer Bar Bushing(14 754 0)

Removal and Installation

1. Refer to: Front Stabilizer Bar (204-01 Front
Suspension, Removal and Installation).

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204-01-18 Front Suspension 204-01-18
REMOVAL AND INSTALLATION

Shock Absorber and Spring Assembly

Special Tool(s) Special Tool(s)
204-159 204-607
Lever, Wheel Knuckle Remover, Ball joint

14039 E63420

204-605 204-609
Separator, Lower arm-ball Protection Cap, Ball Joint
joint Gaiter

E63772
E75372

Removal
NOTE: Removal steps in this procedure may All vehicles
contain installation details.
4. Torque: 60 Nm
1. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).

Vehicles with dynamic suspension

3.

E67357

E67356

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204-01-19 Front Suspension 204-01-19
REMOVAL AND INSTALLATION
5. 1. Loosen: 2 turn(s) 8. Special Tool(s): 204-609
2. WARNING: Make sure that no load is
placed on the brake hose.
Torque: 200 Nm

204-609

1
E81908

2
9. Torque: 110 Nm
E76838

6. Special Tool(s): 204-607

Torque: 100 Nm

204-607

E91647
1
2
10. Special Tool(s): 204-159

E75216

7. Special Tool(s): 204-605 204-159

E94523

204-605

E81907

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204-01-20 Front Suspension 204-01-20
REMOVAL AND INSTALLATION
11. WARNING: This step requires the aid of
another technician.
Torque: 35 Nm

x3

E67363

Installation
1. To install, reverse the removal procedure.
2. Refer to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures).

2008.50 Mondeo 1/2009 G543428en

204-01-21 Front Suspension 204-01-21
DISASSEMBLY AND ASSEMBLY

Shock Absorber and Spring Assembly

Special Tool(s) Special Tool(s)
204-167 204-167-01
Compressor, Coil Spring Adapter for 204-167

1404201
14042

Disassembly
All vehicles Vehicles with dynamic suspension
NOTE: Removal steps in this procedure may 2.
contain installation details.
1. WARNING: Take extra care when
handling the compressed spring.
Compress the spring.
Special Tool(s): 204-167, 204-167-01

204-167-01

204-167
TIE0022852

E71734

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204-01-22 Front Suspension 204-01-22
DISASSEMBLY AND ASSEMBLY
All vehicles NOTE: Make sure that the spring is correctly
located in the lower spring seat.
3.
Special Tool(s): 204-167, 204-167-01

204-167-01

204-167
TIE0022852

6. Align the top mount with the shock absorber as

shown.

E71736

Assembly
4. NOTE: Only tighten the nut finger tight at this
stage.
To assemble, reverse the disassembly
procedure.
5. WARNING: Take extra care when
handling the compressed spring.

E89915

7. Align the lower bearing race with the upper

bearing race as shown.

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204-01-23 Front Suspension 204-01-23
DISASSEMBLY AND ASSEMBLY

E89916

8. Tighten the nut.

Torque: 58 Nm
9. Remove the special tools.

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