Removing and installing the front suspension strut (Mondeo 1 and 2)

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Removal


1. Apply the parking brake.

2. In the engine compartment, remove the strut cap (if present). Holding the strut rod with an Allen key, release the upper support nut and unscrew it 5 turns (see Fig. 4.2). Do not unscrew it completely yet, but keep in mind that you will need a new nut for installation.

2. In the engine compartment, remove the strut cap (if present). Holding the strut rod with an…


3. Loosen the nuts of the corresponding wheel and support the rear wheels with wedges. Raise the front of the car and place it on supports. Remove the front wheel.

4. Unscrew the brake hose support bracket bolt from the front part of the front suspension strut or detach the hose from the bracket (see Fig. 4.4, a, b).

4. Unscrew the brake hose support bracket bolt from the front part of the front suspension strut or…
4. Unscrew the brake hose support bracket bolt from the front part of the front suspension strut or…


5. Remove the ABS sensor (if present - see chapter 9).



6. Loosen the nut and disconnect the anti-roll bar connecting link from the suspension strut. Note that on models with ABS, the ABS sensor wiring bracket is installed under the nut (see Fig. 4.6).

6. Loosen the nut and disconnect the anti-roll bar connecting link from the suspension strut. Note…


7. Remove the brake caliper (chapter 9), without disconnecting the caliper hose. Tie the caliper inside the wheel well without stretching its hose.

8. Remove the cotter pin from the tie rod end ball joint nut. Remove the nut and disconnect the tie rod from the steering knuckle using a ball joint puller. Be careful not to damage the ball joint seal.

9. Remove the clamp securing the inner boot of the drive shaft to the inner constant velocity joint. Disconnect the boot from the joint housing.

10. Note which side the lower arm ball joint clamp bolt is installed on. Then unscrew the bolt from the steering knuckle. Separate the ball joint (by pressing it) from the knuckle. If this is difficult to do, open the clamp with a pry bar or power screwdriver. Do not damage the ball joint seal.

11. Disconnect the electrical connector (if equipped) of the adaptive suspension located on the suspension strut and unclip the wiring.



12. Unscrew the clamp bolt securing the steering knuckle assembly to the front suspension strut, taking into account which side it is installed on. Open the clamp with a crowbar or screwdriver and release the knuckle from the strut (see Fig. 4.12.).

12. Unscrew the clamp bolt securing the steering knuckle assembly to the front suspension strut,…


13. Lower the suspension strut together with the drive shaft and steering knuckle. Remove the drive shaft joint from the inner constant velocity joint housing.

Installation


14. Open the clamp and install the suspension strut onto the steering knuckle. Insert the clamp bolt with its head facing forward. Tighten the bolt to the specified torque.

15. Install the suspension strut (together with the drive shaft and steering knuckle) into its upper support. Screw on the nut.

16. Install the inner constant velocity joint of the drive shaft into its housing. Then install the cover on the housing and secure it with a new clamp.

17. Connect the electrical connector (if available) of the adaptive suspension and secure its wiring.

19. Fully insert the lower arm ball joint pin into the bottom of the steering knuckle. Install the clamp bolt and tighten it to the specified torque.



20. Connect the anti-roll bar connecting link to the strut and tighten the nut to the specified torque. On models equipped with ABS, do not forget to install the sensor wiring bracket under the nut.

21. Install the ABS sensor (if equipped), see chapter 9.

22. Install the ball joint of the tie rod end onto the steering knuckle and tighten the nut to the required torque. Check: the holes for the cotter pin must be aligned. If necessary, turn the nut slightly until aligned, taking into account the required torque specified in Technical requirements. Insert a new cotter pin and bend it.

23. Install the brake caliper (chapter 9).

24. Install the brake hose support bracket onto the strut and tighten its bolt.

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

26. Tighten the wheel nuts to the specified torque.

28. Tighten the upper strut mount nut to the specified torque while holding the piston with an 8 mm Allen key. If you do not have the required adapter, first tighten the nut with a spanner while holding the piston. Then tighten the nut to the specified torque using a regular socket (see Fig. 4.28).

28. Tighten the upper strut mount nut to the specified torque while holding the piston with an 8 mm…






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