All about Ford Mondeo

Rear suspension strut Saloon/Hatchback models) - removal and refitting
Suspension and steering systems / Rear suspension strut Saloon/Hatchback models) - removal and refitting


Note: Before attempting to remove the rear suspension strut, a tool to hold the coil spring in compression must be obtained. Careful use of conventional coil spring compressors will prove satisfactory.

Removal
1 In order to remove the rear suspension strut, the coil spring must be temporarily compressed. This will enable the piston rod to be retracted into the strut, and will provide additional room for releasing the strut from the bump stop on top of the rear suspension crossmember.

Warning: It is important to only use a high-quality spring compressor; carefully follow the tool manufacturer’s instructions provided with it.

2 Chock the front wheels, then jack up the rear of the vehicle and support it on axle stands. Remove the appropriate wheel.

3 Where fitted, unclip the ABS sensor wiring from the strut, and remove the sensor from the knuckle as described in Chapter 9 (see illustration).

11.3 Unclipping the ABS sensor wiring from the strut
11.3 Unclipping the ABS sensor wiring from the strut

4 On models fitted with adaptive damping, unclip the wiring from the strut and disconnect the multi-plug (see illustration).

11.4 Location of the adaptive damping lead (1) and multi-plug (2)
11.4 Location of the adaptive damping lead (1) and multi-plug (2)

5 On drum brake models, fit a brake hose clamp to the rear flexible brake hose, then unscrew the union nut securing the rigid brake pipe to the flexible hose on the strut. Extract the clip, and disconnect the flexible hose from the strut.

6 On models fitted with rear disc brakes, unbolt the caliper from the knuckle as described in Chapter 9, but leave the hydraulic hose attached. Support the caliper on an axle stand, making sure that the flexible hose is not strained.

7 Unscrew the nut securing the rear anti-roll bar link to the front lower arm on the appropriate side. Hold the actual link with an adjustable spanner or grips while unscrewing the nut, to prevent damage to the link joint.

8 Unscrew and remove the bolt securing the tie-bar to the bottom of the knuckle. Move the tie-bar downwards (see illustrations).

11.8A Tie-bar mounting bolt on knuckle
11.8A Tie-bar mounting bolt on knuckle

11.8B Remove the bolt . . .
11.8B Remove the bolt . . .

11.8C . . . and move the tie-bar downwards
11.8C . . . and move the tie-bar downwards

9 Unscrew and remove the bolts securing the front and rear lower arms to the knuckle, and move the arms to one side (see illustrations).

11.9A Unscrew the bolt . . .
11.9A Unscrew the bolt . . .

11.9B . . . and remove the rear lower arm from the knuckle
11.9B . . . and remove the rear lower arm from the knuckle

10 Support the knuckle on a trolley jack, then unscrew and remove the clamp bolt securing the knuckle to the strut (see illustrations).

11.10A Support the knuckle on a trolley jack . . .
11.10A Support the knuckle on a trolley jack . . .

11.10B . . . and remove the knuckle-tostrut clamp bolt
11.10B . . . and remove the knuckle-tostrut clamp bolt

11 Prise the clamp on the knuckle apart using a large flat-bladed tool. Disconnect the knuckle from the strut, and lower it on the trolley jack as far as possible, taking care not to damage the handbrake cable (see illustration).

11.11 Separating the knuckle from the strut
11.11 Separating the knuckle from the strut

12 Fit the coil spring compressor tool (ensuring that it is fully engaged), and compress the coil spring until all tension is relieved from the upper and lower mountings (see illustration). This will also release the bracket on the strut from the bump stop rubber on the top of the rear crossmember.

11.12 Compressor tools fitted to the rear coil spring
11.12 Compressor tools fitted to the rear coil spring

13 Support the strut, then reach up under the wheel arch, and unscrew the two bolts securing the upper mounting to the underbody (see illustration).

11.13 Bolts (arrowed) securing the strut upper mounting to the underbody
11.13 Bolts (arrowed) securing the strut upper mounting to the underbody

14 Slightly lift the strut, to force the piston into the shock absorber and release the strut bracket from the bump stop on the crossmember. Lower the strut assembly and withdraw it from under the vehicle (see illustration).

11.14 Removing the rear suspension strut
11.14 Removing the rear suspension strut

Refitting
15 Locate the strut assembly (together with the coil spring compressor tool) under the wheel arch, and locate the bracket on the bump stop on the rear suspension crossmember. Insert the two bolts securing the upper mounting to the underbody tower, and tighten them to the specified torque.

16 Carefully release the coil spring compressor tool, making sure that the spring locates correctly in the upper and lower seats, and that the strut bracket locates on the crossmember bump stop. The bump stop is tapered inwards, and the strut bracket should be fully engaged with it before releasing the coil spring.

17 Raise the knuckle and engage it with the strut, then insert the clamp bolt and tighten to the specified torque.

18 Reconnect the front and rear lower arms to the knuckle, and finger-tighten the bolts at this stage.

19 Reconnect the tie-bar to the bottom of the knuckle, and finger-tighten the bolt at this stage.

20 Refit the anti-roll bar link to the lower arm, and tighten the nut to the specified torque.

21 On disc brake models, refit the caliper bracket to the knuckle, and tighten the mounting bolts to the specified torque (see Chapter 9). Make sure that the flexible brake hose is not twisted.

22 On drum brake models, connect the flexible hose to the strut, insert the clip, then insert the rigid brake line and tighten the union nut. Remove the brake hose clamp, then bleed the hydraulic brake circuit as described in Chapter 9.

23 Where applicable, reconnect the wiring multi-plug for the adaptive damping, and clip the wiring to the strut.

24 Where applicable, refit the ABS sensor as described in Chapter 9, and clip the wiring to the strut.

25 Refit the wheel, and lower the vehicle to the ground.

26 With the weight of the vehicle on the rear suspension, fully tighten the lower arm and tie-bar mounting bolts.


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