Post on 10-Feb-2018
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 1/61
SECTION 204-01 Front Suspension
PAGECONTENTS
SPECIFICATIONS
204-01-2Specifications......................................................................................................................
DESCRIPTION AND OPERATION
204-01-3Front Suspension................................................................................................................204-01-3Overview.............................................................................................................................204-01-4Front Suspension — 2.5L Duratec-RS (VI5) (Overview)....................................................204-01-4General information............................................................................................................
204-01-5Front Suspension — 2.5L Duratec-RS (VI5) (System Operation and Component
Description).......................................................................................................................204-01-5System Operation...............................................................................................................204-01-5Revo spindle...................................................................................................................
DIAGNOSIS AND TESTING
204-01-7Front Suspension................................................................................................................
REMOVAL AND INSTALLATION
204-01-8(14 371 0)Wheel Hub......................................................................................................204-01-10(14 371 0)Wheel Hub — 2.5L Duratec-RS (224kW/305PS) - VI5..................................204-01-11(14 706 0)Lower Arm......................................................................................................
204-01-15
(14 706 0;14 707 0;14 709 0)
Lower Arm — 2.5L Duratec-RS (224kW/305PS) - VI5...................................
204-01-17Front Stabilizer Bar .............................................................................................................204-01-26(14 752 0)Front Stabilizer Bar — 2.5L Duratec-RS (224kW/305PS) - VI5.....................204-01-33(14 735 0)Lower Arm Ball Joint.......................................................................................204-01-36Wheel Knuckle....................................................................................................................204-01-42(14 343 0)Wheel Knuckle — 2.5L Duratec-RS (224kW/305PS) - VI5............................
204-01-46Strut and Spring Assembly.................................................................................................
204-01-50(14 781 0;14 782 0)
Front Strut and Spring Assembly — 2.5L Duratec-RS (224kW/305PS) - VI5.
204-01-53
(14 411 0;14 411 4;
Front Wheel Bearing — 2.5L Duratec-RS (224kW/305PS) - VI5...................
14 412 0;14 414 4;14 416 4)
204-01-55(14 754 0;14 754 4)
Front Stabilizer Bar Bushing — 2.5L Duratec-RS (224kW/305PS) - VI5.......
204-01-56(14 758 0)Front Stabilizer Bar Ball Joint — 2.5L Duratec-RS (224kW/305PS) - VI5......
DISASSEMBLY AND ASSEMBLY
204-01-61Strut and Spring Assembly.................................................................................................
204-01-1Front Suspension204-01-1
.
ACK TO CHAPTER INDEX
TO MODEL INDEX
VEHICLE APPLICATION: 2011.00 Focus
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 2/61
Torque Specifications
lb-inlb-ftNmDescription
-2432Top mount retaining bolts
-1825Top mount brace to bulkhead retaining nuts
-3750Thrust bearing retaining nut
-3548Stabilizer bar link retaining nuts
-6690Wheel knuckle to strut and spring assembly pinchbolt
71-8Headlamp leveling front sensor bracket retainingbolt
80-9Lower arm ball joint heat shield retaining nut
-85115Brake caliper anchor plate retaining bolts
-5270Lower arm ball joint retaining nut
-3548Tie-rod end retaining nut
-3548Stabilizer bar to stabilizer bar link retaining nut
-3548Stabilizer bar clamp retaining bolts
-129175Lower arm front retaining bolt
-85115Lower arm rear clamp retaining bolts
-5270Lower arm ball joint to lower arm retaining bolts
-85115Front axle crossmember front retaining bolts
-203275Front axle crossmember rear retaining bolt
-5270Front axle crossmember bracket retaining bolts
--a)Wheel hub retaining bolt
-3851Catalytic converter to rear muffler flange retainingnuts - Vehicles with diesel engine
-3548Catalytic converter to rear muffler flange retainingnuts - All except vehicles with diesel engine
-5980Engine support insulator front retaining bolt
80-9Wheel speed sensor retaining bolt-2128Steering column to steering gear pinion retaining
bolt
a) Refer to the procedure in this section.
G163138en
204-01-2Front Suspension204-01-2
SPECIFICATIONS
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 3/61
Front Suspension
Overview
E42462
NOTE: The Anti-lock Brake System (ABS) sensor ring is incorporated into the wheel hub. Incorrectinstallation of the wheel hub would result in an ABSmalfunction.
The front suspension features McPherson strutsand 'L' shaped lower arms which are attached tothe front axle crossmember by means of twomaintenance-free bushings.
The ball joint is attached to the lower arm by meansof three rivets. Bolt-on replacement ball joints areavailable for service operations.
The correct installation position must be observedwhen installing the strut and spring assembly turretsupport bearings. To make sure that the strut andspring assembly turret support bearings, springsand piston rods are all aligned correctly, the springretainers and strut and spring assembly turretsupport bearings have alignment marks.
G187539en
204-01-3Front Suspension204-01-3
DESCRIPTION AND OPERATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 4/61
Front Suspension — 2.5L Duratec-RS (VI5) – Overview
General information
The front axle is based on the McPherson strutlayout. The front wheel suspension is a newdevelopment, the so-called "Revo" axle.
It is designed to reduce the effects of torquesteering.
E112840
1
2
7
6
3
8
5
4
9
DescriptionItem
Subframe1
Lower Control Arm2
Lower support insulator 3
wheel hub assembly,4
DescriptionItem
Wheel knuckle5
Top mount6
Spring7
Stabilizer bar mount8
Stabilizer bar 9
G1165387en
204-01-4Front Suspension204-01-4
DESCRIPTION AND OPERATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 5/61
Front Suspension — 2.5L Duratec-RS (VI5) – System Operation
and Component Description
System Operation
Revo spindle
When front-wheel drive, highly motorized vehiclesaccelerate out of a corner, disruptive steeringtorques often occur. These make it more difficultfor the driver to keep the vehicle in the lane.
The steering torque results from the combinationof forces that have a disruptive effect on thesteering, and the steering axis offset.
The following influences of the disruptive forcesact on the steering:
• High, one-sided drive forces
• Road unevennesses or ruts
• Imbalanced tires.
• Brake disc imbalance.
E113364
3
2
1
A B
DescriptionItem
Revo spindle A
McPherson spindleB
DescriptionItem
Steering axis offset1
Steering shaft2
Center of wheel3
The steering torque can be reduced by
• reducing the steering axis offset• minimizing the acting forces.
With the Revo spindle, the distance between thecenter of the wheel and the steering shaft has beenminimized. This change results in a smaller steering axis offset. This in turn results in a smaller steering lever arm and the transferential steering
G1165388en
204-01-5Front Suspension204-01-5
DESCRIPTION AND OPERATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 6/61
torques are minimized in line with the change tothe steering lever arm.
With the McPherson spindle, the upper pivot pointof the steering shaft is the suspension strut bearing
and the bottom pivot point is on the wheel knuckle.The distance between the center of the wheel andthe steering shaft is 50-70 mm.
With the Revo spindle, the upper and lower pivotpoints of the steering shaft are directly on the wheelknuckle. The distance between the center of thewheel and the steering shaft is 30 mm.
E113369
1
2
3
DescriptionItem
Roller bearing1
Wheel knuckle2
Needle bearing3
The wheel knuckle of the Revo spindle ispositioned as follows:
• Roller bearing, top
• Needle bearing, bottom
NOTE: The wheel bearings have one magneticside (dark grey) and one non-magnetic side (lightgrey). When installing the wheel bearings, it mustbe ensured that the non-magnetic side is pointingoutwards. Otherwise, the ABS (anti-lock brakesystem) function is disrupted.
G1165388en
204-01-6Front Suspension204-01-6
DESCRIPTION AND OPERATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 7/61
Front Suspension
REFER to Section 204-00 [Suspension System -General Information].
G17395en
204-01-7Front Suspension204-01-7
DIAGNOSIS AND TESTING
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 8/61
Wheel Hub(14 371 0)
Special Tool(s)
Remover/Installer, Wheel
Hub/Wheel Bearing204-348
E42977
Protector, Axle Shaft205-332
15108
1. Remove the wheel knuckle.
For additional information, refer to: WheelKnuckle (204-01 Front Suspension,Removal and Installation).
2. Remove the components in the order indicated in the following illustration(s) andtable(s).
E39195
1
DescriptionItem
Wheel hubSee Removal DetailSee Installation Detail
1
3. To install, reverse the removal procedure.
Removal Details
Item 1 Wheel hub
1. Using a hydraulic press and the specialtools, remove the wheel hub.
E44828
204-348
205-332
Installation Details
G307405en
204-01-8Front Suspension204-01-8
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 9/61
Item 1 Wheel hub
1. Using a hydraulic press and the specialtools, install the wheel hub.
TIE44829
204-348
204-348
204-348
G307405en
204-01-9Front Suspension204-01-9
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 10/61
Wheel Hub — 2.5L Duratec-RS (224kW/305PS) - VI5(14 371 0)
Removal
1. Refer to: Front Wheel Bearing - 2.5LDuratec-RS (224kW/305PS) - VI5 (204-01Front Suspension, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1163885en
204-01-10Front Suspension204-01-10
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 11/61
Lower Arm(14 706 0)
Special Tool(s)
Protector, Ball Joint Gaiter
204-349
E42949
General Equipment
Ball joint separator
CAUTION: Make sure the strut and springassembly does not move in a forwards or
rearwards direction, to prevent damage tothe top mount center cup.
1. Remove the wheel and tire.
For additional information, refer to: Wheeland Tire (204-04 Wheels and Tires, Removaland Installation).
2. Remove the engine undershield.
• Rotate the locking tangs counterclockwise.
E40677
3. Detach the headlamp leveling front sensor bracket from the right-hand lower arm andsecure it to one side (if equipped).
TIE44651
8 Nm
4. Remove the components in the order indicated in the following illustration(s) andtable(s).
G296113en
204-01-11Front Suspension204-01-11
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 12/61
E39200
21
DescriptionItem
Lower arm ball jointSee Removal DetailSee Installation Detail
1
Lower armSee Removal DetailSee Installation Detail
2
5. To install, reverse the removal procedure.
6. Check the toe setting and adjust asnecessary.
For additional information, refer to:Specifications (204-00 Suspension System- General Information, Specifications)
/ Front Toe Adjustment (204-00 SuspensionSystem - General Information, GeneralProcedures).
Removal Details
G296113en
204-01-12Front Suspension204-01-12
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 13/61
Item 1 Lower arm ball joint
1. Using the special tool to prevent the ball jointfrom rotating, remove and discard the lower arm ball joint retaining nut.
TIE39073
2.CAUTION: Make sure the special tool is
installed with the curved surface facingupwards to prevent damage to the ball jointseal.
Install the special tool.
TIE44354
3. Using a suitable ball joint separator , detachthe lower arm from the wheel knuckle.
TIE44353
Item 2 Lower arm
1. Remove the lower arm front retaining bolt.
TIE0036674
2. Remove the lower arm rear clamp retainingbolts.
TIE0036676
Installation Details
Item 2 Lower arm
1. NOTE: Do not fully tighten the lower arm rear clamp retaining bolts at this stage.
G296113en
204-01-13Front Suspension204-01-13
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 14/61
Install the lower arm rear clamp retainingbolts.
TIE0036676
2. NOTE: Do not fully tighten the lower arm
front retaining bolt at this stage.
Install the lower arm front retaining bolt.
TIE0036674
3.CAUTION: While tightening the rear clamp
retaining bolts, make sure the lower armdoes not move.
NOTE: Make sure the lower arm rear clamp andthe crossmember are correctly aligned.
Tighten the lower arm rear clamp retainingbolts.
TIE0036677
115 Nm
4. Tighten the lower arm front retaining bolt.
TIE0036675
175 Nm
Item 1 Lower arm ball joint
1. WARNING: Install a new lower arm ball joint retaining nut. Failure to follow thisinstruction may result in personal injury.
Using the special tool to prevent the ball jointfrom rotating, install the lower arm ball jointretaining nut.
TIE39074
70 Nm
G296113en
204-01-14Front Suspension204-01-14
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 15/61
Lower Arm — 2.5L Duratec-RS (224kW/305PS) - VI5(14 706 0;
14 707 0; 14 709 0)
Special Tool(s)
204-605Separator, Lower Arm BallJoint
E63772
204-609Protection Cap, Ball JointGaiter
E75372
Removal
NOTE: Removal steps in this procedure maycontain installation details.
1. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2.
E40677
3. If equipped.
E75215
4. Torque: 83 Nm
E112595
5. Special Tool(s): 204-605
E97732
204-605
G1155684en
204-01-15Front Suspension204-01-15
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 16/61
6. Special Tool(s): 204-609
E81908
204-609
7. Torque:• Stage 1: 100 Nm
• Stage 2: Loosen: 90°• Stage 3: 125 Nm
1.
2. Torque: 125 Nm
E115186
1
2
Installation
1. To install, reverse the removal procedure.
2. Check the toe setting and adjust as necessary.
Refer to: Specifications (204-00 SuspensionSystem - General Information, Specifications).
G1155684en
204-01-16Front Suspension204-01-16
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 17/61
Front Stabilizer Bar
Special Tool(s)
Protector, Ball Joint Gaiter
204-349
E42949
Alignment Pins, Subframe205-316 (15-097A)
15097A
Separator, Ball Joint211-020
13006
General Equipment
Ball joint separator
Securing strap
Transmission jack
CAUTION: Make sure the strut and springassembly does not move in a forwards or rearwards direction, to prevent damage tothe top mount center cup.
All vehicles
1. NOTE: Make sure the road wheels are in thestraight ahead position.
Centralize the steering wheel and lock it inposition.
TIE38834
2. Detach the steering column from the steeringgear pinion.
• Discard the bolt.
TIE0027063
3. Remove the front wheels and tires.
For additional information, refer to: Wheeland Tire (204-04 Wheels and Tires, Removaland Installation).
4. Remove the engine undershield.
E40677
G296114en
204-01-17Front Suspension204-01-17
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 18/61
5. Detach the headlamp leveling front sensor bracket from the right-hand lower arm andsecure it to one side (if equipped).
TIE44651
8 Nm
6. CAUTION: Over bending of the exhaustflexible pipe may cause damage resulting infailure.
Support the exhaust flexible pipe with asuitable support wrap or a suitable splint.
TIE0002772
7.CAUTION: Take care when removing the
exhaust hanger insulators to preventdamage.
Detach the exhaust flexible pipe from thefront axle crossmember exhaust hanger insulators.
TIE39009
All except vehicles with diesel engine
8.CAUTION: Using suitable cable ties,
support the rear muffler and exhaust tailpipeassembly to prevent damage to the exhausthanger insulators.
Detach the exhaust flexible pipe from therear muffler flange.
• Discard the gasket and nuts.
E50598
48 Nm
Vehicles with diesel engine9.
CAUTION: Using suitable cable ties,support the rear muffler and exhaust tailpipeassembly to prevent damage to the exhausthanger insulators.
Detach the exhaust flexible pipe from therear muffler flange (2.0L Duratorq-TDCi (DW)Diesel shown).
G296114en
204-01-18Front Suspension204-01-18
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 19/61
• Discard the gasket and nuts.
TIE40628
51 Nm
10. Remove the components in the order indicated in the following illustration(s) andtable(s).
E39001
3
48 Nm 148 Nm2
DescriptionItem
Tie-rod end retaining nutSee Removal DetailSee Installation Detail
1
Stabilizer bar link retaining nutSee Removal DetailSee Installation Detail
2
Lower arm ball joint retaining nutSee Removal DetailSee Installation Detail
3
G296114en
204-01-19Front Suspension204-01-19
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 20/61
TIE45173
80 Nm 4
5
DescriptionItem
Engine support insulator front retainingbolt
4
Front axle crossmember See Removal DetailSee Installation Detail
5
G296114en
204-01-20Front Suspension204-01-20
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 21/61
E40394
7
48 Nm 6
8
48 Nm 6
DescriptionItem
Stabilizer bar clamp retaining bolts6
Stabilizer bar clamps7
Stabilizer bar See Removal DetailSee Installation Detail
8
11. To install, reverse the removal procedure.
12.WARNING: Install a new steering column
to steering gear pinion bolt. Failure to
follow this instruction may result inpersonal injury.
NOTE: Make sure the road wheels are in thestraight ahead position.
G296114en
204-01-21Front Suspension204-01-21
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 22/61
Attach the steering column to the steeringgear pinion.
TIE0027064
28 Nm
13. Check the front toe setting and adjust asnecessary.
For additional information, refer to:Specifications (204-00 Suspension
System - General Information,Specifications) / Front Toe Adjustment (204-00 Suspension
System - General Information, GeneralProcedures).
Removal Details
Item 1 Tie-rod end retaining nut
1.CAUTION: Leave the tie-rod end retaining
nut in place to protect the ball joint stud.
NOTE: Use a 5 mm Allen key to prevent the ball joint stud from rotating.
Loosen the tie-rod end retaining nut on bothsides.
TIE0026775
2.CAUTION: Protect the ball joint seal using
a soft cloth to prevent damage.
Using the special tool, detach the tie-rod endfrom the wheel knuckle on both sides.
• Discard the tie-rod end retaining nut.
E52983
211-020
Item 2 Stabilizer bar link retaining nut
1. NOTE: Use a 5 mm Allen key to prevent theball joint stud from rotating.
Detach the stabilizer bar link from thestabilizer bar on both sides.
Item 3 Lower arm ball joint retaining nut
1. Using the special tool to prevent the ball jointfrom rotating, remove the lower arm ball jointretaining nut on both sides.
G296114en
204-01-22Front Suspension204-01-22
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 23/61
• Discard the lower arm ball joint retaining nut.
TIE39073
2.CAUTION: Make sure that the special tool
is installed with the curved surface facingupwards to prevent damage to the ball jointseal.
Install the special tool.
TIE44354
3. Using a suitable ball joint separator, detachthe lower arm from the wheel knuckle onboth sides.
TIE44353
Item 5 Front axle crossmember
1. Using a transmission jack and a woodenblock, support the front axle crossmember.
2. Using a suitable securing strap, secure thefront axle crossmember to the transmission
jack.
3. Remove the front axle crossmember bracket
retaining bolts on both sides.
TIE44500
4. Remove the front axle crossmember retaining bolts (transmission jack shownremoved for clarity).
TIE39071
5.CAUTION: To prevent damage to the
power steering lines, only lower thecrossmember sufficiently to allow thestabilizer bar to be removed.
Lower the front axle crossmember.
G296114en
204-01-23Front Suspension204-01-23
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 24/61
Item 8 Stabilizer bar
1. Remove the stabilizer bar bushings.
TIE0046824
Installation Details
Item 8 Stabilizer bar
1.CAUTION: The stabilizer bar bushings
must be located correctly on the flats of thestabilizer bar with no lubricant.
Install the stabilizer bar bushings.
TIE0046825
2. Position the stabilizer bar on the front axlecrossmember.
Item 5 Front axle crossmember 1. Using a transmission jack and the special
tool, position and align the front axlecrossmember.
1. Insert the alignment pins through the frontaxle crossmember alignment holes.
2. Slide the locking plates into the groove of thespecial tool and tighten the alignment pinsleeve.
3. Raise the front axle crossmember engagingthe alignment pins into the front axlecrossmember alignment holes.
TIE0000859
1
3
2205-316
2.CAUTION: While tightening the front axle
crossmember retaining bolts, make sure thefront axle crossmember does not move.
Install the front axle crossmember retainingbolts (transmission jack shown removed for clarity).
TIE39072
115 Nm
275 Nm
G296114en
204-01-24Front Suspension204-01-24
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 25/61
3. Install the front axle crossmember bracketretaining bolts on both sides.
TIE44501
70 Nm
4. Remove the securing strap.
5. Lower and remove the transmission jack andthe wooden block.
Item 3 Lower arm ball joint retaining nut
1.WARNING: Install a new lower arm ball
joint retaining nut. Failure to follow thisinstruction may result in personal injury.
Using the special tool to prevent the ball jointfrom rotating, install the lower arm ball jointretaining nut on both sides.
TIE39074
70 Nm
Item 2 Stabilizer bar link retaining nut
1. NOTE: Use a 5 mm Allen key to prevent theball joint stud from rotating.
Attach the stabilizer bar link to the stabilizer bar on both sides.
Item 1 Tie-rod end retaining nut
1. NOTE: Use a 5 mm Allen key to prevent the
ball joint stud from rotating.
Attach the tie-rod end to the wheel knuckleon both sides.
G296114en
204-01-25Front Suspension204-01-25
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 26/61
Front Stabilizer Bar — 2.5L Duratec-RS (224kW/305PS) -
VI5(14 752 0)
Special Tool(s)
205-316A Alignment Pins, Subframe
15097A
211-020Separator, Ball Joint
13006
General Equipment
Cable Ties
Transmission Jack
Vise
Removal
NOTE: Removal steps in this procedure maycontain installation details.
1. Refer to: Wheel and Tire (204-04 Wheels andTires, Removal and Installation).
2.
E40677
3. If equipped.
Torque: 11 Nm
E75215
4. CAUTION: Make sure that the ball jointball does not rotate.
On both sides.Torque: 110 Nm
E112596
5. CAUTION: Make sure that the ball jointball does not rotate.
Torque: 48 Nm
E112598
G1155685en
204-01-26Front Suspension204-01-26
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 27/61
6. Special Tool(s): 211-020
211-020E112599
7. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
E98334
8.
E98346
9. Torque:• Stage 1: 35 Nm• Stage 2: Loosen: 360°• Stage 3: 85 Nm
1.
E89385
10. General Equipment: Cable TiesTorque:• Stage 1: 40 Nm• Stage 2: 60°
E98557
11. General Equipment: Transmission Jack
E99060
G1155685en
204-01-27Front Suspension204-01-27
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 28/61
12. Remove the following items:
1. Torque: 70 Nm
2.
Torque:• Stage 1: 140 Nm• Stage 2: 180°
3. Torque: 125 Nm
E115435
1 1
2 2
3
35 mm
4
13. Torque: 48 Nm
G1155685en
204-01-28Front Suspension204-01-28
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 29/61
E115436
x 4
1
23
14.
E115437
75 mm
NOTE: This step is only necessary when installing
a new component.
15. NOTE: Note the position of the componentsbefore removal.
On both sides.
General Equipment: Vise
G1155685en
204-01-29Front Suspension204-01-29
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 30/61
E115443
Installation
1. To install, reverse the removal procedure.
NOTE: This step is only necessary when installinga new component.
2. NOTE: Make sure that the component is clean,
free of foreign material and lubricant.
NOTE: Make sure that the component isinstalled to the position noted before removal.
1. Metal strip
General Equipment: Vise
G1155685en
204-01-30Front Suspension204-01-30
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 31/61
E115444
1
3. Special Tool(s): 205-316A
E116296
205-316A
G1155685en
204-01-31Front Suspension204-01-31
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 32/61
4. Refer to: Front Toe Adjustment (204-00Suspension System - General Information,General Procedures).
G1155685en
204-01-32Front Suspension204-01-32
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 33/61
Lower Arm Ball Joint(14 735 0)
Special Tool(s)
Protector, Ball Joint Gaiter
204-349
E42949
General Equipment
Ball joint separator
Electric hand drill
CAUTION: Make sure the strut and springassembly does not move in a forwards or rearwards direction, to prevent damage tothe top mount center cup.
1. Remove the wheel and tire.
For additional information, refer to: Wheeland Tire (204-04 Wheels and Tires, Removaland Installation).
2. Detach the headlamp leveling front sensor bracket from the right-hand lower arm andsecure it to one side (if equipped).
TIE44651
8 Nm
3. Remove the components in the order indicated in the following illustration(s) andtable(s).
E40735
1
DescriptionItem
Lower arm ball jointSee Removal DetailSee Installation Detail
1
4. To install, reverse the removal procedure.
5. Check the toe setting and adjust asnecessary.
For additional information, refer to:Specifications (204-00 Suspension System- General Information, Specifications)
/ Front Toe Adjustment (204-00 SuspensionSystem - General Information, GeneralProcedures).
Removal Details
G325338en
204-01-33Front Suspension204-01-33
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 34/61
Item 1 Lower arm ball joint
1. Using the special tool to prevent the ball jointfrom rotating, remove and discard the lower arm ball joint retaining nut.
TIE39073
2.CAUTION: Make sure that the special tool
is installed with the curved surface facingupwards to prevent damage to the ball jointseal.
Install the special tool.
TIE44354
3. Using a suitable ball joint separator, detachthe lower arm from the wheel knuckle.
TIE44353
4. Remove the lower arm ball joint.
• Using a suitable electric hand drill removethe rivets.
TIE0036826
Installation Details
G325338en
204-01-34Front Suspension204-01-34
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 35/61
Item 1 Lower arm ball joint
1. Using suitable M10 nuts and M10 x 30 mmbolts, install a new lower arm ball joint.
TIE0036827
70 Nm
2.WARNING: Install a new lower arm ball
joint retaining nut. Failure to follow thisinstruction may result in personal injury.
Using the special tool to prevent the ball jointfrom rotating, install the lower arm ball jointretaining nut.
TIE39074
70 Nm
G325338en
204-01-35Front Suspension204-01-35
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 36/61
Wheel Knuckle
Special Tool(s)
Lever, Wheel Knuckle
204-159 (14-039)
14039
Protector, Ball Joint Gaiter 204-349
E42949
Separator, Ball Joint211-020
13006
General Equipment
Ball joint separator
CAUTION: Make sure the strut and springassembly does not move in a forwards or
rearwards direction, to prevent damage tothe top mount center cup.
1. Remove the wheel & tire.
For additional information, refer to: Wheeland Tire (204-04 Wheels and Tires, Removaland Installation).
2. Detach the headlamp leveling front sensor bracket from the right-hand lower arm andsecure it to one side (if equipped).
TIE44651
8 Nm
3. Remove the components in the order indicated in the following illustration(s) andtable(s).
G296115en
204-01-36Front Suspension204-01-36
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 37/61
E40389
10
9 Nm3
2
1 8
9 Nm 6
9
4
7
5
45 m
DescriptionItem
Brake caliper and anchor plateSee Removal DetailSee Installation Detail
1
Brake discSee Removal Detail
2
Wheel speed sensor retaining bolt3
Wheel hub retaining bolt4
Tie-rod endSee Removal DetailSee Installation Detail
5
DescriptionItem
Lower arm ball joint heat shield6
Lower arm ball jointSee Removal DetailSee Installation Detail
7
Wheel knuckle to strut and springassembly pinch boltSee Installation Detail
8
Strut and spring assemblySee Removal Detail9
Wheel knuckle10
G296115en
204-01-37Front Suspension204-01-37
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 38/61
4. To install, reverse the removal procedure.
Removal Details
Item 1 Brake caliper and anchor plate
1.CAUTION: Suspend the brake caliper and
anchor plate to prevent load being placedon the brake hose.
Detach the brake caliper and anchor plateassembly from the wheel knuckle.
TIE0030230
Item 2 Brake disc
1. Remove the brake disc.
• Remove and discard the retaining washer (if equipped)
E0032118
Item 5 Tie-rod end
1.CAUTION: Leave the tie-rod end retaining
nut in place to protect the ball joint stud.
NOTE: Use a 5 mm Allen key to prevent the ball joint stud from rotating.
Loosen the tie-rod end retaining nut.
TIE0026775
2.CAUTION: Protect the ball joint seal using
a soft cloth to prevent damage.
Using the special tool, detach the tie-rod endfrom the wheel knuckle.
1. Release the tie-rod end.
2. Remove and discard the tie-rod end retainingnut.
TIE0026773
211-020 1
2
G296115en
204-01-38Front Suspension204-01-38
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 39/61
Item 7 Lower arm ball joint
1. Using the special tool to prevent the ball jointfrom rotating, remove and discard the lower arm ball joint retaining nut.
TIE39073
2.CAUTION: Make sure the special tool is
installed with the curved surface facingupwards to prevent damage to the ball jointseal.
Install the special tool.
TIE44354
3. Using a suitable ball joint separator, detachthe lower arm from the wheel knuckle.
TIE44353
4. CAUTIONS:
Support the halfshaft. The inner constantvelocity (CV) joint must not be bent morethan 23 degrees. The outer CV joint must notbe bent more than 45 degrees.
Do not apply excessive force to the strutand spring assembly. Do not pull the strutand spring assembly outwards by more than28 mm.
NOTE: Make sure the halfshaft is still fully engagedin the tripode housing.
Detach the halfshaft from the wheel hub.
• Pull the strut and spring assembly outwardsapproximately 28 mm.
Item 9 Strut and spring assembly
1. Using the special tool, detach the strut andspring assembly from the wheel knuckle.
TIE0000944
204-159
Installation Details
G296115en
204-01-39Front Suspension204-01-39
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 40/61
Item 8 Wheel knuckle to strut and spring
assembly pinch bolt
1.CAUTION: The wheel knuckle to strut and
spring assembly pinch bolt must be installed
from the front of the wheel knuckle.
Attach the strut and spring assembly to thewheel knuckle.
TIE0005688
90 Nm
Item 7 Lower arm ball joint
1. CAUTIONS:
Support the halfshaft. The inner constantvelocity (CV) joint must not be bent morethan 23 degrees. The outer CV joint must not
be bent more than 45 degrees.
Do not apply excessive force to the strutand spring assembly. Do not pull the strutand spring assembly outwards by more than28 mm.
Attach the halfshaft to the wheel hub.
• Pull the strut and spring assembly outwardsapproximately 28 mm.
2.WARNING: Install a new lower arm ball
joint retaining nut. Failure to follow thisinstruction may result in personal injury.
Using the special tool to prevent the ball jointfrom rotating, install the lower arm ball jointretaining nut.
TIE39074
70 Nm
Item 5 Tie-rod end
1.WARNING: Install a new tie-rod end
retaining nut. Failure to follow thisinstruction may result in personal injury.
NOTE: Use a 5 mm Allen key to prevent the ball joint from rotating.
Attach the tie-rod end to the wheel knuckle.
TIE41742
48 Nm
G296115en
204-01-40Front Suspension204-01-40
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 41/61
Item 1 Brake caliper and anchor plate
1. Attach the brake caliper and anchor plate tothe wheel knuckle.
TIE0036772
115 Nm
G296115en
204-01-41Front Suspension204-01-41
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 42/61
Wheel Knuckle — 2.5L Duratec-RS (224kW/305PS) -
VI5(14 343 0)
Special Tool(s)
204-159Lever, Wheel Knuckle
14039
204-605Separator, Lower Arm BallJoint
E63772
204-609Protection Cap, Ball JointGaiter
E75372
205-071-01 Adapter for 205-071 (ThrustPad)
15026A01
211-020Separator, Ball Joint
13006
General Equipment
Puller
Removal
NOTE: Removal steps in this procedure maycontain installation details.
1. Refer to: Wheel and Tire (204-04 Wheels andTires, Removal and Installation).
2. Torque:• Stage 1: 45 Nm• Stage 2: 90°
E112606
3. Special Tool(s): 205-071-01General Equipment: Puller
205-071-01205-071-01
E101038
4. WARNINGS:
Make sure that no load is placed on thebrake hose.
G1163891en
204-01-42Front Suspension204-01-42
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 43/61
Make sure that the brake hose is nottwisted and is correctly located.
Torque: 200 Nm
E115549
5. If equipped.
E75215
6. CAUTION: Make sure that the ball jointball does not rotate.
Torque: 110 Nm
E112596
7. Torque: 83 Nm
E112595
8. Special Tool(s): 204-605
E97732
204-605
9. Special Tool(s): 204-609
E81908
204-609
G1163891en
204-01-43Front Suspension204-01-43
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 44/61
10. NOTE: This step is only necessary wheninstalling a new component.
E112605
11. CAUTION: Make sure that the ball joint
ball does not rotate.
Torque: 48 Nm
E112598
12. Special Tool(s): 211-020
211-020E112599
13. Refer to: Front Wheel Speed Sensor (206-09 Anti-Lock Control, Removal and Installation).
14. Torque:• Stage 1: 80 Nm• Stage 2: 180°
E112597
15. Special Tool(s): 204-159
G1163891en
204-01-44Front Suspension204-01-44
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 45/61
E112604
4
1
2
3
204-159
16. NOTE: This step is only necessary wheninstalling a new component.
Refer to: Front Wheel Bearing - 2.5LDuratec-RS (224kW/305PS) - VI5 (204-01Front Suspension, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1163891en
204-01-45Front Suspension204-01-45
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 46/61
Strut and Spring Assembly
Special Tool(s)
Lever, Wheel Knuckle
204-159
14039
CAUTION: Make sure the strut and springassembly does not move in a forwards or rearwards direction, to prevent damage tothe top mount center cup.
1. Remove the engine upper cover.2. Remove the cowl panel grille.
For additional information, refer to: CowlPanel Grille (501-02 Front End Body Panels,Removal and Installation).
3. Remove the bulkhead extension panel.
1. Remove the retaining screws and washers.
2. Detach the panel from the retaining clips.
E50990
1
2
4. Detach the strut and spring assembly topmount brace from the bulkhead (left-handside shown).
TIE0036727
25 Nm
5.CAUTION: Make sure that new bolts are
installed.
Remove the strut and spring assembly topmount brace (left-hand side shown).
• Loosely install the strut and spring assemblytop mount bolts.
E42604
32 Nm
6. Remove the wheel and tire.
For additional information, refer to: Wheeland Tire (204-04 Wheels and Tires, Removaland Installation).
7. Remove the components in the order indicated in the following illustration(s) andtable(s).
G401518en
204-01-46Front Suspension204-01-46
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 47/61
E40390
5
2
4
3
1
DescriptionItem
Stabilizer bar link to strut and springassembly retaining nutSee Removal DetailSee Installation Detail
1
Brake hose2
Wheel knuckle to strut and springassembly pinch boltSee Removal DetailSee Installation Detail
3
DescriptionItem
Strut and spring assembly top mountretaining boltsSee Removal DetailSee Installation Detail
4
Strut and spring assembly5
8. To install, reverse the removal procedure.
Removal Details
Item 1 Stabilizer bar link to strut and spring
assembly retaining nut
NOTE: Use a 5 mm Allen key to prevent the ball joint from rotating.
G401518en
204-01-47Front Suspension204-01-47
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 48/61
Item 3 Wheel knuckle to strut and spring
assembly pinch bolt
1. Using the special tool, detach the strut andspring assembly from the wheel knuckle.
TIE0000944
204-159
Item 4 Strut and spring assembly top mount
retaining bolts
CAUTION: With the aid of another technician, support the strut and spring
assembly.
Installation Details
Item 4 Strut and spring assembly top mount
retaining bolts
1.CAUTION: With the aid of another
technician, support the strut and springassembly.
Install the strut and spring assembly topmount bolts.
1. Use old bolts.
E126084
32 Nm
1
1
Item 3 Wheel knuckle to strut and spring
assembly pinch bolt
1.WARNING: Install a new wheel knuckle
to strut and spring assembly pinch bolt.Failure to follow this instruction may resultin personal injury.
CAUTION: The wheel knuckle to strut andspring assembly pinch bolt must be
installed from the front of the wheelknuckle.
Attach the strut and spring assembly to thewheel knuckle.
TIE0005688
90 Nm
Item 1 Stabilizer bar link to strut and springassembly retaining nut
1. NOTE: Use a 5 mm Allen key to prevent theball joint from rotating.
G401518en
204-01-48Front Suspension204-01-48
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 49/61
Install the stabilizer bar link to strut andspring assembly retaining nut.
TIE0021919
48 Nm
2. Remove the strut and spring assembly top
mount bolts.
TIE44530
G401518en
204-01-49Front Suspension204-01-49
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 50/61
Front Strut and Spring Assembly — 2.5L Duratec-RS
(224kW/305PS) - VI5(14 781 0; 14 782 0)
Special Tool(s)
204-159Lever, Wheel Knuckle
14039
204-605Separator, Lower Arm BallJoint
E63772
204-609Protection Cap, Ball JointGaiter
E75372
General Equipment
Tire Lever
Removal
NOTE: Removal steps in this procedure maycontain installation details.
1. Refer to: Cowl Panel Grille (501-02 Front EndBody Panels, Removal and Installation).
2. Refer to: Wheel and Tire (204-04 Wheels andTires, Removal and Installation).
3. If equipped.Torque: 11 Nm
E75215
4. CAUTION: Make sure that the ball jointball does not rotate.
Torque: 110 Nm
E112596
5. Torque: 83 Nm
E112595
G1188792en
204-01-50Front Suspension204-01-50
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 51/61
6. Special Tool(s): 204-605
E97732
204-605
7. Special Tool(s): 204-609
E81908
204-609
8. General Equipment: Tire Lever 1.
E115072
1
9. Torque:• Stage 1: 80 Nm• Stage 2: 180°
E112597
10.
E115536
11. Special Tool(s): 204-159
G1188792en
204-01-51Front Suspension204-01-51
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 52/61
E115537
204-159
1
2
3
12. WARNING: This step requires the aid of another technician.
Torque: 35 Nm
x3x3
E113538
Installation
1. To install, reverse the removal procedure.
G1188792en
204-01-52Front Suspension204-01-52
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 53/61
Front Wheel Bearing — 2.5L Duratec-RS (224kW/305PS) -
VI5(14 411 0; 14 411 4; 14 412 0; 14 414 4; 14 416 4)
Special Tool(s)
204-348/3Remover/Installer, WheelHub/Wheel Bearing
E87735
204-348/3
204-348-01A Adapter for 204-348
E106983
204-595Remover/Installer, WheelHub/Wheel Bearing
E62064
204-752Remover/Installer FrontWheel Bearing
E103305
General Equipment
Hydraulic Press
Removal
NOTE: Removal steps in this procedure maycontain installation details.
1. Refer to: Wheel Knuckle - 2.5L Duratec-RS(224kW/305PS) - VI5 (204-01 FrontSuspension, Removal and Installation).
2. Special Tool(s): 204-752, 204-348/3General Equipment: Hydraulic Press
E113797
204-752
204-348/3
G1163886en
204-01-53Front Suspension204-01-53
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 54/61
Installation
1. Special Tool(s): 204-348-01A, 204-348/3,204-595General Equipment: Hydraulic Press
E113798
204-348/3
204-348-01A
204-595-07
2. Refer to: Wheel Knuckle - 2.5L Duratec-RS(224kW/305PS) - VI5 (204-01 FrontSuspension, Removal and Installation).
G1163886en
204-01-54Front Suspension204-01-54
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 55/61
Front Stabilizer Bar Bushing — 2.5L Duratec-RS (224kW/305PS)
- VI5(14 754 0; 14 754 4)
Removal
1. Refer to: Front Stabilizer Bar - 2.5L Duratec-RS(224kW/305PS) - VI5 (204-01 FrontSuspension, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1163890en
204-01-55Front Suspension204-01-55
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 56/61
Front Stabilizer Bar Ball Joint — 2.5L Duratec-RS (224kW/305PS)
- VI5(14 758 0)
Special Tool(s)
204-288ARemover/Installer, Ball Joint
E115081
204-605Separator, Lower Arm BallJoint
E63772
204-609Protection Cap, Ball JointGaiter
E75372
205-066-01 Adapter for 205-066
1503301
211-198Remover, Power SteeringPump Pulley
ES13021
303-038-01 Adapter for 303-038
21008A01
General Equipment
Tire Lever
Removal
NOTE: Removal steps in this procedure maycontain installation details.
1. Refer to: Wheel and Tire (204-04 Wheels andTires, Removal and Installation).
2. CAUTION: Make sure that the ball jointball does not rotate.
Torque: 110 Nm
E112596
3. If equipped.Torque: 11 Nm
E75215
G1163892en
204-01-56Front Suspension204-01-56
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 57/61
4. Torque: 83 Nm
E112595
5. Special Tool(s): 204-605
E97732
204-605
6. Special Tool(s): 204-609
E81908
204-609
7. General Equipment: Tire Lever 1.
E115072
1
8. Special Tool(s): 204-288A
G1163892en
204-01-57Front Suspension204-01-57
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 58/61
E112602
204-288/A 204-288A/1
Installation
1. To install, reverse the removal procedure.2.
G1163892en
204-01-58Front Suspension204-01-58
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 59/61
E115149
1 2
3. Special Tool(s): 204-288A, 205-066-01,211-198, 303-038-01
G1163892en
204-01-59Front Suspension204-01-59
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 60/61
E112603
204-288A/1211-198205-066-01 204-288/A 303-038-01
G1163892en
204-01-60Front Suspension204-01-60
REMOVAL AND INSTALLATION
ACK TO CHAPTER INDEX
TO MODEL INDEX
2011.00 Focus 8/2010
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL
7/22/2019 Front Suspension .pdf
http://slidepdf.com/reader/full/front-suspension-pdf 61/61
Strut and Spring Assembly
Special Tool(s)
Compressor, Coil Spring
204-167 (14-042)
14042
Adapters for 204-167204-167-01 (14-042-01)
1404201
WARNING: The spring is under extremetension; care must be taken at all times.
Failure to follow this instruction may resultin personal injury.
1. Disassemble the components in the order indicated in the following illustration(s) andtable(s).
E38791
6
3
2
4
5
50 Nm1
DescriptionItem DescriptionItem
Th t b i d i t bl3
204-01-61Front Suspension204-01-61
DISASSEMBLY AND ASSEMBLY
ACK TO CHAPTER INDEX
TO MODEL INDEX
FORD FOCUS RS & ST WORKSHOP REPAIR MANUAL