Ford Fusion: Rear Suspension / Wheel Knuckle - AWD. 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 bearing and wheel hub.
   Refer to: Wheel Bearing and Wheel Hub - AWD (204-02 Rear Suspension, Removal and Installation).
   

1. 1. Remove the wheel speed sensor bolt and position the wheel speed sensor aside.
      
   2. Remove the brake hose bracket bolt and position the brake hose bracket aside.
      

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

1. Remove the lower arm vertical link.
   Refer to: Lower Arm Vertical Link (204-02 Rear Suspension, Removal and Installation).
   

1. Support the halfshaft.
   
   1. Remove and discard the lower arm-to-wheel knuckle bolt.
      
   2. Remove and discard the toe link-to-wheel knuckle bolt and flagnut.
      
   3. Remove and discard the upper arm-to-wheel knuckle bolt and remove the wheel knuckle.
      

Installation

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.

   1. Position the wheel knuckle and install the new upper arm-to-wheel knuckle bolt.
      Torque: 136 lb.ft (185 Nm)
   2. Install the new toe link-to-wheel knuckle bolt and flagnut.
      Torque: 76 lb.ft (103 Nm)
   3. Install the new lower arm-to-wheel knuckle bolt.
      Torque:
         Aluminum lower arm::   203 lb.ft (275 Nm)
         Cast-iron lower arm::   166 lb.ft (225 Nm)

1. Install the lower arm vertical link.
   Refer to: Lower Arm Vertical Link (204-02 Rear Suspension, Removal and Installation).
   

1. 1. Position the brake hose bracket and install the brake hose bracket bolt.
      Torque: 124 lb.in (14 Nm)
   2. Position the wheel speed sensor and install the wheel speed sensor bolt.
      Torque: 80 lb.in (9 Nm)

1. Install the wheel bearing and wheel hub.
   Refer to: Wheel Bearing and Wheel Hub - AWD (204-02 Rear Suspension, Removal and Installation).
   

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