Chapter 1 Routine maintenance and servicing

Suspension and steering 10•11positioning of the voids. Install the bush onthe other side in the same way.9 With the new bushes in position, refit thebody mounting brackets loosely to the trailingarms - do not fully tighten the pivot bolts atthis stage. Final tightening is carried out withthe vehicle standing on its roadwheels.10 Raise the axle assembly so that theconical locating pegs on the body mountingbrackets engage in their body locations. Refitthe body mounting bracket bolts and tightento the specified torque.11 On ABS equipped models, reconnect theload-apportioning valve operating links to therear axle beam12 If the flexible brake hoses weredisconnected during this operation, reconnectthem and bleed the brake hydraulic system(see Chapter 9).13 Lower the vehicle to the ground.14 Fully tighten the bush pivot bolt nuts tothe specified torque.April 1990 models onward15 As mentioned in the note at the start ofthis Section, all later models are fitted withrevised bushes which use 12 mm (thread size)pivot bolts. If the later type bushes are to befitted to a pre-April 1990 model, twocorresponding bolts and nuts must beobtained at the same time, and either thebody mounting brackets must be replaced bythe corresponding modified items, or theholes in the original brackets must be openedout (to 12.5 mm) to suit the new bolts.16 Carry out the operations described inparagraphs 1 to 4 above.17 Using a steel tube of suitable diameter,various flat washers and a long bolt and nut,draw the bush out of its location in the axletrailing arm.18 Clean the bush eye in the trailing arm;lubricate it, and the new bush, with a soapysolution (washing-up liquid, for example) priorto installation.19 Locate the new bush in position, togetherwith the steel tube, washers, bolt and nut asused for removal. Ensure that the bush flangeis positioned on the outside, then draw thebush fully into position so that its lip isengaged (see illustration).20 Raise the axle to reposition the bush pin13.19 Pivot bush renewal (April 1990models onwards) - correct engagement ofbush lip on rear axleA New bush, installed correctlyB New bush, installed incorrectlybores in line with the bolt holes in themounting brackets, then insert the pivot bolts.Screw the retaining nuts into position on thepivot bolts, but do not fully tighten them atthis stage.21 Carry out the operations described inparagraphs 11 to 14 above.14 Rear suspension anti-roll bar(all models except Courier) -removal and refitting2Removal1 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”).2 Undo the front clamp bolt from each end ofthe bar, then support the bar and undo therear bolt at each end; withdraw the bar (seeillustration).3 Prise open the clamps to release the rubberbushes, if required. Fit the new bushes usingsoapy water as a lubricant.Refitting4 On refitting, offer up the bar and align firstthe front clamp on each side, refitting thebolts loosely.5 Align and refit the rear clamp on each side;again, tighten the bolts only loosely.14.2 Rear suspension anti-roll bar1 Rear suspension strut2 Anti-roll bar3 Inset showing (front) mounting clamp6 Lower the vehicle to the ground, rock it tosettle the suspension, then tighten the clampbolts to the specified torque settings.15 Rear suspensioncomponents (Couriermodels) - generalAlthough it is possible to remove the rearsuspension torsion bars and stabiliser barindependently of the complete rear axleassembly, it is essential to have certainspecial tools available to complete the worksuccessfully.Due to the complexity of the tasks, and therequirement for special tools to accurately setthe suspension geometry and vehicle rideheight on refitting, the removal and refitting ofindividual rear suspension components isconsidered to be beyond the scope of DIYwork and should be entrusted to a Forddealer.Procedures for removal and refitting of therear shock absorbers, and the complete rearsuspension assembly are given in Sections 16and 17 respectively.16 Rear shock absorber(Courier models) - removal,examination and refitting116.2a Removing a shock absorber uppermounting . . .16.2b . . . and lower mounting on CouriermodelsRemoval1 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”).2 Support the relevant trailing arm of thesuspension assembly and unscrew the uppermounting bolt and nut, followed by the lowerbolt. Withdraw the shock absorber from underthe vehicle (see illustrations).Examination3 Examine the shock absorber body for signsof fluid leakage or damage and check the101595Ford Fiesta Remake