Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake10•10 Suspension and steering3 Unscrew and remove the upper mountingthrough-bolt and nut.4 Withdraw the upper mounting cup and thespring seat.5 The suspension strut and coil spring can nowbe separated. If the coil spring or strut is to berenewed, the original coil spring must bereleased from the compressor. If it is to be reused,the coil spring can be left in compression.Examination6 With the strut assembly now completelydismantled, examine the mountingcomponents for wear, damage or deformation.Renew any of the components as necessary.7 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 deterioration ofthe mountings. Test the operation of the strut,holding it in an upright position, by moving thepiston through a full stroke, and then throughshort strokes of 50 to 100 mm. In both cases,the resistance felt should be smooth andcontinuous. If the resistance is jerky, oruneven, or if there is any visible sign of wearor damage to the strut, renewal is necessary.Reassembly8 Reassembly is a reversal of the dismantlingprocedure but note the following points:a) When the spring is located over thesuspension strut, the spring seat, cup andthrough-bolt fitted, tighten the retainingbolt to the specified torque.b) When reassembled, check that the upperand lower spring tails are correctlyengaged with their spring seats beforeremoving the spring compressor.12 Rear axle (all models exceptCourier) -3removal and refittingRemoval1 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe rear roadwheels.2 Refer to Chapter 9 for details, and disconnectthe handbrake cable equaliser from the primarycable. Remove the handbrake rear cable fromits adjuster and its fixed body locations.3 Disconnect the rear brake flexible hydraulicbrake hoses from their rigid line connections.Clamp the hoses before disconnecting them,to minimise the fluid loss and air entry into thehydraulic system (see Chapter 9 for details).4 On ABS-equipped models, undo theretaining nuts and detach the ABS loadapportioningvalve operating links from theaxle beam. Do not remove the loadapportioningvalve (see Chapter 9).5 Locate suitable jacks or axle stands underthe axle beam to support its weight (not to liftit), then unscrew the four mounting bracketbolts each side.6 Unscrew and remove the strut-to-axlemounting bolt each side.7 Check that all associated fittings are clear,then lower the axle and remove it from underthe vehicle.8 If the twist beam axle has been damaged, itmust be renewed. Refer to Chapter 9 fordetails on removing the rear brakes from theaxle. To remove the front mounting/pivotbrackets from the axle, unscrew the pivot bolt.Refitting9 Refitting is a reversal of the removalprocedure, but note the following:a) Reconnect the axle at the front floormountings first, and tighten the retainingbolts to the specified torque.b) Reconnect the axle to the suspensionstruts, but do not fully retighten the securingbolts until after the vehicle is lowered to theground and is standing on its wheels.c) Ensure that all brake fluid line connectionsare clean before reconnecting them. Referto the appropriate Sections in Chapter 9for specific details on reconnecting thebrake lines, bleeding the brake hydraulicsystem, and for reconnecting thehandbrake cable and its adjustment.d) When the vehicle is lowered and is standingon its wheels, tighten the suspensionfastenings to their specified torque settings.13 Rear axle pivot bushes (allmodels except Courier) - 3renewalNote: Two different types of pivot busheshave been fitted during the course of Fiestaproduction. It is understood that once stocksof the early type are exhausted, only the lattertype will be supplied by Ford parts dealers. Ifrenewing pivot bushes on a pre-April 1990model, and only the later type bushes areavailable, fit the new bushes as describedfrom paragraph 15 onward.Pre-April 1990 models1 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”).13.8a Correct pivot bush positioning intrailing armA Left-hand side B Right-hand side13.4 Pivot bush bolt (A) and bodymounting bracket bolts (B)2 Position a suitable support (preferablyadjustable) under the axle twist beam so thatit is capable of carrying the weight of the axle(not the weight of the vehicle).3 On ABS-equipped models, undo theretaining nuts and detach the ABS loadapportioningvalve operating links from theaxle beam. Do not remove the loadapportioningvalve (see Chapter 9).4 Unscrew the nuts, withdraw the pivot bolts,then lower the rear axle so that the bushes areclear of their mounting brackets (seeillustration). Take care not to allow the brakepipes to become distorted and stretched - ifnecessary, disconnect the hydraulic lines (seeChapter 9 for details).5 Undo the four body mounting bracket boltsand remove the brackets.6 Using a soft-faced hammer and a suitablepunch or drift, drive the bushes from theirlocations, taking care not to raise any burrs onthe trailing arm eyes.7 To fit the new bushes, obtain a steel tube ofa diameter slightly less than that of the bushlocation in the axle, various flat washers and along bolt and nut.8 Place the new bush in position in its axlelocation with the bush collar nearest to theouter edge of the vehicle. The bush must beinstalled with its voids positioned as shown(see illustration). Using the steel tube,washers, long bolt and nut, draw the bushinwards towards the centre of the vehicle (seeillustration). Care should be taken to avoiddamage to the bush and to obtain correct13.8b Fitting pivot bush with its collar(arrowed) towards the outer edge of thevehicle