Ford Fusion: Uni-Body, Subframe and Mounting System / Front Subframe - 2.7L EcoBoost (238kW/324PS). Removal and Installation

Special Tool(s) / General Equipment

	300-OTC1585AE Powertrain Lift
Tie Rod End Remover
Wooden Block

Materials

Removal

NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

1. NOTICE: Disconnect the battery ground cable anytime the steering gear is being serviced or damage to the steering gear internal power relay may occur resulting in steering gear replacement.

   Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Steering wheel in straight ahead position.
   

1.   WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   Remove and discard the steering column shaft coupler bolt and separate the coupler from the steering shaft.
   

1. Remove the retainers and the radiator sight shield.
   

1. 
   Support the cooling module.
   
   • Remove the upper cooling module support brackets.
     
   • Using zip ties or mechanics wire through the upper location holes to support the cooling module.
     

1. Remove the wheels and tires.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the retainers and the underbody shield.
   

1. Remove the retainers and the front underbody straps.
   

1. Remove the retainers and the underbody shields.
   

1. Remove the retainers, bolts, and underbody air deflector.
   

1. NOTE: Index-mark the subframe for reference during installation.

   On both sides.
   Mark the position of front subframe.
   

1. NOTE: Support the radiator.

   Remove the retainers and remove the radiator core support.
   

1. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or damage to the wheel knuckle may result.

   NOTICE: Use care when installing the tie rod separator or damage to the outer tie-rod end boot may occur.

   On both sides.
   Remove and discard the tie rod end nut and separate the tie rod end from the wheel knuckle.
   Use the General Equipment: Tie Rod End Remover

1. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque.

   NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut.

   On both sides.
   Remove and discard the stabilizer bar link lower nut and position aside the stabilizer bar link.
   

1. NOTICE: The front suspension height sensor must be disconnected from the lower control arm prior to servicing suspension components or damage to the suspension height sensor and/or the vehicle dynamic suspension system may occur. The sensor will need to be recalibrated after reassembly.

   On both sides.
   Disconnected the front suspension height sensor electrical connectors. Remove the bolt and position the bracket aside.
   

1. NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.

   NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may occur.

   On both sides.
   Remove and discard the ball joint pinch bolt and nut and separate the ball joint from the wheel knuckle.
   

1. Remove the retainers and remove the cross brace.
   

1. Remove the exhaust flexible pipe.
   Refer to: Exhaust Flexible Pipe (309-00D Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. If equipped.
   Remove the exhaust support bracket bolts.
   

1. Remove the roll restrictor bolt.
   

1. If equipped.
   Unclip and position aside the electrical harness.
   

1. Detach the coolant tube retainers from the subframe.
   

1. Disconnect the PTU temperature sensor.
   

1. Detach the wiring harness retainers.
   

1. Disconnect the EPAS gear electrical connectors and unclip the harness retainers and position the harness aside.
   

1. Position a powertrain lift under the front subframe.
   Use Special Service Tool: 300-OTC1585AE  Powertrain Lift.
   Use the General Equipment: Wooden Block

1. 1. Remove and discard the rearward front subframe bolts.
      
   2. Remove the bracket bolts.
      

1. Remove and discard the forward front subframe bolts.
   

1. Lower the subframe.
   Use Special Service Tool: 300-OTC1585AE  Powertrain Lift.
   Use the General Equipment: Wooden Block

Installation

1. Partially raise the subframe and position it to the vehicle.
   Use Special Service Tool: 300-OTC1585AE  Powertrain Lift.
   Use the General Equipment: Wooden Block

1. NOTE: Align reference marks made during removal.

   Finger tight at this stage.
   Install the new forward front subframe bolts.
   

1. 1. Finger tight at this stage.
      Install the new rearward front subframe bolts.
      
   2. Finger tight at this stage.
      Install the bracket bolts.
      

1. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

   Tighten the new forward front subframe bolts.
   Torque: 173 lb.ft (235 Nm)

1. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

   1. Install the new rearward front subframe bolts.
      Torque:
        Stage 1:  76 lb.ft (103 Nm)
        Stage 2:  270°
   2. Tighten the bracket bolts.
      Torque: 44 lb.ft (60 Nm)

1. Connect the PTU temperature sensor.
   

1. Position and clip the wiring harness retainers.
   

1. Position and clip the coolant tube retainers to the subframe.
   

1. Position the EPAS gear harness, clip the harness retainers and connect the electrical connectors.
   

1. Install the roll restrictor bolt.
   Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)
   Torque: 85 lb.ft (115 Nm)

1. Install the exhaust flexible pipe.
   Refer to: Exhaust Flexible Pipe (309-00D Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. If equipped.
   Install the exhaust support bracket bolts.
   Torque: 18 lb.ft (25 Nm)

1. Install the cross brace and the retainers.
   Torque: 33 lb.ft (45 Nm)

1. If equipped.
   Position and clip the electrical harness.
   

1. Connect the lower ball joint to the wheel knuckle and install the new ball joint pinch bolt and nut.
   Torque: 76 lb.ft (103 Nm)

1. On both sides.
   Connected the front suspension height sensor electrical connectors. Position the bracket and install the bolt.
   Torque: 177 lb.in (20 Nm)

1. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque.

   NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut.

   On both sides.
   Position the stabilizer bar links and install the new stabilizer bar link lower nut.
   Torque: 85 lb.ft (115 Nm)

1. On both sides.
   Connect the tie rod end to the wheel knuckle and install the new tie rod end nut.
   Torque: 111 lb.ft (150 Nm)

1. Position the radiator core support and install the retainers.
   Torque: 177 lb.in (20 Nm)

1. Install the underbody air deflector, retainers and bolts.
   

1. Install the front air deflectors and retainers.
   

1. Install the retainers and the front underbody straps.
   

1. Install the underbody shield and the retainers.
   

1. Install the wheels and tires.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1.   WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   Position the steering shaft coupler and install the new steering shaft coupler bolt.
   Torque: 18 lb.ft (25 Nm)

1. Install the upper radiator grommets.
   

1. Install the radiator sight shield and the retainers.
   

1. Connect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Check and if necessary adjust front toe.
   Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).
   

1. Calibrate the suspension system. Connect the scan tool and carry out the Ride Height Calibration routine. Follow the scan tool directions.