Chapter 1 Routine maintenance and servicing

Suspension and steering 10•17RefittingAll models38 Refitting is a reversal of removal, bearingin mind the following points:a) Tighten all nuts and bolts to the specifiedtorque. Remove the plugs from thedisconnected pipes, hoses and unionsand ensure that the pipes are locatedcorrectly so that they do not foul anysurrounding components.b) Refit the auxiliary drivebelt as described inChapter 1.c) Where drained, refill the cooling systemas described in Chapter 1.d) Refit or reconnect any additionalcomponents removed for access asdescribed in the relevant Sections andChapters of this manual.e) On completion, bleed the power steeringhydraulic system as described in Section27. Check for any signs of fluid leakagefrom the system hoses and connections.26 Power steering fluid cooler -removal and refitting2Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Position a suitable container beneath thepower steering fluid cooler hose connections,then disconnect the hoses at the quick-fitcouplings on the fluid cooler. Allow the fluid todrain from the hose and reservoir into thecontainer.3 Plug the exposed ends of the hose and thereservoir, to prevent the ingress of dirt andexcessive fluid loss.4 Refer to Chapter 11 and remove the bonnetlock assembly and the front bumper.5 Undo the bolts securing the cooler sidesupport bracket and the bonnet lock stay, andremove the fluid cooler and bonnet lock stayas an assembly.6 Undo the two bolts and remove the stayfrom the fluid cooler.Refitting7 Refitting is a reversal of removal. Oncompletion, bleed the power steeringhydraulic system as described in Section 27.27 Power steering hydraulicsystem - bleeding2fluid to the “MAX” or “MAX COLD” level mark.Pour the fluid slowly to prevent air bubblesforming, and use only the specified fluid (referto “Lubricants, fluids and tyre pressures”).3 Start the engine and allow it to idle. Checkthe hoses and connections for leaks.4 Stop the engine and recheck the fluid level.Add more, if necessary, up to the “MAX” or“MAX COLD” level mark.5 Start the engine again, allow it to idle, thenbleed the system by slowly moving thesteering from lock-to-lock several times. Thisshould purge the system of all internal air.However, if air remains in the system(indicated by the steering operation being verynoisy), leave the vehicle overnight and repeatthe procedure again the next day.6 If air still remains in the system, it may benecessary to resort to the Ford method ofbleeding, which uses a vacuum pump and amodified reservoir filler cap to which the pumpcan be connected. Turn the steering to theright until it is near the stop, then fit thevacuum pump to the fluid reservoir, and apply0.51 bars of vacuum. Maintain the vacuum fora minimum of 5 minutes, then repeatthe procedure with the steering turned to theleft.7 Keep the fluid level topped-up throughoutthe bleeding procedure; note that the fluidtemperature increases, the level will rise.8 On completion, switch the engine off, andreturn the wheels to the straight-aheadposition.28 Track rod end balljoint -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 appropriate front roadwheel.2 Using a suitable spanner, slacken the trackrod end balljoint locknut on the track rod by aquarter of a turn only (see illustration). Holdthe balljoint stationary with another spannerengaged with the flats at its inner end toprevent it from turning.3 Extract the split pin, then loosen off theretaining nut. If the balljoint is to be renewed,the nut can be fully removed. If the existingballjoint is to be reconnected, the nut shouldbe slackened off a couple of turns only at first,and left in position to protect the joint threadsas the joint is separated from the spindlecarrier. To release the tapered shank of thejoint from the spindle carrier, use a balljointseparator tool as shown (see illustration). Ifthe joint is to be re-used, take care not todamage the rubber dust cover when using aseparator tool.4 Unscrew the balljoint from the track rod,counting the number of turns necessary toremove it.Refitting5 Screw the balljoint into the track rod thenumber of turns noted during removal until theballjoint just contacts the locknut. Now tightenthe locknut while holding the balljoint.6 Engage the shank of the balljoint with thespindle carrier arm, and refit the retaining nut.Tighten the nut to the specified torque andsecure with a new split pin.7 Refit the roadwheel, and lower the vehicleto the ground.8 Finally, have the front wheel toe settingchecked (see Section 29).29 Wheel alignment andsteering angles - generalinformation4General1 A car’s steering and suspension geometryis defined in four basic settings - all anglesare expressed in degrees (toe settings arealso expressed as a measurement); therelevant settings are camber, castor, steeringaxis inclination, and toe-setting. With theexception of front wheel toe-setting, none ofthese settings are adjustable.101 Following any operation in which the powersteering fluid lines have been disconnected,the power steering system must be bled toremove any trapped air.2 With the front wheel in the straight-aheadposition, check the power steering fluid levelin the reservoir and, if low, top-up with fresh28.2 Track rod end balljoint showing thelocknut (A) retaining flats (B) and theballjoint-to-spindle carrier arm retainingnut and split pin (C)28.3 Balljoint separator tool in position.Note that the nut should be left loosely inposition to protect the thread for re-use1595Ford Fiesta Remake