Pinpoint tests of suspension

A1: CHECKING FOR LEFT OR RIGHT DRIVE

WARNING: To avoid personal injury due to loss of vehicle control, two people should perform the inspection. This will help maintain safe driving conditions. One person should drive while the other watches the time. Always hold the steering wheel properly. Failure to follow these instructions may result in personal injury.

NOTE:When assessing the condition of a vehicle, the following conditions must be met. In general, vehicles tend to pull downwards depending on the cross slope of the road. It is important to establish whether the vehicle has a strong pull to one side when driving on a road with a cross slope to the left and right, or whether the pull is acceptably balanced. A comparison drive in a known good vehicle can reassure the customer that their Ford is in satisfactory condition.

1Road test the vehicle.

• Does the vehicle pull?

→ Yes

Go to A2

→ No

Check the customer complaint.

A2: CHECKING THE CAR'S WHEEL ALIGNMENT ANGLES

1Check the wheel alignment angles of the vehicle.

• Is the steering wheel centered and are the wheel alignments within specifications?

→ Yes

Go to A3

→ No

If necessary, INSTALL new components. Refer to Section 211-02 for additional information. ADJUST wheel alignment to specification. Check for proper system operation.

A3: INSPECTION OF WHEEL BEARINGS

1Inspect the wheel bearings. Refer to Section 204-00 for additional information.

• Is there any slack in the bearings or uneven running?

→ Yes

If necessary, INSTALL new wheel bearings. Refer to Section 204-01 for additional information. CHECK that the system operates normally.

→ No

Go to A4

A4: REVERSING THE FRONT WHEELS AND TIRES

NOTE:The tire rotation procedure is only suitable for tires that are bi-directional.

1Swap the left front wheel and tire assembly with the right front wheel and tire assembly.

- Conduct a road test.

• Does the vehicle pull?

→ Yes

Go to A5

→ No

The problem has been resolved.

A5: REVERSING THE REAR WHEELS AND TIRES

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Swap the left rear wheel and tire assembly with the right rear wheel and tire assembly.

- Conduct a road test.

• Does the vehicle pull?

→ Yes

Go to A6

→ No

The problem has been resolved.

A6: REVERSING LEFT WHEELS WITH TIRES

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Swap the left front wheel and tire assembly with the left rear wheel and tire assembly.

- Conduct a road test.

• Does the vehicle pull?

→ Yes

Go to A7

→ No

The problem has been resolved.

A7: REVERSING THE RIGHT-HAND TIRE AND WHEEL ASSEMBLY

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Swap the right front wheel and tire assembly with the right rear wheel and tire assembly.

- Conduct a road test.

• Does the vehicle pull?

→ Yes

Go to A8

→ No

The problem has been resolved.

A8: REVERSING THE LEFT FRONT WHEEL AND TIRE ASSEMBLY

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Swap the left front wheel and tire assembly with the right rear wheel and tire assembly.

- Conduct a road test.

• Does the vehicle pull?

→ Yes

Go to A9

→ No

The problem has been resolved.

A9: REVERSING THE RIGHT FRONT WHEEL AND TIRE ASSEMBLY

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Swap the right front wheel and tire assembly with the left rear wheel and tire assembly.

- Conduct a road test.

• Does the vehicle pull?

→ Yes

Go to A10

→ No

The problem has been resolved.

A10: INSTALLING NEW TYRES

NOTE:Install new tires only once.

1Install new tires on four wheels. Check if the system works properly.

• Does the vehicle pull?

→ Yes

Check possible causes, refer to the Malfunction Symptom Table.

→ No

The problem has been resolved.

B1: INSPECTION OF STEERING ELEMENTS

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Inspect steering components for excessive wear or damage.

• Do steering components show excessive wear or damage?

→ Yes

Install new components if necessary. Refer to Section 211-00 / 204-01 for additional information.

→ No

Go to B2

B2: CHECKING THE CAR WHEEL ALIGNMENT ANGLES

1Check the wheel alignment angles of the vehicle.

- Make sure the front wheels are facing straight ahead.

• Is the steering wheel centered and are the wheel alignments within specifications?

→ Yes

The problem has been resolved.

→ No

Adjust wheel alignment to specification.

C1: CHECKING THE LONGITUDINAL INCLINATION OF THE WHEEL STEERING AXIS

1Check the wheel alignment angles of the vehicle.

• Is the caster angle within specification?

→ Yes

Go to C2

→ No

Install new suspension components if necessary. Adjust wheel alignment to specification.

C2: CHECKING THE REAR SUSPENSION

1Measure the wheelbase of the vehicle on the left and right sides.

- Compare the measurement results.

• Are the results equal?

→ Yes

Check the customer complaint.

→ No

Inspect the rear suspension components for wear or damage. Install new components if necessary. Refer to Section 204-02 for additional information.

D1: CHECKING THE FRONT STRUT ASSEMBLY WITH SPRINGS AND REAR SHOCK ABSORBERS

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Inspect the front suspension struts and springs and rear shock absorbers for oil leaks or damage.

• Are the front suspension struts and springs and rear shock absorbers damaged or leaking?

→ Yes

INSTALL new components as necessary. Refer to Section 204-01 (Front Suspension) for additional information. Refer to Section 204-02 (Rear Suspension) for additional information.

→ No

Check the customer complaint.

E1: SUSPENSION INSPECTION

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Inspect the suspension bolts.

• Are there any loose or damaged bolts?

→ Yes

TIGHTEN or INSTALL new suspension bolts. Refer to Section 204-01. (Front Suspension) for additional information. Refer to Section 204-02. (Rear Suspension) for additional information.

→ No

Go to E2

E2: INSPECTION OF SPRINGS

1Inspect the suspension springs for damage.

• Are the springs damaged?

→ Yes

INSTALL new springs. Refer to Section 204-01 (Front Suspension) for additional information. Refer to Section 204-02 (Rear Suspension) for additional information.

→ No

Go to E3

E3: INSPECTING THE FRONT SUSPENSION LOWER ARM

1Inspect the front lower control arm bushings for excessive wear or damage.

• Do the front lower arm bushings show excessive wear or damage?.

→ Yes

Install a new front lower control arm. Refer to Section 204-01 for additional information.

→ No

Go to E4

E4: TIRE INSPECTION

1Inspect tires for uneven wear.

• Do the tires wear unevenly?

→ Yes

Install new tires. Adjust wheel alignment to specification. Check if the system operates normally.

→ No

Go to E5

E5: INSPECTING FRONT WHEEL BEARINGS

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Rock each wheel by grasping it from above and below and pushing the wheel in and out alternately. Feel for excessive slack in the bearings.

- Rotate each front wheel by hand, observing the unevenness of the ride.

• Is there any slack in the bearings or uneven running?

→ Yes

Install new wheel bearings if necessary. Check if the system is working properly.

→ No

Check the customer complaint.

F1: TIRE INSPECTION

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Inspect the tires for uneven wear on the outside or inside edge or for the presence of a "saw-tooth" pattern.

• Do the tires wear unevenly?

→ Yes

Replace tires if wear is excessive. Adjust wheel alignment to specification.

→ No

Go to F2

F2: CHECKING TIRES FOR SHAPE CHANGE

1Inspect the tires for cupping or concavity.

• Are the tires cupped or concave?

→ Yes

Install new tire(s) if necessary. CHECK and ADJUST tire pressure.

→ No

Check the customer complaint.

G1: TIRE INSPECTION

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Inspect tires for excessive wear or damage.

• Do the tires show excessive wear or damage?

→ Yes

Install new tires. Check if the system works properly.

→ No

Go to G2

G2: INSPECTING FRONT WHEEL BEARINGS

1Raise and support the vehicle. Refer to Section 100-02 for additional information.

- Rock each front wheel by grasping it from above and below, pushing the wheel in and out alternately. Feel for excessive slack in the bearings.

- Rotate each front wheel by hand, observing the unevenness of the ride.

• Is there any slack in the bearings or uneven running?

→ Yes

Go to G3

→ No

Go to G4

G3: MEASURING AXIAL CLEARANCE IN FRONT WHEEL BEARINGS

1Remove the wheel and front disc brake caliper.

- Place the dial indicator, mounted on a tripod, opposite the wheel hub.

- Move the wheel hub axially back and forth by hand and measure the axial clearance of the front wheel bearing. There should be no clearance.

• Is there any gap?

→ Yes

Go to G13

→ No

Check the tie rod end ball joint. For more information, refer to Checking Components in this section.. Go to G4

G4: INSPECTING REAR WHEEL BEARINGS

1Rock each rear wheel by grasping it from above and below and pushing the wheel in and out alternately. Feel for excessive slack in the bearings.

2Rotate each wheel by hand, observing for uneven movement.

• Is there any slack in the bearings or uneven running?

→ Yes

Go to G5

→ No

Go to G6

G5: MEASURING AXIAL CLEARANCE IN REAR WHEEL BEARINGS

1Remove the rear wheel and brake drum or disc.

2Place the dial indicator, mounted on a tripod, opposite the wheel hub.

3Move the wheel hub axially back and forth by hand and measure the axial clearance of the front wheel bearing. There should be no clearance.

• Is there any gap?

→ Yes

Go to G13

→ No

Go to G6

G6: MEASURING WHEEL/TIRE RUNOUT ON A VEHICLE

1Measure the runout of the wheels/tires on the vehicle using suitable equipment. The runout of the unit should be less than 1.14 mm (0.045 in) in both the radial and lateral directions.

• Does the measurement result meet the specification?

→ Yes

Go to G12

→ No

Go to G7

G7: MEASURING WHEEL/TIRE RUNOUT OFF-VEHICLE

1Measure the wheel/tire runout at any position where the runout exceeds 1.14 mm (0.045 in) in the radial or lateral direction. Before removing the wheel/tire, mark the wheel stud and corresponding hole so that the wheel can be reinstalled in the same position. Remove the wheel and mount it on the wheel balancer. Measure the runout. The runout of the wheel and tire assembly should be less than 1.14 mm (0.045 in) in both the radial and lateral directions.

• Does the measurement result meet the specification?

→ Yes

Go to G10

→ No

Go to G8

G8: ADJUSTING THE INSTALLATION POSITION

1Mark the position of maximum runout on the tire and on the wheel. Release the pressure in the tire and rotate it 180 degrees (half a turn) relative to the wheel. Inflate the tire and measure the runout.

• Are the wheels and tires balanced?

→ Yes

Install the wheel on the vehicle. Check if the system works properly.

→ No

If the maximum runout position is not within 100 mm (4 in) of the first maximum runout location on the tire, Proceed to G9

G9: MEASURING WHEEL RUNOUT

1Remove the tire and mount the wheel on a wheel balancer. Measure the runout of both flanges. The runout should be less than 1.14 mm (0.045 in) in both the radial and lateral directions.

• Is the runout within specification?

→ Yes

Find and mark the "point" of least runout on the wheel and install the tire on the wheel, adjusting the "point" of maximum runout on the tire to this location. Balance the unit. Check if the system operates normally.

→ No

Install a new wheel. Check the runout of the new wheel. If the runout on the new wheel is within specification, find and mark the "point" of least runout. Install the tire, matching the "point" of maximum runout on the tire to the "point" of minimum runout on the wheel. Balance the unit. Install the wheel on the vehicle. Check that the system operates normally.

G10: REAR HUB RUNOUT AND STUD CIRCLE

1Remove the rear wheel and brake drum or disc.

- Measure the hub flange axial runout (more than 0.254 mm (0.010 in)), stud circle runout (more than 0.08 mm (0.003 in)) and radial runout (more than 0.05 mm (0.002 in)).

• Are the measurement results within specification?

→ Yes

Go to G11

→ No

INSTALL a new rear hub. Refer to Section 204-02 for additional information.

G11: FRONT HUB RUNOUT AND STUD CIRCLE

1Remove the front wheel and brake disc.

- Measure the stud circle runout (more than 0.06 mm (0.002 in)) and the brake disc radial runout (more than 0.05 mm (0.002 in)).

• Are the measurement results within specification?

→ Yes

Check the front brake disc and rear brake disc runout. Refer to Section 206-00 for additional information.

→ No

INSTALL a new hub. Refer to Section 204-01 for additional information.

G12: WHEEL BALANCING

1Perform wheel balancing. Conduct a road test.

• Is there any vibration felt?

→ Yes

For additional information, see Section 100-04.

→ No

Check the customer complaint.

G13: INSPECTION OF THE WHEEL HUB FASTENING NUT

1Measure the tightening torque of the wheel hub nut.

• Does the measurement result meet the specification?

→ Yes

If necessary, INSTALL a new wheel bearing. Refer to Section 204-01. (Front Suspension) for additional information. Refer to Section 204-02. (Rear Suspension) for additional information. Check that the system operates normally.

→ No

TIGHTEN the wheel hub nut to the correct torque. The wheel hub nut can be reused 4 times, check the marking on the nut and INSTALL a new nut if necessary. Check if the system operates normally.