Removing and installing the rear suspension strut (Sedan and Hatchback) (Mondeo 1 and 2)

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Note: To remove the rear suspension strut, you will need to temporarily compress the coil spring. This is to retract the piston rod into the strut and provide space to remove the strut from the bump stop located on top of the rear suspension beam.

Removal


1. Support the front wheels with wedges, then lift the rear and place it on supports. Remove the corresponding wheel.

2. Disconnect the ABS sensor wiring (if equipped) and remove the sensor from the axle support (chapter 9) (see Fig. 11.2).

2. Disconnect the ABS sensor wiring (if equipped) and remove the sensor from the axle support…


3. On models with adaptive suspension, unclip the wiring from the strut and disconnect the electrical connector (see Fig. 11.3).

3. On models with adaptive suspension, unclip the wiring from the strut and disconnect the…


4. On models with drum brakes, install the clamp on the rear brake hose. Then unscrew the nut securing the brake line to the flexible hose on the suspension strut. Release the clamp and disconnect the flexible hose from the strut.



5. On models with rear disc brakes, remove the brake caliper mounting bolts from the axle support (chapter 9). There is no need to disconnect the hydraulic hose. Prop the caliper up on a support so that the hose is not stretched.

6. Remove the nut securing the rear stabilizer bar connecting link to the front lower control arm on the appropriate side of the vehicle. Hold the connecting link while removing the nut.

7. Unscrew the bolt securing the reaction lever to the lower part of the axle support. Move the lever down (see Fig. 11.7, a-c).

7. Unscrew the bolt securing the reaction lever to the lower part of the axle support. Move the…
7. Unscrew the bolt securing the reaction lever to the lower part of the axle support. Move the…


7. Unscrew the bolt securing the reaction lever to the lower part of the axle support. Move the…


8. Unscrew the bolts securing the front and rear lower arms to the axle support. Move the arms to the side (see Fig. 11.8,a,b).



8. Unscrew the bolts securing the front and rear lower arms to the axle support. Move the arms to…
8. Unscrew the bolts securing the front and rear lower arms to the axle support. Move the arms to…


9. Support the axle support on a movable jack. Then unscrew the bolt securing the axle support to the suspension strut (see Fig. 11.9, a, b).

9. Support the axle support on a movable jack. Then unscrew the bolt securing the axle support to…
9. Support the axle support on a movable jack. Then unscrew the bolt securing the axle support to…


10. Open the clamp on the axle support with a pry bar. Disconnect the axle support from the strut. Lower the strut on the jack as low as possible without damaging the handbrake cable (see Fig. 11.10).



10. Open the clamp on the axle support with a pry bar. Disconnect the axle support from the strut.…


11. Mount the compressor on the spring and compress it so as to release the upper and lower supports from its force (see Fig. 11.11). This will also release the bracket mounted on the strut, which is pressed against the rubber bumper located on the upper part of the rear suspension beam.

11. Mount the compressor on the spring and compress it so as to release the upper and lower…


12. Support the stand. Then, inside the wheel arch, unscrew the two bolts securing the upper support to the bottom (see Fig. 11.12).

12. Support the stand. Then, inside the wheel arch, unscrew the two bolts securing the upper…


13. Raise the strut slightly to press the rod into the shock absorber and release the strut bracket from the bump stop on the beam. Lower the strut and pull it out from under the car (see Fig. 11.13).



13. Raise the strut slightly to press the rod into the shock absorber and release the strut bracket…


Installation


14. Install the strut assembly (with the spring compressor) by inserting the strut through the wheel well. Install the bracket onto the bump stop located on the rear suspension beam. Insert the two bolts securing the upper support to the underbody recess and tighten them to the specified torque. Carefully release the compressor compressing the spring so that it fits into the upper and lower saddles, and the strut bracket fits onto the beam bump stop. The bump stop has a conical undercut and the strut bracket must fit completely into it before the spring is released.

15. Install the rear axle support and connect it to the strut. Then insert the clamp bolt and tighten it to the specified torque.

16. Install the front and rear lower arms onto the rear axle support. Tighten the bolts.

17. Connect the reaction arm to the lower part of the rear axle support and tighten the bolt.

18. Install the stabilizer bar connecting link to the lower arm. Tighten the nut to the specified torque.

19. On models with rear disc brakes, install the caliper bracket onto the axle support and tighten the bolts to the specified torque (chapter 9). Check: the brake hose should not be twisted.



20. On models with rear drum brakes, connect the hose to the strut, install the clamp, then install the brake line and tighten the nut that secures it. Remove the clamp from the brake hose and bleed the hydraulic system (chapter 9).

21. Connect the adaptive suspension electrical connector (if equipped) and secure the wiring to the pillar.

22. Install the ABS sensor (if available - see chapter 9) and secure the wiring to the rack.

23. Install the wheel and lower the vehicle to the ground.

25. Now that the vehicle is supported by the suspension, fully tighten the torque arm and lower control arms mounting bolts.

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