2009 Ford Focus SES

2009 SUSPENSION Front Suspension - Focus

2009 SUSPENSION

Front Suspension - Focus

SPECIFICATIONS
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Description Nm lb-ft lb-in
Ball joint nut 63 46 -
Brake caliper guide pin bolts 27 20 -
Lower arm forward bolt 215 159 -
Lower arm inboard bracket nut 160 118 -
Lower arm outboard bracket nut 103 76 -
Stabilizer bar bracket bolts 55 41 -
Stabilizer bar link nuts 55 41 -
Strut rod nut 90 66 --
Strut upper nuts 35 26 -
Subframe front bolts 175 129 -
Subframe rear bolts 103 76 -
Tie-rod end nut 35 26 -
Wheel hub nut - - -
Wheel knuckle-to-strut bolt 150 111 -
Wheel speed sensor bolt 9 - 80

DESCRIPTION AND OPERATION

FRONT SUSPENSION

The front suspension consists of the following components:

l Wheel bearings
l Wheel hubs
l Lower arms
l Stabilizer bar, busings and links
l Strut and spring assemblies
l Wheel knuckles

The front suspension utilizes a MacPherson strut system. This suspension system incorporates a strut assembly
that takes the place of the upper arm and ball joint. The strut performs the function of a shock absorber and is
encompassed by a coil spring. The strut and spring assembly carries the sprung weight of the vehicle and is also
the pivot point for the steering knuckle. This system uses a lower control arm and ball joint for the lower

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

(unloaded) pivot point of the steering knuckle.

DIAGNOSTIC TESTS
FRONT SUSPENSION

Refer to SUSPENSION SYSTEM - GENERAL INFORMATION article.

REMOVAL AND INSTALLATION

WHEEL BEARING

Special Tools
Illustration Tool Name Tool Number

Installer, Drive Pinion Bearing Cup 205-140 (T80T-4000-F)

205-D064 (D84L-1123-A) or
Puller, Bearing
equivalent

Installer, Wheel Hub Bearing Cup 204-023 (T73T-1217-A)

Remover/Installer, Bushing 204-180 (T93P-5493-A)

Adapter for 303-224 (Handle) 205-153 (T80T-4000-W)

Installer, Wheel Speed Sensor Ring 206-054 (T93P-20202-A)

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 1: Wheel Bearing Components

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 1104 Wheel hub
2 3K171 LH/ 3K170 RH Wheel knuckle
3 1215 Wheel bearing
4 W700068 Circlip

REMOVAL

1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle.
2. Remove the circlip from the wheel knuckle.

NOTE: After the wheel hub is removed from the knuckle, the wheel bearing must
be discarded. The bearing inner ring will remain in the wheel knuckle.

3. Using the special tools, remove the wheel hub and outer bearing race.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 2: Removing Wheel Hub And Outer Bearing Race

Courtesy of FORD MOTOR CO.

NOTE: The special tools must be used to prevent damage to the hub. If the hub is
damaged, a new hub must be installed.

NOTE: Do not use heat to remove the bearing inner ring or damage to the bearing
may occur.

4. Using the special tools, remove the bearing inner ring from the wheel hub.

Fig. 3: Removing Bearing Inner Ring From Wheel Hub

Courtesy of FORD MOTOR CO.

5. To aid in removal of the bearing outer ring, install the bearing cage onto the inner ring and install the
assembly into the wheel knuckle.
6. Using the special tools, remove the bearing outer ring from the wheel knuckle.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 4: Removing Bearing Outer Ring From Wheel Knuckle

Courtesy of FORD MOTOR CO.

INSTALLATION

NOTE: To prevent wheel speed sensor ring damage, make sure that the sensor ring is
clean. Make sure that the sensor ring does not make contact with metal
surfaces and avoid any impact on the sensor ring.

NOTE: Make sure the wheel bearing is installed into the wheel knuckle with the
wheel speed sensor ring, colored black, at the wheel speed sensor end of
the wheel knuckle.

1. Using the special tools, install the new wheel bearing to the wheel knuckle.

Fig. 5: Installing Wheel Bearing To Wheel Knuckle

Courtesy of FORD MOTOR CO.

2. Using the special tools, install the wheel hub into the wheel knuckle.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 6: Installing Wheel Hub Into Wheel Knuckle

Courtesy of FORD MOTOR CO.

NOTE: Make sure the circlip does not cover the wheel speed sensor or damage to
the sensor may occur.

3. Install the circlip into the wheel knuckle.

4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle.

WHEEL STUDS

Special Tools
Illustration Tool Name Tool Number

Installer/Remover, C-Frame and

211-023 (T74P-3044-A1)
Screw

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 7: Wheel Studs Components

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 1107 Wheel stud

REMOVAL

CAUTION: Suspension fasteners are critical parts because they affect

performance of vital components and systems and their failure may
result in major service expense. New parts must be installed with the
same part numbers or equivalent part, if replacement is necessary.
Do not use a replacement part of lesser quality or substitute design.
Torque values must be used as specified during reassembly to make
sure correct retention of these parts.

NOTE: Make sure the steering wheel is in the UNLOCKED position.

1. Remove the brake disc. For additional information, refer to FRONT DISC BRAKE article.
2. Using the special tool, remove the wheel stud.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 8: Removing Wheel Stud

Courtesy of FORD MOTOR CO.

INSTALLATION

NOTE: Make sure to use washers that have an inside diameter that is larger than
the outside diameter of the wheel stud serrations. Use enough washers
(approximately 4) to allow the wheel stud to fully seat against the hub
flange.

1. Position the wheel stud in the flange, making sure the serrations on the stud line up with the serrations in
the flange. Install the washers and a wheel nut.

Fig. 9: Installing Wheel Stud

Courtesy of FORD MOTOR CO.

CAUTION: Do not use power tools to install the wheel stud or damage to the
flange may occur.

2. Tighten the wheel nut until the stud is seated against the hub flange.
3. Remove the wheel nut and the washers. Discard the wheel nut.
4. Install the brake disc. For additional information, refer to FRONT DISC BRAKE article.

LOWER ARM

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 10: Lower Arm Components With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W500442 Lower arm outboard bracket bolt
2 W500562 Lower arm inboard bracket bolt
3 3051 LH/ 3042 RH Lower arm
4 W520213 Ball joint nut
5 W712393 Ball joint bolt
6 W520215 Lower arm forward nut
7 W706861 Lower arm forward bolt
8 W520215 Lower arm outboard bracket nut
9 W520214 Lower arm inboard bracket nut

REMOVAL

NOTE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense.
New parts must be installed with the same part numbers or equivalent part, if
replacement is necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly
to make sure correct retention of these parts.

1. Remove the wheel and tire. For additional information, refer to WHEELS AND TIRES article.

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 2009 Ford Focus SES
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NOTE: 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.

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

2. Remove and discard the ball joint nut and bolt.

l Insert a pry bar in the lower arm body opening, separate the lower arm from the wheel knuckle and
remove the ball joint heat shield.

Fig. 11: Inserting Prybar In Lower Arm Body

Courtesy of FORD MOTOR CO.

3. Remove the lower arm bushing bracket nuts, bolts and the bracket.
l Discard the nuts and bolts.

4. Remove and discard the lower arm forward nut and bolt and remove the lower arm.

INSTALLATION

NOTE: To prevent incorrect clamp load or component damage, install the

fasteners in their original orientation. Install the lower arm bushing clamp
bolts with their heads facing down.

NOTE: Do not tighten the nuts and bolts at this time.

1. Position the lower arm and loosely install the forward nut and bolt and the 2 bracket nuts and bolts.

NOTE: Make sure the ball joint heat shield is installed on the ball joint stud or
damage to the ball joint may occur.

2. Install the ball joint heat shield.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 12: Identifying Ball Joint Heat Shield

Courtesy of FORD MOTOR CO.

3. Insert the ball joint stud into the wheel knuckle and install the ball joint bolt and nut.
l Tighten to 63 Nm (46 lb-ft).

4. Install the wheel and tire. For additional information, refer to WHEELS AND TIRES article.
5. Lower the hoist so the weight of the vehicle is resting on the wheels and tires.
6. Tighten the lower arm forward bolt to 215 Nm (159 lb-ft).
7. Tighten the lower arm inboard bracket nut to 160 Nm (118 lb-ft).
8. Tighten the lower arm outboard bracket nut to 103 Nm (76 lb-ft).
9. Check and, if necessary, align the front end. For additional information, refer to SUSPENSION
SYSTEM - GENERAL INFORMATION article.

STABILIZER BAR

Special Tools
Illustration Tool Name Tool Number

Remover, Tie-Rod End 211-001 (TOOL-3290-D)

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Fig. 13: Stabilizer Bar Components With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W710091 Subframe front bolt (4 required)
2 W709634 Subframe rear bolt (2 required)
3 5494 Stabilizer bar

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Stabilizer bar link lower nut (2 required)

4 W520213
(early build vehicles)
Stabilizer bar link lower nut (2 required)
4 W713760
(late build vehicles)
5 5484 Stabilizer bar bushing (2 required)
6 51836 Stabilizer bar spacer (2 required)
Stabilizer bar bushing bracket (2
7 5488
required)
8 W520203 Tie-rod end nut (2 required)
9 W710899/900 Stabilizer bar bracket bolt (4 required)
10 5019 Subframe

REMOVAL

CAUTION: Suspension fasteners are critical parts because they affect performance of
vital components and systems and their failure may result in major service
expense. New parts must be installed with the same part numbers or
equivalent part, if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used as
specified during reassembly to make sure correct retention of these parts.

1. Remove the wheel and tire. For additional information, refer to WHEELS AND TIRES article.
2. Loosen the tie-rod end nuts.
3. Using the special tool, detach the tie-rod ends from the wheel knuckles.
l Discard the tie-rod end nuts.

Fig. 14: Detaching Tie-Rod Ends From Wheel Knuckles

Courtesy of FORD MOTOR CO.

4. Remove and discard the stabilizer bar link lower nuts and detach the stabilizer bar links from the
stabilizer bar.

NOTE: If only replacing the stabilizer bar bushings, go to Step 8.

5. Using a suitable transmission jack, support the subframe.

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 2009 Ford Focus SES
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6. Index mark the subframe position.

7. Remove the 4 subframe front bolts and 2 subframe rear bolts.

CAUTION: The power steering lines are attached to the steering gear. Failure to
use caution when lowering the subframe may result in steering line
damage.

8. Lower the subframe to gain access to the stabilizer bar.

Fig. 15: Lowering Subframe To Gain Access To Stabilizer Bar

Courtesy of FORD MOTOR CO.

9. Remove the stabilizer bar bracket bolts and brackets.

l Discard the bolts.

10. Remove the stabilizer bar bushings.

11. Remove the stabilizer bar.

INSTALLATION

1. Install the stabilizer bar.

CAUTION: The stabilizer bar bushings must be positioned correctly on the flats
of the stabilizer bar or damage to the bushings may occur.

CAUTION: Do not apply any type of lubricant to the stabilizer bar or bushings or
damage to the bushings may occur.

2. Install the stabilizer bar bushings.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 16: Installing Stabilizer Bar Bushings

Courtesy of FORD MOTOR CO.

3. Position the stabilizer bar with the bushings against the spacer and set it to the specification listed using
tie straps or mechanic's wire.

Fig. 17: Positioning Stabilizer Bar Using Specification

Courtesy of FORD MOTOR CO.

4. Position the stabilizer bar brackets and install the bolts.

l Tighten to 55 Nm (41 lb-ft).

5. Remove the stabilizer bar supports.

NOTE: Do not fully tighten the subframe retaining bolts at this time.

6. Using the index marks made during removal, install the subframe retaining bolts.
l Tighten the bolts until snug.

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

7. Tighten the 4 subframe front bolts.

l Tighten to 175 Nm (129 lb-ft).

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

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 2009 Ford Focus SES
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8. Tighten the 2 subframe rear bolts.

l Tighten to 103 Nm (76 lb-ft).

9. Lower and remove the transmission jack.

10. Attach the stabilizer bar links to the stabilizer bar and install the nuts.
l Tighten to 55 Nm (41 lb-ft).

CAUTION: Install new tie-rod end nuts. Failure to follow this instruction may
result in incorrect clamp load.

11. Attach the tie-rod ends to the wheel knuckles and install the nuts.
l Tighten to 35 Nm (26 lb-ft).

12. Install the wheel and tire. For additional information, refer to WHEELS AND TIRES article.

WHEEL KNUCKLE

Special Tools
Illustration Tool Name Tool Number

Installer, Halfshaft 204-161 (T97P-1175-A)

205-D070 (D93P-1175-B) or
Remover, Front Wheel Hub
equivalent

Remover, Tie-Rod End 211-001 (TOOL-3290-D)

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 18: Wheel Knuckle Components With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 - Brake caliper and pad assembly
Brake caliper guide pin bolt (2 required)
2 -
(part of 2386 service kit)
3 1125 Brake disc
4 3B477 Wheel hub nut
5 W5000012 Wheel speed sensor bolt
6 2C204 Wheel speed sensor
7 3K171 LH/3K170 RH Wheel knuckle and hub assembly
8 W520203 Tie-rod end nut
9 W711725 Wheel knuckle-to-strut bolt
10 W712393 Ball joint bolt
11 W520213 Ball joint nut

REMOVAL

NOTE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense.
New parts must be installed with the same part numbers or equivalent part, if
replacement is necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly
to make sure correct retention of these parts.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

1. Loosen the 3 strut upper nuts 5 turns.

Fig. 19: Locating LH Strut And Spring Assembly Top Mount Nuts
Courtesy of FORD MOTOR CO.

2. Remove the wheel and tire. For additional information, refer to WHEELS AND TIRES article.
3. Remove and discard the wheel hub nut.
4. Remove the brake hose retainer.

Fig. 20: Identifying Brake Hose Retainer

Courtesy of FORD MOTOR CO.

NOTE: Do not allow the brake caliper to hang from the brake hose or damage to
the hose can occur.

5. Remove the 2 brake caliper guide pin bolts and position the caliper assembly aside.
l Support the caliper assembly using mechanic's wire.

6. Remove the brake disc.

7. If equipped with ABS, remove the wheel speed sensor bolt and position the sensor aside.

NOTE: Leave the tie-rod end nut in place or damage to the tie-rod end may occur.

8. Loosen the tie-rod end nut.

9. Using the Tie-Rod End Remover, detach the tie-rod end from the wheel knuckle.
l Remove and discard the tie-rod end nut.

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 2009 Ford Focus SES
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Fig. 21: Removing Tie-Rod End From Wheel Knuckle

Courtesy of FORD MOTOR CO.

NOTE: 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.

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

10. Remove and discard the ball joint nut and bolt.
l Insert a pry bar in the lower arm body opening and separate the ball joint from the wheel knuckle.

Fig. 22: Inserting Prybar In Lower Arm Body

Courtesy of FORD MOTOR CO.

NOTE: The inner joint must not be bent more than 18 degrees. The outer joint
must not be bent more than 45 degrees. Damage to the halfshaft will
occur.

11. Using the Front Wheel Hub Remover, press out the halfshaft from the wheel hub and detach the halfshaft
from the wheel hub.
l Support the halfshaft.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 23: Pressing Halfshaft From Wheel Bearing & Hub

Courtesy of FORD MOTOR CO.

12. Remove and discard the wheel knuckle-to-strut bolt.

13. Remove the wheel knuckle.

INSTALLATION

1. Position the wheel knuckle and install a new wheel knuckle-to-strut bolt.
l Tighten to 150 Nm (111 lb-ft).

2. Insert the hafshaft into the wheel hub.

NOTE: Make sure the ball joint heat shield is installed on the ball joint stud or
damage to the ball joint may occur.

3. Insert the ball joint stud into the wheel knuckle and install a new bolt and nut.
l Tighten to 63 Nm (46 lb-ft).

4. Attach the tie-rod end to the wheel knuckle and install a new nut.
l Tighten to 35 Nm (26 lb-ft).

5. If equipped with ABS, position the wheel speed sensor and install the bolt.
l Tighten to 9 Nm (80 lb-in).

6. Install the brake disc.

7. Position the caliper assembly and install the 2 brake caliper guide pin bolts.
l Tighten to 27 Nm (20 lb-ft).

8. Install the brake hose retainer.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 24: Identifying Brake Hose Retainer

Courtesy of FORD MOTOR CO.

9. Tighten the 3 strut upper nuts to 35 Nm (26 lb-ft).

10. Using the Halfshaft Installer, install the halfshaft into the wheel hub.

Fig. 25: Identifying Halfshaft Installer

Courtesy of FORD MOTOR CO.

NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut
must be tightened to specification before the vehicle is lowered onto the
wheels. Wheel bearing damage will occur if the wheel bearing is loaded
with the weight of the vehicle applied.

NOTE: Install and tighten the new wheel hub nut to specification in a continuous
rotation. Always install a new wheel hub nut after loosening or when not
tightened to specification in a continuous rotation or damage to the
component may occur.

NOTE: Apply the brake to keep the halfshaft from rotating.

11. Install the new wheel hub nut.

l Tighten to 270 Nm (199 lb-ft) in a continuous rotation.

12. Install the wheel and tire. For additional information, refer to WHEELS AND TIRES article.

STRUT AND SPRING ASSEMBLY

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 26: Strut and Spring Assembly Components With Torque Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W520213 Stabilizer bar link upper nut
2 18K001 LH/ 18045 RH Strut and spring assembly
3 W520102 Strut upper nut (3 required)
4 - Brake hose
5 W711725 Wheel knuckle-to-strut bolt

REMOVAL AND INSTALLATION

CAUTION: Suspension fasteners are critical parts because they affect performance of
vital components and systems and their failure may result in major service
expense. New parts must be installed with the same part numbers or
equivalent part, if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used as
specified during reassembly to make sure correct retention of these parts.

1. Remove the wheel and tire. For additional information, refer to WHEELS AND TIRES article.
2. Detach the brake hose from the support bracket.

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 27: Locating Brake Hose

Courtesy of FORD MOTOR CO.

3. Remove the stabilizer bar link upper nut and detach the link from the strut.
l To install, tighten to 55 Nm (41 lb-ft).

4. Remove the wheel knuckle-to-strut bolt.

l To install, tighten to 150 Nm (111 lb-ft).

5. Detach the wheel knuckle from the strut and spring assembly.
l Support the halfshaft using mechanic's wire.

CAUTION: Support the strut and spring assembly to prevent damage.

6. Remove the strut upper nuts.

l To install, tighten to 35 Nm (26 lb-ft).

7. Remove the strut and spring assembly.

8. To install, reverse the removal procedure.
l For additional information on the disassembly and assembly of the strut and spring assembly, refer
to Strut and Spring Assembly.
9. Check and, if necessary, align the front end. For additional information, refer to SUSPENSION
SYSTEM - GENERAL INFORMATION article.

DISASSEMBLY AND ASSEMBLY

STRUT AND SPRING ASSEMBLY

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 2009 Ford Focus SES
2009 SUSPENSION Front Suspension - Focus

Fig. 28: Strut and Spring Assembly Components With Torque Specification
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 5310 Spring
2 5A318 Spring upper seat
3 - Upper mount bearing (part of 3K155)
4 3K155 Upper mount bearing
5 W711949 Strut rod nut
6 3025 Jounce bumper
7 18124 Strut

DISASSEMBLY AND ASSEMBLY

CAUTION: 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 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 during
reassembly to make sure of correct retention of these parts.

1. Remove the strut and spring assembly. For additional information, refer to Strut and Spring Assembly.

WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock
absorbers or struts can extend unassisted. Failure to follow this

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 2009 Ford Focus SES
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instruction may result in serious personal injury.

2. Using a suitable coil spring compressor, compress the spring.

Fig. 29: Compressing Spring

Courtesy of FORD MOTOR CO.

NOTE: Use the holding feature to prevent the strut rod from rotating while
removing the nut.

3. Carefully remove and discard the strut rod nut.

l To install, tighten to 90 Nm (66 lb-ft).

Fig. 30: Locating Strut Rod Nut

Courtesy of FORD MOTOR CO.

4. Remove the upper mount, spring upper seat and dust boot.
5. Remove the strut and jounce bumper.
6. Carefully remove the spring from the spring compressor.

CAUTION: Make sure the upper mount is correctly seated before assembly or
damage to the upper mount may occur.

CAUTION: Make sure the spring is installed with the flat surface facing up and
with the spring end correctly positioned against the spring seat

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 2009 Ford Focus SES
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(color code at the bottom). This is to prevent spring seat damage and
incorrect spring position.

7. To assemble, reverse the disassembly procedure.

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