Rear Upper Control Arm
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Rear Upper Control Arm
I need to replace the right rear upper control arm on my 2005 five hundred. After working on it for about 6 hours I decided it was easier to remove the rear subframe wich only took about an hour (lesson learned). Does anyone know the procedures to remove the rear upper control arm and bushings and reinstall in the subframe?
Junior Member
Joined: Nov 2010
Posts: 8
SECTION 204-02 Rear Suspension
CONTENTS PAGE
Upper Arm .................................................. .................................................. .................................................. ................... 204-02-2
204-02-i Rear Suspension 204-02-i
2005 Freestyle, Five Hundred, Montego, 11/2004
Upper Arm
Special Tool(s)
2-Jaw Puller
205-D072 (D97L-4221-A) or equivalent
Puller, Bearing
205-D063 (D84L-1122-A) or equivalent
Forcing Screw
204-356
Adapter
204-039, Part of 205-813
Remover/Installer, Bushing
204-357 or equivalent
Separator, Ball Joint
204-592
205-D072 (D97L-4221-A) or equivalent
Puller, Bearing
205-D063 (D84L-1122-A) or equivalent
Forcing Screw
204-356
Adapter
204-039, Part of 205-813
Remover/Installer, Bushing
204-357 or equivalent
Separator, Ball Joint
204-592
204-02-2 Rear Suspension 204-02-2
2005 Freestyle, Five Hundred, Montego, 11/2004
Adapter for 204-592
204-592/1
204-592/1
Removal
NOTICE:
Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major
service expense. A new part with the same part number, or an equivalent part, must be installed if installation is necessary. Do not use a new part of
lesser quality or substitute design. Torque values must be used as specified to make sure of correct retention of these parts.
NOTE:
service expense. A new part with the same part number, or an equivalent part, must be installed if installation is necessary. Do not use a new part of
lesser quality or substitute design. Torque values must be used as specified to make sure of correct retention of these parts.
NOTE:
The forward and rearward upper arm bushings are removed and installed as a pair.
All vehicles
1. Remove the rear subframe. For additional information, refer to Section 502-00.
2. Place a suitable support under the wheel knuckle.
3. Remove and discard the stabilizer bar link upper nut and separate the link from the upper arm.
4. Remove and discard the upper arm-to-subframe bolts.
2. Place a suitable support under the wheel knuckle.
3. Remove and discard the stabilizer bar link upper nut and separate the link from the upper arm.
4. Remove and discard the upper arm-to-subframe bolts.
Front wheel drive (FWD) vehicles
5. Remove and discard the upper arm-to-knuckle bolt and separate the upper arm from the wheel knuckle.
All wheel drive (AWD) vehicles
6. Remove and discard the wheel knuckle ball joint nut.
7.
7.
NOTE:
It may be necessary to tap the knuckle to disconnect the upper arm.
Using the special tools, separate the wheel knuckle from the upper arm.
Using the special tools, separate the wheel knuckle from the upper arm.
All vehicles
8. Using the special tool, separate the upper arm and front bushing from the rear bushing. Once the upper arm and front bushing are separated from the
rear bushing, use the special tool to pull the arm and bushing out of the bushing bore.
rear bushing, use the special tool to pull the arm and bushing out of the bushing bore.
204-02-3 Rear Suspension 204-02-3
(Continued)
2005 Freestyle, Five Hundred, Montego, 11/2004
9. Using the special tools, separate the upper arm front bushing from the upper arm.
10. Remove the upper arm from the subframe.
11. Using the special tool, remove the upper arm rear bushing from the subframe.
10. Remove the upper arm from the subframe.
11. Using the special tool, remove the upper arm rear bushing from the subframe.
Installation
All vehicles
1.
NOTICE:
Use only liquid soap, if necessary, to lubricate the bushing. Do not use any other types of lubricants or damage to the bore or bushing may
occur.
NOTE:
occur.
NOTE:
Make sure the bushing bore on the subframe is clean and free of foreign materials. To aid in installation, a small amount of liquid soap may be applied
to the outer diameter of the bushing.
Position the upper arm rear bushing into the bushing bore from the rear of the subframe and, using the special tools, install the bushing into the
subframe.
Use the opposite side bushing as a guide to install the bushing to the correct depth in the subframe.
to the outer diameter of the bushing.
Position the upper arm rear bushing into the bushing bore from the rear of the subframe and, using the special tools, install the bushing into the
subframe.
Use the opposite side bushing as a guide to install the bushing to the correct depth in the subframe.
204-02-4 Rear Suspension 204-02-4
(Continued)
2005 Freestyle, Five Hundred, Montego, 11/2004
AWD vehicles
2.
NOTICE:
Do not fully tighten the nut at this time or incorrect clamp load or bushing damage may occur.
Position the upper arm into the forward bushing bore and into the rear bushing, then position the upper arm onto the wheel knuckle ball joint stud and
install the ball joint nut.
• Tighten the nut until snug.
install the ball joint nut.
• Tighten the nut until snug.
FWD vehicles
3.
NOTICE:
Do not fully tighten the bolt at this time or incorrect clamp load or bushing damage may occur.
Position the upper arm into the forward bushing bore and into the rear bushing, then position the upper arm onto the wheel knuckle and install the
upper arm-to-knuckle bolt.
• Tighten the bolt until snug.
upper arm-to-knuckle bolt.
• Tighten the bolt until snug.
All vehicles
4. Loosely install the upper arm-to-subframe rear bolt.
5.
5.
NOTE:
The upper arm height setting is measured from the top of the subframe to the bottom of the upper arm.
While an assistant holds the upper arm, adjust it to the correct height. Refer to the table below for correct upper arm height setting specifications.
While an assistant holds the upper arm, adjust it to the correct height. Refer to the table below for correct upper arm height setting specifications.
Vehicle Upper Arm Height Settings
Freestyle Front Wheel Drive (FWD) 163 mm (6.4 in)
Five Hundred/Montego FWD 147 mm (5.7 in)
Freestyle All Wheel Drive (AWD) 158 mm (6.2 in)
Five Hundred/Montego AWD 138 mm (5.4 in)
6. Tighten the upper arm-to-subframe rear bolt to 110 Nm (81 lb-ft).
7. While an assistant holds the upper arm in the center of the bushing bore, use the special tools to install the upper arm front bushing into the subframe.
Five Hundred/Montego FWD 147 mm (5.7 in)
Freestyle All Wheel Drive (AWD) 158 mm (6.2 in)
Five Hundred/Montego AWD 138 mm (5.4 in)
6. Tighten the upper arm-to-subframe rear bolt to 110 Nm (81 lb-ft).
7. While an assistant holds the upper arm in the center of the bushing bore, use the special tools to install the upper arm front bushing into the subframe.
204-02-5 Rear Suspension 204-02-5
(Continued)
2005 Freestyle, Five Hundred, Montego, 11/2004
8. Install the forward upper arm bushing to the correct depth in the subframe. Use the opposite side bushing as a guide.
9. Install the upper arm-to-subframe front bolt.
• Tighten to 110 Nm (81 lb-ft).
9. Install the upper arm-to-subframe front bolt.
• Tighten to 110 Nm (81 lb-ft).
AWD vehicles
10. Tighten the wheel knuckle ball joint nut to 110 Nm (81 lb-ft).
FWD vehicles
11. Tighten upper arm-to-wheel knuckle bolt to 110 Nm (81 lb-ft).
All vehicles
12. Position the stabilizer bar link and install the stabilizer bar link upper nut.
• Tighten to 38 Nm (28 lb-ft).
13. Install the rear subframe. For additional information, refer to Section 502-00.
• Tighten to 38 Nm (28 lb-ft).
13. Install the rear subframe. For additional information, refer to Section 502-00.
204-02-6 Rear Suspension 204-02-6
(Continued)
2005 Freestyle, Five Hundred, Montego, 11/2004
Junior Member
Joined: Nov 2010
Posts: 8
REMOVAL AND INSTALLATION
Subframe — Rear
Item Part Number Description Item Part Number Description
1 5K812 Rear subframe-to-underbody 4 W709433-S/ Rear shock-to-lower control
spacers — front wheel drive W708740 arm bolts (2 required)
(FWD) Freestyle only (4 5 W709583-S439 Rear subframe bracket bolts
required) — all wheel drive (AWD)
2 — Rear caliper pin (4 required) only (4 required)
3 — Rear subframe assembly 6 W710716-S Rear subframe bolts (4
spacers — front wheel drive W708740 arm bolts (2 required)
(FWD) Freestyle only (4 5 W709583-S439 Rear subframe bracket bolts
required) — all wheel drive (AWD)
2 — Rear caliper pin (4 required) only (4 required)
3 — Rear subframe assembly 6 W710716-S Rear subframe bolts (4
(Continued)
required)
(Continued)
Copyright
ã 2004, Ford Motor Company
Last updated: 11/16/2006
2005 Freestyle, Five Hundred, Montego, 11/2004
502-00-2 Uni-Body, Subframe and Mounting System 502-00-2
REMOVAL AND INSTALLATION (Continued)
Item Part Number Description
9. Position the trailing link aside.
7 — Driveshaft washers — AWD
only (3 required)
only (3 required)
10. Remove the rear shock-to-lower control arm
8 — Driveshaft bolts — AWD
bolts.
only (6 required)
• To install, tighten the rear shock-to-lower
9 5084AA/ Rear subframe bracket —
control arm bolts — all wheel drive (AWD)
5084AB AWD only (LH/RH)
to 142 Nm (105 lb-ft).
10 W505253-S Park brake cable routing bolt
• To install, tighten the rear shock-to-lower
control arm bolts — front wheel drive
control arm bolts — front wheel drive
Removal and Installation
(FWD) to 110 Nm (81 lb-ft).
All vehicles
11. Disconnect the rear wheel speed sensor
electrical connectors.
1. Measure and record the vehicle ride height. For
additional information, refer to Section 204-00.
2. Remove the rear wheels. For additional
information, refer to Section 204-04.
3. With a wax pencil, mark the relational
alignment of the rear subframe to the
underbody at the mounting locations.
4. Remove the catalytic converter, muffler and
tailpipe assembly.
electrical connectors.
1. Measure and record the vehicle ride height. For
additional information, refer to Section 204-00.
2. Remove the rear wheels. For additional
information, refer to Section 204-04.
3. With a wax pencil, mark the relational
alignment of the rear subframe to the
underbody at the mounting locations.
4. Remove the catalytic converter, muffler and
tailpipe assembly.
•
Remove the 2 catalytic converter nuts.
X
To install, tighten to 40 Nm (30 lb-ft). AWD vehicles
•
Disconnect the muffler and tailpipe
assembly from the isolators. 12. Remove the rear axle assembly. For additional
assembly from the isolators. 12. Remove the rear axle assembly. For additional
•
Remove the assembly. information, refer to Section 205-02.
5. NOTE: Index the driveshaft before All vehicles
5. NOTE: Index the driveshaft before All vehicles
disconnecting from the rear drive axle.
NOTE:
It is necessary to install new driveshaft 13. Release the park brake cable tension. For
bolts during installation. Reuse of the driveshaft additional information, refer to Section 206-05.
bolts is not recommended.
14. Disconnect the intermediate park brake cable
Remove the 6 driveshaft bolts. from the front park brake cable.
bolts during installation. Reuse of the driveshaft additional information, refer to Section 206-05.
bolts is not recommended.
14. Disconnect the intermediate park brake cable
Remove the 6 driveshaft bolts. from the front park brake cable.
•
To install, tighten to 25 Nm (18 lb-ft).
6. Loosen the trailing link-to-subframe bolts.
6. Loosen the trailing link-to-subframe bolts.
•
To install, tighten to 105 Nm (77 lb-ft).
7. Support and raise the knuckle with a suitable
jack.
7. Support and raise the knuckle with a suitable
jack.
•
Raise the knuckle until the tilt angle of the
trailing link is horizontal to the body.
8. Remove the trailing link-to-knuckle bolts.
trailing link is horizontal to the body.
8. Remove the trailing link-to-knuckle bolts.
•
To install, tighten to 105 Nm (77 lb-ft).
2005 Freestyle, Five Hundred, Montego, 11/2004
502-00-3 Uni-Body, Subframe and Mounting System 502-00-3
REMOVAL AND INSTALLATION (Continued)
15. Disconnect the intermediate cable from the
AWD vehicles
body bracket.
22. Remove the 4 rear subframe bracket bolts.
22. Remove the 4 rear subframe bracket bolts.
•
To install, tighten to 55 Nm (41 lb-ft).
All vehicles
23.
CAUTION: When positioning the
lifting table, be sure to support the rear
subframe on the subframe rails. Do not lift
on the rear differential or rear control arms,
damage may occur.
lifting table, be sure to support the rear
subframe on the subframe rails. Do not lift
on the rear differential or rear control arms,
damage may occur.
Position a lifting table.
24. Remove the 4 rear subframe bolts.
16. Remove the park brake cable-to-body bracket.
24. Remove the 4 rear subframe bolts.
16. Remove the park brake cable-to-body bracket.
•
To install, tighten to 115 Nm (85 lb-ft).
•
To install, tighten to 12 Nm (9 lb-ft).
AWD vehicles
17. Disconnect the rear park brake cables at the
equalizer. 25. Remove the 2 rear subframe brackets.
18. Disconnect the rear park brake cables from the
equalizer. 25. Remove the 2 rear subframe brackets.
18. Disconnect the rear park brake cables from the
All vehicles
park brake levers at the rear calipers.
19. Disconnect the rear park brake cables from the 26. Remove the rear subframe assembly.
park brake brackets.
27. Transfer components as necessary.
20. Remove the rear brake caliper pins.
19. Disconnect the rear park brake cables from the 26. Remove the rear subframe assembly.
park brake brackets.
27. Transfer components as necessary.
20. Remove the rear brake caliper pins.
•
To install, tighten to 35 Nm (26 lb-ft).
21. Remove the rear calipers and the rear caliper
brackets and attach aside to the body with
mechanic’s wire. It is not necessary to
disconnect the hydraulic brake lines.
21. Remove the rear calipers and the rear caliper
brackets and attach aside to the body with
mechanic’s wire. It is not necessary to
disconnect the hydraulic brake lines.
2005 Freestyle, Five Hundred, Montego, 11/2004
502-00-4 Uni-Body, Subframe and Mounting System 502-00-4
REMOVAL AND INSTALLATION (Continued)
28.
NOTE: Install new suspension fasteners during
assembly.
assembly.
NOTE:
Before tightening the upper control, toe
link, trailing arm and lower control arm bolts,
use a jackstand to raise the rear suspension to
ride height.
To install, reverse the removal procedure.
link, trailing arm and lower control arm bolts,
use a jackstand to raise the rear suspension to
ride height.
To install, reverse the removal procedure.
•
For installation, align the subframe to the
body following the alignment specification.
body following the alignment specification.
•
Check and, if necessary, adjust the rear toe.
For additional information, refer to Section
204-00.
For additional information, refer to Section
204-00.
2005 Freestyle, Five Hundred, Montego, 11/2004
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