rear FORD S-MAX 2006 Service Repair Manual

Suspensi\bn Syste\f - General Inf\br\fati\bn
- Specificati\bnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Fr\bnt Wheel Align\fent (at curb weight)
Rear Wheel Align\fent (at curb weight)
Descrip\bionTo\ferance Range Se\b\bing or
Nomina\f Maximum Variance Lef\b or Righ\b
C\bster\f\bngle\fDegrees\f\bnd\fminutes4°25'\fto\f2°22'3°23'1°00'
Decim\bl\fdegrees4.42°\fto\f2.36°3.39°1.00°
C\bmber\f\bngle\fDegrees\f\bnd\fminutes0°35'\fto\f-1°57'-0°41'1°15'
Decim\bl\fdegrees0.59°\fto\f-1.95°-0.68°1.25°
Tot\bl\ftoemm1.4\fToe-in\f±\f2.51.4\fToe-in\f±\f1.0-
Degrees\f\bnd\f
minutes0°12'\fToe-in\f±\f 0°21'0°12'\fToe-in\f±\f0°08'-
Decim\bl\fdegrees0.20°\fToe-in\f±\f0.35°0.20°\fToe-in\f±\f0.14°-
Kingpin\fAngle\f@\fDMDecim\bl\fdegrees-13.61°-
Descrip\bionTo\ferance Range Se\b\bing or
Nomina\f Maximum Variance Lef\b or
Righ\b
C\bmber\f \bngle\fDegrees\f\bnd\f minutes-0°21'\fto\f-2°53'-1°37'1°15'
Decim\bl\fdegrees-0.35°\fto\f-2.89°-1.62°1.25°
Tot\bl\ftoemm2.8\fToe-in\f±\f2.52.8\fToe-in\f±\f1.0-
Degrees\f\bnd\fminutes0°24'\fToe-in\f±\f0° 21'0°24'\fToe-in\f±\f0°08'-
Decim\bl\fdegrees0.40°\fToe-in\f±\f0.35°\f0.40°\fToe-in\f±\f0.14°-
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Pinp\bint Tests
Front\fstrut\f\bnd\fspring\f
\bssemblies.\f\f
*CARRY\fOUT\fthe\fStrut\for\fShock\fAbsorber\f
Testing\fcomponent\ftest\fin\fthis\fprocedure.\f CHECK\f\bnd\fINSTALL\fnew\fsuspension\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\f Shock\fAbsorber\f\bnd\fSpring\f
Ass

embly \f(204-01\fFront\fSuspension,\f
Dis

\bssembly\f\bnd\fAssembly).\f
*
*
D\bm\bged\ffront\fsuspension\f
lower\f\brm(s).\f
*CHECK\f\bnd\fINSTALL\fnew\fsuspension\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\f Lower\fArm \f(204-01\fFront\f
Sus

pension,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Vehicle\fle\bnLo\bd-levelling\fshock\f
\bbsorbers.\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
PINPOINT TEST A : DRIFT LEFT OR RIGHT
WARNING:\fTo\f\bvoid\fperson\bl\finjury\fdue\fto\fthe\floss\fof\fvehicle\fcontrol,\fthe\finspection\f
should\fbe\fc\brried\fout\fby\ftwo\fpeople\fto\fm\bint\bin\fs\bfe\fdriving\fconditions.\fAdequ\bte\fgrip\f
should\f\blw\bys\fbe\fm\bint\bined\fon\fthe\fsteering\fwheel.\fF\bilure\fto\ffollow\fthese\finstructions\f
m\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\ffollowing\fconditions\fmust\fbe\fmet\fwhen\fev\blu\bting\fthe\fvehicle.\f
NOTE:\fThe\ftire\fsw\bpping\fprocedures\f\bre\ffor\fbi-direction\bl\frot\bting\ftires\fonly.\f
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\f
Lif
ting,\fDescription\f\bnd\fOper\btion).\f

Sw\bp\fthe\ffront\fleft-h\bnd\fwheel\f\bnd\ftire\f\bssembly\fwith\fthe\ffront\f
ri

ght-h\bnd\fwheel\f\bnd\ftire\f\bssembly.\f

Ro\bd\ftest\fthe\fvehicle.\f
1
Does\fthe\fvehicle\fdrift?\f
Yes
GO\fto\fA2.\f\f
N\b T

he\fconcern\fh\bs\fbeen\fcorrected.\f
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\f
Lif
ting,\fDescription\f\bnd\fOper\btion).\f

Sw\bp\fthe\fre\br\fleft-h\bnd\fwheel\f\bnd\ftire\f\bssembly\fwith\fthe\fre\br\fright-
h\bn

d\fwheel\f\bnd\ftire\f\bssembly.\f

Ro\bd\ftest\fthe\fvehicle.\f
1
Does\fthe\fvehicle\fdrift?\f
Yes
GO\fto\fA3.\f\f
N\b T

he\fconcern\fh\bs\fbeen\fcorrected.\f
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\f
Lif
ting,\fDescription\f\bnd\fOper\btion).\f

Sw\bp\fthe\ffront\fleft-h\bnd\fwheel\f\bnd\ftire\f\bssembly\fwith\fthe\fre\br\fleft-
h\bn

d\fwheel\f\bnd\ftire\f\bssembly.\f
1
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Inst\bll\btion).\f
N\b GO\fto\fB5.\f\f
B5: INSPECT THE SUSPENSION LOWER ARM BALL JOINTS
C\brry\fout\fthe\fB\bll\fJoint\fInspection\fcomponent\ftest\fin\fthis\fprocedure.\f1
Is\fthe\flower\f\brm\fb\bll\fjoint\for\fg\biter\fd\bm\bged?\f
Yes INSTALL\fnew\flower\f\brm.\f\f
REFER\fto:\f Lower\fArm \f(204-01\fFront\fSuspension,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
N\b GO\fto\fB6.\f\f
B6: INSPECT THE WHEEL BEARINGS
Check\fthe\fwheel\fbe\brings.\f\f1
Are\fthe\fwheel\fbe\brings\fd\bm\bged?\f
Yes INSTALL\f\b\fnew\fwheel\fhub(s).\f
N\b GO\fto\fB7.\f\f
B7: INSPECT THE WHEEL AND TIRES
Inspect\fthe\ftires\ffor\funeven\fwe\br.\f1
Is\fthere\funeven\fwe\br?\f
Yes REFER\fto\fthe\fsymptom\fch\brt.\f
N\b
GO\fto\fB8.\f\f
B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING
INTERFACE
Loosen\fthe\fstrut\f\bnd\fspring\f\bssemblies\f\bnd\fshock\f\bbsorbers\ftop\f\bnd\f
bottom\fmounting\fbolts\f\bnd\fnuts.\fTighten\fthe\fmounting\fbolts\f\bnd\fnuts.\f

C\brry\fout\f\b\fro\bd\ftest.\f\f
RE

FER\fto:\f Ro\bd/Roller\fTesting\f(100-00\fGener\bl\fInform\btion,\fDescription\f
\bn d

\fOper\btion).\f
1
Is\fthe\fconcern\fstill\fevident?\f
Yes
GO\fto\fB9.\f\f
N\b V

ehicle\fcondition\fcorrected.\f
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBER
COMPONENTS
Check\fth\bt\fthe\fspring\fis\fcorrectly\floc\bted\fon\fthe\fspring\fse\bt\f\bnd\fh\bs\fnot\f
moved.\f1
Dis\bssemble\fthe\fstrut\f\bnd\fspring\f\bnd\f\bssembly\f\bnd\finspect\fthe\findividu\bl\f
components.\f\f
REFER\fto:\f Shock\fAbsorber\f\bnd\fSpring\fAssembly \f(204-
01\fFront\fSuspension,\f
Dis\bssembly\f\bnd\fAssembly).\f
2
Inspect\fthe\fshock\f\bbsorber\ftop\fmount\ffor\fwe\br\for\fd\bm\bge.\f3
C\brry\fout\fthe\fStrut\for\fShock\fAbsorber\fTesting\fcomponent\ftest\fin\fthis\f
procedure.\f4
Are\f\bny\fof\fthe\fstrut\f\bnd\fspring\f\bssemblies\for\fshock\f\bbsorber\fcomponents\f
d\bm\bged?\f
Yes
INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
Shock\fAbsorber\f\bnd\fSpring\fAssembly \f(204-01\fFront\fSuspension,\f
Di s

\bssembly\f\bnd\fAssembly),\f
Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\f
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Suspensi\bn Syste\f - General Inf\br\fati\bn
- Rear T\be Adjust\fentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equip\fent
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f
Wheel\f\blignment\fsystem
1. Check\fthe\ftoe\fsetting.\f\fRefer\fto:\f Specific\btions \f(204-00\fSuspension\f
Sys

tem\f-\fGener\bl\fInform\btion,\fSpecific\btions).\f
General \bqui\fment: Wheel\f\blignment\fsystem\f
2. R

\bise\f\bnd\fsupport\fthe\fvehicle.\f\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
3. \f\f 1.
Loosen\fthe\fre\br\flower\f\brm\f\bdjustment\fc\bm\f
nut\fon\fboth\fsides.\f
2. Torque: 8\fNm
\f
4. Lower\fthe\fvehicle.\f
5. Bounce\fthe\fvehicle\fto\fm\bke\fsure\fth\bt\fthe\f suspension\fis\fin\fits\fnorm\bl\fresting\fposition.\f
6. Adjust\fthe\ftoe\fsetting.\f
7. NOTE:\fOnly\ftighten\fthe\fnuts\f\bnd\fbolts\fwhen\f
t
h

e\fsuspension\fis\fin\fthe\fnorm\bl\fdrive\f
position.\f
Torque: 103\fNm
\f
\f
\f\f
\f
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Rear Su\bpen\bi\fn - Rear Su\bpen\bi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bcripti\fn and Operati\fn
Vehicle\b with \btandard \bu\bpen\bi\fn
\f\f
De\bcripti\fn
St\bnd\brd\fshock\f\bbsorber\f
Upper\f\brm\f
Spring\fse\bt\f
Re\br\fsubfr\bme\f
Re\br\flower\f\brm\f\bdjustment\fc\bm\fnut\f
St\bbilizer\fb\br,\fbushings\f\bnd\fcl\bmps\f
Bump\fstop\f
Item
1
2
3
4
5
6
7
\f
Part Number -
-
-
-
-
-
-
-
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Rear Su\bpen\bi\fn - Wheel KnuckleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and In\btallati\fn
Rem\fval
1. Refer\fto:\fSp
ring\f(204-02\fRe\br\fSuspension,\f
Rem
ov\bl\f\bnd\fInst\bll\btion).\f
2. NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
in

st\blling\f\b\fnew\fcomponent\fto\fthe\fleft-h\bnd\f
side.\f
3. NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
i
n

st\blling\f\b\fnew\fcomponent\fto\fthe\fright-h\bnd\f
side.\f
4. \f
5.

\f 6. \f
\f\f
\f\f
\f\f
\f\f
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Rear Su\bpen\bi\fn - Rear Wheel BearingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and In\btallati\fn
Rem\fval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
In\btallati\fn 1. Remove\fthe\fbr\bke\fc\bliper.\f\f
Re
fer\fto:\f Br\bke\fC\bliper \f(206-04\fRe\br\fDisc\fBr\bke,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f\f 1.Torque:\b 5\fNm
\f
2. Torque:\b 110\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
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Rear Su\bpen\bi\fn - Upper ArmS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and In\btallati\fn
General Equipment
Rem\fval
Tr\bnsmission\fj\bck
1. Remove\fthe\fspring.\f\fRefer\fto:\f Spring\f(204-02\fRe\br\fSuspension,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
2. F\bbric\bte\f\b\fsp\bcer.\f
3. General \bqui\fment: Tr\bnsmission\fj\bck\f
4. I

nst\bll\fthe\fsp\bcer.\fM\bke\fsure\fth\bt\fthe\fsp\bcer\fis\f
in\f\b\fvertic\bl\fpl\bne\f\bnd\fr\bise\fthe\fsuspension\fto\f
the\fdesign\fheight\fsetting.\f
5. \f
6. \f
\f\f
\f\f
\f\f
\f\f
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Rear Su\bpen\bi\fn - Fr\fnt L\fwer ArmS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and In\btallati\fn
General Equipment
Rem\fval
In

\btallati\fn
Tr\bnsmission\fj\bck 1. Remove\fthe\fspring.\f\fRefer\fto:\f Spring\f(204-02\fRe\br\fSuspension,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
2. F\bbric\bte\f\b\fsp\bcer.\f
3. General \bqui\fment: Tr\bnsmission\fj\bck\f
4. I

nst\bll\fthe\fsp\bcer.\fM\bke\fsure\fth\bt\fthe\fsp\bcer\fis\f
in\f\b\fvertic\bl\fpl\bne\f\bnd\fr\bise\fthe\fsuspension\fto\f
the\fdesign\fheight\fsetting.\f
5. \f
1. Torque: 130\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Rear Su\bpen\bi\fn - Rear L\fwer ArmS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and In\btallati\fn
General Equipment
Rem\fval
In

\btallati\fn
Tr\bnsmission\fj\bck 1. Remove\fthe\fspring.\f\fRefer\fto:\f Spring\f(204-02\fRe\br\fSuspension,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
2. F\bbric\bte\f\b\fsp\bcer.\f
3. General \bqui\fment: Tr\bnsmission\fj\bck\f
4. I

nst\bll\fthe\fsp\bcer.\fM\bke\fsure\fth\bt\fthe\fsp\bcer\fis\f
in\f\b\fvertic\bl\fpl\bne\f\bnd\fr\bise\fthe\fsuspension\fto\f
the\fdesign\fheight\fsetting.\f
5. \f
1. NOTE:\fOnly\ftighten\fthe\fnut\f\bnd\fbolts\ffinger\f
t
i

ght\f\bt\fthis\fst\bge.\f
\f\f
\f\f
\f\f
\f\f
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