service FORD SIERRA 1992 2.G Suspension And Steering Workshop Manual

Front suspension
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent by MacPherson struts with coil springs and integral
telescopic shock absorbers. Anti-roll bar fitted to all models
Rear suspension
Type:
Saloon, Hatchback and Estate models . . . . . . . . . . . . . . . . . . . . . . . Independent by semi-trailing arms and coil springs with telescopic
shock absorbers mounted behind coil springs on Saloon and
Hatchback models but concentric with coil springs on Estate models.
Self-levelling rear shock absorbers on certain Estate models. Anti-roll
bar fitted to certain models
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Live beam axle with leaf springs and telescopic shock absorbers
Steering
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack-and-pinion steering gear linked to collapsible steering column by
flexible coupling and universal joint. Power steering available on
certain models
Front wheel alignment*
Production toe-setting:
Saloon, Hatchback and Estate models . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in) ± 1.0 mm (0.04 in) toe-in
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in) ± 2.0 mm (0.08 in) toe-in
Service tolerance before adjustment is required . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in) toe-out to 4.5 mm (0.18 in) toe-in
*Toe-setting figures are quoted for vehicle at kerb weight with 3.0 litres (0.66 gallons) of fuel in tank
Chapter 11
Suspension and steering
Front anti-roll bar - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .7
Front anti-roll bar-to-lower arm compliance bushes - renewal . . . . . .8
Front hub carrier - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .5
Front suspension crossmember - removal and refitting . . . . . . . . . . . .2
Front suspension lower arm - removal, overhaul and refitting . . . . . . .3
Front suspension lower arm inner pivot bush - renewal . . . . . . . . . . .9
Front suspension strut - removal, overhaul and refitting . . . . . . . . . . .4
Front wheel - alignment checking and adjusting . . . . . . . . . . . . . . . .34
Front wheel bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Manual steering gear - removal and refitting . . . . . . . . . . . . . . . . . . .27
Power steering fluid circuit - bleeding . . . . . . . . . . . . . . . . . . . . . . . .31
Power steering fluid hoses - removal and refitting . . . . . . . . . . . . . . .30
Power steering gear - removal and refitting . . . . . . . . . . . . . . . . . . . .28
Power steering pump - removal and refitting . . . . . . . . . . . . . . . . . . .29
Rear anti-roll bar (Saloon, Hatchback and Estate models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear coil spring (Saloon, Hatchback and Estate models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Rear shock absorber - removal and refitting . . . . . . . . . . . . . . . . . . .12
Rear suspension and axle assembly (P100 models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Rear suspension and final drive unit assembly (Saloon, Hatchback and
Estate models) - removal and refitting . . . . . . . . . . . . . . . . . . . . . .10
Rear suspension/final drive unit rear mounting (Saloon Hatchback and
Estate models) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Rear suspension front mounting (Saloon, Hatchback and Estate
models) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Rear suspension leaf spring (P100 models) - removal and refitting . .19
Rear suspension leaf spring bush (P100 models) - renewal . . . . . . .21
Rear suspension leaf spring shackle (P100 models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Rear suspension lower arm (Saloon, Hatchback and Estate models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Rear wheel bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Steering column adjuster - dismantling and reassembly . . . . . . . . . .25
Steering column - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .24
Steering gear rubber gaiter - renewal . . . . . . . . . . . . . . . . . . . . . . . . .32
Steering intermediate shaft and flexible coupling - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Steering wheel - centralising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .22
Tie-rod end - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .33
11•1
Specifications Contents
11
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

4Extract the split pin and unscrew the
castellated nut (see illustration).
5Using a balljoint separator tool, release the
tie-rod end from the hub carrier (see
illustration).
6Unscrew the tie-rod end from the tie-rod,
noting the number of turns necessary to
remove it.
Refitting
7Refitting is a reversal of removal, bearing in
mind the following points.
8Screw the tie-rod end onto the tie-rod the
number of turns noted during removal.
9Tighten the nuts to the specified torque,
and fit a new split pin to the castellated nut.
10On P100 models, align the previously
made marks on the roadwheel and wheel
stud.
11On completion, check and if necessary
adjust the front wheel alignment.
1Front wheel alignment is defined by
camber, castor steering axis inclination and
toe setting. The first three factors are
determined in production; only toe can be
adjusted in service. Incorrect toe will cause
rapid tyre wear.
2Toe is defined as the amount by which the
distance between the front wheels, measured
at hub height, differs from the front edges tothe rear edges. If the distance between the
front edges is less than that at the rear, the
wheels are said to toe-in; the opposite case is
known as toe-out.
3To measure toe, it will be necessary to
obtain or make a tracking gauge. These are
available in motor accessory shops, or one
can be made from a length of rigid pipe or bar
with some kind of threaded adjustment facility
at one end. Many tyre specialists will also
check toe free, or for a nominal sum.
4Before measuring toe, check that all
steering and suspension components are
undamaged and that tyre pressures are
correct. The vehicle must be at approximately
kerb weight, with the spare wheel and jack in
their normal positions and any abnormal loads
removed.
5Park the vehicle on level ground and
bounce it a few times to settle the suspension.
6Use the tracking gauge to measure the
distance between the inside faces of the front
wheel rims, at hub height, at the rear of the
front wheels. Record this distance; call it
measurement “Y” (see illustration).7Push the vehicle forwards or backwards so
that the wheels rotate exactly 180º (half a
turn). Measure the distance between the front
wheel rims again, this time at the front of the
wheels. Record this distance; call it
measurement “X”.
8Subtract measurement “X” from
measurement “Y”. If the answer is positive it is
the amount of toe-in; if negative it is the
amount of toe-out. Permissible values are
given in the Specifications.
9If adjustment is necessary loosen the
tie-rod end locknuts and the outer bellows
clips, then rotate each tie-rod by equal
amounts until the setting is correct. Hold the
tie-rod ends in their horizontal position with a
spanner while making the adjustment.
10Tighten the locknuts and outer bellows
clips.
11Provided the tie-rods have been adjusted
by equal amounts the steering wheel should
be central when moving straight-ahead. The
amount of visible thread on each tie-rod
should also be equal. If necessary refer to
Section 23.
34Front wheel alignment
- checking and adjusting
Suspension and steering 11•19
11
34.6 Front wheel alignment
A CamberB CastorC Toe setting
For X and Y, see text
33.5 Using a balljoint separator tool to
release the tie-rod end from the hub
carrier
33.4 Extracting the split pin from the tie-
rod balljoint castellated nut