Ford Fusion: Front Suspension / Lower Arm. Removal and Installation

Special Tool(s) / General Equipment

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

1. Remove the 11 screws and 2 clips and remove the front under body shield.
   

1. NOTE: If equipped.

   Remove the 2 screws and remove the shield.
   

1. NOTE: If equipped. LH or RH as necessary.

   Remove the retainers and shields as needed.
   

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.

   Remove the front height sensor arm bracket bolt and position the front height sensor arm 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.

   Remove and discard the lower ball joint pinch bolt and nut and separate the ball joint from the wheel knuckle.
   

1. Remove and discard the 1 forward and 2 rearward lower arm bolts and remove the lower arm.
   

Installation

1. NOTE: Only tighten the bolts finger tight at this stage.

   Position the lower arm and install the 2 new rearward and 1 new forward lower arm bolts.
   

1. Support the front suspension to ride height.
   Use the General Equipment: Vehicle/Axle Stands

1. NOTICE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight of the vehicle resting on the wheels and tires, otherwise incorrect clamp load and bushing damage may occur.

   Tighten the 2 new rearward and 1 new forward lower arm bolts.
   Torque:
      1:   122 lb.ft (165 Nm)
      2:   159 lb.ft (215 Nm)

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

1. Position the front height sensor arm bracket and install the front height sensor arm bracket bolt.
   Torque: 177 lb.in (20 Nm)

1. NOTE: If equipped. LH or RH as necessary.

   Install the shields and retainers as needed.
   

1. NOTE: If equipped.

   Install the shield and the 2 screws.
   

1. Install the front under body shield and install the 2 clips and 11 screws.
   

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

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.