Chapter 1 Routine maintenance and servicing

Suspension and steering 10•7A Suspension strutB Coil springC Bump-stopD GaiterE Upper spring seatF Thrust bearingG Lower cup seatmounting5.3 Exploded view of front suspension strut assembly5.9 Correct spring location in its lowerseatbearing, upper spring seat, gaiter andbump-stop from the piston rod (seeillustration).4 The suspension strut and coil spring maynow be separated. If a new suspension strutis to be fitted there is no need to release thecoil spring from compression, but if a new coilspring is to be fitted, release the compressorsgently until the spring is in its released state,then remove it.Examination5 With the strut assembly now completelydismantled, examine the mountingcomponents for wear, damage ordeformation. Renew any of the componentsas necessary.6 Examine the strut for signs of fluid leakage.Check the strut piston for signs of pittingalong its entire length, and check the strutbody for signs of damage or corrosion. Testthe operation of the strut, holding it in anupright position, by moving the piston througha full stroke, and then through short strokes of50 to 100 mm. In both cases, the resistancefelt should be smooth and continuous. If theresistance is jerky, or uneven, or if there is anyvisible sign of wear or damage to the strut,renewal is necessary.Reassembly7 If a new spring is to be fitted, engage the6.3 Anti-roll bar connecting link-to-strutconnectioncompressors as during removal, andcompress the spring sufficiently to enablesuspension strut reassembly.8 Reunite the spring and suspension strut,and refit the bump-stop gaiter, spring seat,thrust bearing and lower cup seat mounting,renewing components as necessary. Refit thespring retaining nut and tighten to thespecified torque.9 Carefully release the spring tension,ensuring that the spring locates correctly intoits upper and lower spring seats (seeillustration).10 Remove the spring compressors.11 The rubber insulator fitted to the top of theinner wing is a simple push fit, and is easilyreplaceable. Ensure when replacing this,that the lip sits evenly around the locatinghole.6 Front suspension anti-rollbar - removal and refitting 2Removal1 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheels.2 Remove the one-piece undertray wherefitted, by turning its bayonet-type fasteners,and on XR2i models, remove the front6.5 Anti-roll bar bracket and mountingboltssuspension crossmember as described inSection 7.3 Undo the nut securing the upper end of theanti-roll bar connecting link to the suspensionstrut bracket, and disconnect the link (seeillustration).4 Undo the nut securing the lower end of theconnecting link to the anti-roll bar, andremove the link.5 Remove the two bolts securing the anti-rollbar brackets to each lower suspension armmounting bracket (see illustration), removethe anti-roll bar brackets and withdraw theanti-roll bar from the vehicle.6 The rubber bushes locating the anti-roll barcan be removed by sliding them off over thelink connections.Refitting7 Refitting is a reversal of the removalprocedure, tightening the retaining nuts to thespecified torque settings.7 Front suspensioncrossmember -removal and refitting2Note: The front suspension crossmember isonly fitted to XR2i models.Removal1 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheels.2 Remove the one-piece undertray wherefitted, by turning its bayonet-type fasteners.3 The crossmember, which serves as anadditional bracing component, is locatedbetween the lower suspension arm mountingbrackets, and is secured to these brackets byfour bolts. To remove it, simply undo the fourbolts and lower it from the vehicle.Refitting4 Refitting is the reverse sequence toremoval, ensuring that the bolts are tightenedto the specified torque.101595Ford Fiesta Remake