Yandex MC
1996-97 SUSPENSION Front - 4WD Torsion Bar - Explorer & Mountaineer <meta name="InColGX" content=""> </head> <body bgcolor="white" text="black"> <h1>1996-97 SUSPENSION</h1> <h1>Front - 4WD Torsion Bar - Explorer & Mountaineer</h1><a name="S17928475452001011600000"></a><h2 class="clsHeadOne">DESCRIPTION</h2> <p>Torsion bar suspension consists of torsion bars, upper and lower control arms with integral ball joints and bushings, adjusting cams, shock absorbers, wheel hubs, knuckles and stabilizer bar. See <a class="clsGraphicLink" onclick="return ajaxHrefModalImg(event,$(this))" href="#S31749690572001011600000">Fig. 1</a> .</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G95G27868" name="S31749690572001011600000">Fig. 1: Identifying Front Suspension Components</a><br><span class="clsCourtesyNote">Courtesy of FORD MOTOR CO.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>For information on 4WD drive axles, see appropriate article in DRIVE AXLES.</td> </tr> </table></span></p><a name="S05101753042001011600000"></a><h2 class="clsHeadOne">ADJUSTMENTS & INSPECTION</h2><a name="S33812746402001011600000"></a><h2 class="clsHeadTwo">WHEEL ALIGNMENT</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.</td> </tr> </table></span></p><a name="S23166809262001011600000"></a><h2 class="clsHeadTwo">WHEEL BEARINGS</h2> <p>Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support front of vehicle. Remove wheels. Reinstall 3 lug nuts to secure rotor to hub. Check hub nut for correct torque. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Using a dial indicator, measure axial end play at hub. Maximum axial end play is .003" (.08 mm). If reading exceeds specification, replace wheel bearing assembly.</p><a name="S38726267172001011600000"></a><h2 class="clsHeadTwo">RIDING HEIGHT</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.</td> </tr> </table></span></p><a name="S08253010612001011600000"></a><h2 class="clsHeadTwo">BALL JOINT CHECKING</h2> <p>Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Ensure wheel bearings are properly adjusted. See <a class="clsHyperlink" href="#S23166809262001011600000">WHEEL BEARINGS</a> . Hold wheel and move it in and out while watching knuckle and lower control arm. Knuckle movement must not exceed 1/32" (.80 mm) at upper or lower control arms. Replace ball joints if worn beyond limit.</p><a name="S24562644282001011600000"></a><h2 class="clsHeadOne">REMOVAL & INSTALLATION</h2><a name="S11663520522001011600000"></a><h2 class="clsHeadTwo">WHEEL HUB & BEARINGS</h2><a name="S02639518712001011600000"></a><h2 class="clsHeadThree">Removal</h2> <ol class="clsARABICNUM"> <li>Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Remove wheel assembly. Remove hub nut and washer. Remove brake caliper and brake caliper bracket assembly. Remove brake rotor retaining screw (if equipped), and remove brake rotor. Remove 3 brake rotor shield retaining bolts, and remove brake rotor shield. Remove ABS sensor retaining bolt, and disconnect sensor. Reinstall rotor (without screw). </li> <li>Using Puller (T81P-1104-C), Metric Stud Adapter (T83P-1104-BH), Stud Adapter (T86P-1104-A1), Hub Remover Adapter (T81P-1104-A), separate axle shaft from wheel hub. See <a class="clsGraphicLink" onclick="return ajaxHrefModalImg(event,$(this))" href="#S29012181342001011600000">Fig. 2</a> . Remove brake rotor. Remove 3 wheel hub retaining bolts, and remove wheel hub and bearing assembly. </li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G95I27001" name="S29012181342001011600000">Fig. 2: Removing Axle Shaft From Hub Assembly</a><br><span class="clsCourtesyNote">Courtesy of FORD MOTOR CO.</span></span></p><a name="S40172599282001011600000"></a><h2 class="clsHeadThree">Installation</h2> <ol class="clsARABICNUM"> <li>Connect ABS sensor to wheel hub and position wheel hub assembly onto axle shaft and knuckle. Install hub retaining bolts and tighten to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Install washer and hub nut, and tighten to specification. </li> <li>Install ABS sensor bolt and tighten to specification. Install brake rotor shield and tighten bolts to specification. Install rotor. Install brake caliper and brake caliper bracket assembly. Tighten bolts to specification. Install wheel and lower vehicle. </li> </ol><a name="S26607835032001011600000"></a><h2 class="clsHeadTwo">WHEEL KNUCKLE</h2><a name="S10369646462001011600000"></a><h2 class="clsHeadThree">Removal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>Before disconnecting steering linkage from knuckle, always place steering system in the centered position.</td> </tr> </table></span></p> <ol class="clsARABICNUM"> <li>Place steering wheel and steering system in the centered position. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Remove wheel assembly. Remove brake caliper and brake caliper mounting bracket. Remove brake rotor retaining screw, and remove brake rotor. </li> <li>Remove 3 brake rotor shield retaining bolts, and remove brake rotor shield. Remove ABS sensor retaining bolt, and disconnect sensor. Remove hub nut and washer. Remove cotter pin and nut attaching tie rod end-to-knuckle. Using Pitman Arm Puller (T64P-3590-F), separate tie rod end from knuckle. </li> <li>Unload torsion bar using Torsion Bar Unloader (T95T-5310-A) and Torsion Bar Unloader Adapter (T96T-5310-A1). Support lower control arm with jack. Remove lower ball joint cotter pin, and loosen lower ball joint nut. Use pitman arm puller to loosen lower ball joint from knuckle. Remove puller and lower ball joint nut. Raise lower control arm and separate from lower ball joint. Reinstall rotor (without screw). </li> <li>Using Puller (T81P-1104-C), Metric Stud Adapter (T83P-1104-BH), Stud Adapter (T86P-1104-A1), Hub Remover Adapter (T81P-1104-A), separate axle shaft from wheel hub. See <a class="clsGraphicLink" onclick="return ajaxHrefModalImg(event,$(this))" href="#S29012181342001011600000">Fig. 2</a> . Remove brake rotor. Remove upper ball joint pinch bolt. Remove knuckle and hub assembly. Remove hub from knuckle (if necessary). </li> <li>Inspect upper and lower ball joints. Replace worn or damaged components as necessary. Upper and lower ball joints are an integral part of control arms, and must be replaced as an assembly. Installation </li> </ol><a name="S20857655831999030800000"></a><h2 class="clsHeadThree">Installation</h2> <ol class="clsARABICNUM"> <li>Install wheel hub onto knuckle (if removed). Tighten bolts to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Align axle shaft with knuckle and hub assembly, and position knuckle and hub assembly onto upper ball joint stud. Install upper ball joint pinch bolt and tighten to specification. </li> <li>Connect lower ball joint to knuckle. Ensure lower ball joint is seated into knuckle. Install lower ball joint nut, and tighten to specification. Install NEW cotter pin. Connect tie rod end to knuckle arm. Ensure tie rod end is seated in knuckle arm to prevent turning while tightening. </li> <li>Install tie rod end nut, and tighten to specification. Install NEW cotter pin. Install ABS sensor, and tighten bolt to specification. Install washer and hub nut, and tighten to specification. Install brake rotor shield, and tighten bolts to specification. Install brake rotor. </li> <li>Install brake caliper and brake caliper bracket assembly. Tighten bolts to specification. Remove torsion bar unloader. Check and set ride height. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Install wheel and lower vehicle. </li> </ol><a name="S14875300802001011600000"></a><h2 class="clsHeadTwo">SHOCK ABSORBERS</h2><a name="S24040837682001011600000"></a><h2 class="clsHeadThree">Removal (Automatic Ride Control)</h2> <ol class="clsARABICNUM"> <li>Place vehicle in 2-wheel drive. Turn off automatic ride control switch. Switch is located behind right rear quarter panel. Raise and support vehicle. Support lower control arm with jack. Disconnect automatic ride control electrical connector, and pry harness retainers from frame. Disconnect air line from shock absorber by pushing in on plastic ring, while pulling out on air line. </li> <li>If removing left shock absorber, release spring clip, and disconnect height sensor from upper bracket. Remove shock absorber upper nut, washer and bushing. Remove 2 lower shock absorber-to-lower control arm nuts. Compress shock absorber and remove from vehicle. </li> </ol><a name="S29822744342001011600000"></a><h2 class="clsHeadThree">Installation</h2> <p>To install, reverse removal procedure. Tighten nuts to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Turn on automatic ride control.</p><a name="S17135958662001011600000"></a><h2 class="clsHeadThree">Removal (Without Automatic Ride Control)</h2> <p>Raise and support vehicle. Support lower control arm with jack. Remove upper shock absorber nut, washer and bushing. Remove 2 lower shock absorber-to-lower control arm nuts. Compress shock absorber and remove from vehicle.</p><a name="S06331399882001011600000"></a><h2 class="clsHeadThree">Installation</h2> <p>To install, reverse removal procedure. Tighten nuts to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table.</p><a name="S40662761722001011600000"></a><h2 class="clsHeadTwo">STABILIZER BAR</h2><a name="S34451804182001011600000"></a><h2 class="clsHeadThree">Removal</h2> <p>Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Remove stabilizer bar-to-stabilizer bar link nut, washer and bushing assembly. Remove stabilizer bar links from lower control arms (if necessary). Remove stabilizer bar-to-frame mounting brackets, and remove stabilizer bar from vehicle. Remove and replace stabilizer bar insulators (if necessary).</p><a name="S04485141382001011600000"></a><h2 class="clsHeadThree">Installation</h2> <p>To install, reverse removal procedure. Tighten stabilizer bar-to-stabilizer bar links with vehicle lowered to curb height. Tighten nuts to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table.</p><a name="S31193372032001011600000"></a><h2 class="clsHeadTwo">LOWER CONTROL ARM, BALL JOINT & BUSHINGS</h2><a name="S18465297072001011600000"></a><h2 class="clsHeadThree">Removal</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>Lower ball joints and bushings are an integral part of the lower control arm, and are replaced only as an assembly.</td> </tr> </table></span></p> <ol class="clsARABICNUM"> <li>Place steering wheel and steering system in the centered position. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise vehicle on hoist. Remove wheel assembly. Disconnect stabilizer link from lower control arm. Remove shock absorber. See <a class="clsHyperlink" href="#S14875300802001011600000">SHOCK ABSORBERS</a> . Place jackstands under jacking pads, and lower hoist while maintaining working room. </li> <li>Remove torsion bar. See <a class="clsHyperlink" href="#S13509107372001011600000">TORSION BAR</a> . Loosen lower control arm pivot bolts. Remove lower ball joint cotter pin and loosen lower ball joint nut. Using Pitman Arm Puller (T64P-3590-F), loosen lower ball joint in lower control arm. Remove puller and lower ball joint nut, while supporting lower control arm with jack. </li> <li>Raise lower control arm and separate knuckle from lower control arm. Remove lower control arm pivot bolts, and remove lower control arm from vehicle. Inspect lower ball joint and lower control arm bushings for wear and/or damage. If necessary, replace lower control arm assembly. </li> </ol><a name="S33046091592001011600000"></a><h2 class="clsHeadThree">Installation</h2> <ol class="clsARABICNUM"> <li>Position lower control arm into crossmember. Install and snug lower control arm pivot bolts. Install torsion bar. See <a class="clsHyperlink" href="#S13509107372001011600000">TORSION BAR</a> . Raise lower control arm and engage lower ball joint into knuckle. Install lower ball joint nut, and tighten to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Install NEW cotter pin. Raise vehicle. </li> <li>Install shock absorber. Tighten upper and lower shock absorber nuts to specification. Install wheel assembly, and lower vehicle. Connect stabilizer bar link-to-lower control arm, and tighten nut to specification. Tighten lower control arm pivot bolts to specification. Check and set ride height and wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. </li> </ol><a name="S13509107372001011600000"></a><h2 class="clsHeadTwo">TORSION BAR</h2><a name="S21451865882001011600000"></a><h2 class="clsHeadThree">Removal</h2> <ol class="clsARABICNUM"> <li>Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise vehicle on hoist. Remove bolts attaching torsion bar protector-to-frame. See <a class="clsGraphicLink" onclick="return ajaxHrefModalImg(event,$(this))" href="#S01914280772001011600000">Fig. 3</a> . Remove bolt from torsion bar nut, noting number of turns required to remove bolt for installation. </li> <li>Using Torsion Bar Unloader (T95T-5310-A) and Torsion Bar Unloader Adapter (T96T-5310-A1), raise torsion bar adjuster. Remove torsion bar nut, and lower torsion bar adjuster. Slide torsion bar forward, and remove torsion bar adjuster. Remove torsion bar from vehicle. </li> </ol><a name="S25284441582001011600000"></a><h2 class="clsHeadThree">Installation</h2> <ol class="clsARABICNUM"> <li>Slide torsion bar into lower control arm. Position torsion bar adjuster, and slide torsion bar into torsion bar adjuster. Raise adjuster using torsion bar unloader. Install torsion bar nut. Lubricate tip of torsion bar adjusting bolt. Install torsion bar adjusting bolt. </li> <li>Tighten torsion bar adjusting bolt same number of turns recorded during removal. Tighten bolt an additional 2 turns. Install torsion bar protector and tighten bolts to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Lower vehicle and check ride height. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. </li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G95E27726" name="S01914280772001011600000">Fig. 3: Exploded View Of Torsion Bar Adjuster</a><br><span class="clsCourtesyNote">Courtesy of FORD MOTOR CO.</span></span></p><a name="S27115803532001011600000"></a><h2 class="clsHeadTwo">UPPER CONTROL ARM, BALL JOINT & BUSHINGS</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>Upper ball joints and bushings are an integral part of the upper control arm, and are replaced only as an assembly.</td> </tr> </table></span></p><a name="S19879645692001011600000"></a><h2 class="clsHeadThree">Removal</h2> <ol class="clsARABICNUM"> <li>Place steering wheel and steering system in the centered position. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise vehicle on hoist, and support lower control arm. Remove wheel and tire assembly. Secure knuckle from tilting, and remove upper ball joint-to-knuckle pinch bolt. Separate upper ball joint from knuckle. </li> <li>For removal of left upper control arm, remove nuts and cam bolts attaching upper control arm-to-frame, and remove upper control arm. See <a class="clsGraphicLink" onclick="return ajaxHrefModalImg(event,$(this))" href="#S19316880632001011600000">Fig. 4</a> . </li> <li>Right upper control arm is a 2 piece design. Remove 2 nuts attaching right upper ball joint assembly-to-adjusting arm, and remove right upper ball joint. Remove adjusting arm cam bolts, and remove adjusting arm. </li> </ol><a name="S40097022522001011600000"></a><h2 class="clsHeadThree">Installation</h2> <ol class="clsARABICNUM"> <li>To install right upper control arm, position adjusting arm into frame. Install adjusting arm cam bolts, and tighten to specification. See <a class="clsHyperlink" href="#S15764844862001011600000">TORQUE SPECIFICATIONS</a> table. Install ball joint assembly onto adjusting arm, and tighten nuts to specification. Position upper ball joint into knuckle. Install upper ball joint pinch bolt, and tighten to specification. </li> <li>To install left upper control arm, position upper control arm into frame. Install upper control arm cam bolts, and tighten to specification. Connect upper control arm ball joint-to-knuckle. Install upper ball joint pinch bolt, and tighten to specification. </li> <li>Remove jackstand from under lower control arm. Install wheel and tire assembly. Lower vehicle and check wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. </li> </ol> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G95G27728" name="S19316880632001011600000">Fig. 4: Left & Right Upper Control Arm Assemblies</a><br><span class="clsCourtesyNote">Courtesy of FORD MOTOR CO.</span></span></p><a name="S02384289392001011600000"></a><h2 class="clsHeadOne">TORQUE SPECIFICATIONS</h2> <p><span class="clsArticleTable"><a name="S15764844862001011600000"></a><span class="clsTableTitle">TORQUE SPECIFICATIONS</span><br><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="19px"> <col span="1" id="COL2" width="252px"> <col span="1" id="COL3" width="125px"> </colgroup> <thead> <tr class="clsTblHead"> <th colspan="2" valign="BOTTOM" align="LEFT" class="clsCellNormal">Application</th> <th valign="BOTTOM" align="RIGHT" class="clsCellNormal">Ft. Lbs. (N.m)</th> </tr> </thead> <tbody> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Brake Caliper Bracket Bolt</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">56-77 (76-104)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Hub Nut</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">157-213 (213-289)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Hub Retaining Bolts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">74-96 (100-130)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Jounce Bumper Bolt</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">14-19 (19-26)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Lower Ball Joint Nut</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">83-113 (112-153)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Lower Control Arm Pivot Bolts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">111-148 (150-201)</td> </tr> <tr> <td colspan="3" valign="TOP" align="LEFT" class="clsCellNormal">Lower Shock Absorber Nut</td> </tr> <tr> <td colspan="2" style="padding-left: 21px;" valign="TOP" align="LEFT" class="clsCellNormal">With Automatic Ride Control</td> <td style="padding-left: 21px;" valign="TOP" align="RIGHT" class="clsCellNormal">18-24 (24-33)</td> </tr> <tr> <td colspan="2" style="padding-left: 21px;" valign="TOP" align="LEFT" class="clsCellNormal">Without Automatic Ride Control</td> <td style="padding-left: 21px;" valign="TOP" align="RIGHT" class="clsCellNormal">39-53 (53-72)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Right Adjusting Arm Cam Bolts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">83-113 (112-153)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Stabilizer Bar Bracket Bolts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">65-87 (88-118)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Stabilizer Bar Link-To-Lower Control Arm Nut</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">10-13 (14-18)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Tie Rod End-To-Knuckle Nut</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">57-77 (77-104)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Torsion Bar Protector Bolts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">25-34 (34-46)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Upper Ball Joint-To-Adjusting Arm Nut</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">95-128 (129-173)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Upper Ball Joint-To-Knuckle Pinch Bolt</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">30-40 (41-54)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Upper Control Arm Cam Bolts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">83-113 (112-153)</td> </tr> <tr> <td colspan="3" valign="TOP" align="LEFT" class="clsCellNormal">Upper Shock Absorber Nut</td> </tr> <tr> <td colspan="2" style="padding-left: 21px;" valign="TOP" align="LEFT" class="clsCellNormal">With Automatic Ride Control</td> <td style="padding-left: 21px;" valign="TOP" align="RIGHT" class="clsCellNormal">25-34 (34-46)</td> </tr> <tr> <td colspan="2" style="padding-left: 21px;" valign="TOP" align="LEFT" class="clsCellNormal">Without Automatic Ride Control</td> <td style="padding-left: 21px;" valign="TOP" align="RIGHT" class="clsCellNormal">15-21 (20-28)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Wheel Lug Nuts</td> <td valign="TOP" align="RIGHT" class="clsCellNormal"><a class="clsFootnoteLink" href="#S36545913152001011600000"><sup>(1)</sup></a> 100 (136)</td> </tr> <tr> <td colspan="3" valign="TOP" align="RIGHT" class="clsCellNormal"><span class="clsEmphBOLD">INCH Lbs. (N.m)</span> </td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">ABS Sensor Bolt</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">62-97 (7-11)</td> </tr> <tr> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Brake Rotor Shield bolt</td> <td valign="TOP" align="RIGHT" class="clsCellNormal">89-124 (10-14)</td> </tr> <tr class="clsFootnoteRow"> <td colspan="3" valign="TOP" align="LEFT" class="clsCellNormal"> <table class="clsFootnoteTable" width="100%"> <tr valign="top"> <td width="10px"><a name="S36545913152001011600000"><sup>(1)</sup></a></td> <td>Failure to retighten wheel lug nuts at 500 miles after installation, may result in wheel coming loose and loss of vehicle control.</td> </tr> </table> </td> </tr> </tbody> </table></span></p> </body> </html>

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SUSPENSION SYSTEM - FRONT (4WD)
  • HEADINGS
    • DESCRIPTION
    • ADJUSTMENTS & INSPECTION
      • WHEEL ALIGNMENT
      • WHEEL BEARINGS
      • RIDING HEIGHT
      • BALL JOINT CHECKING
    • REMOVAL & INSTALLATION
      • WHEEL HUB & BEARINGS
        • Removal
        • Installation
      • WHEEL KNUCKLE
        • Removal
        • Installation
      • SHOCK ABSORBERS
        • Removal (Automatic Ride Control)
        • Installation
        • Removal (Without Automatic Ride Control)
        • Installation
      • STABILIZER BAR
        • Removal
        • Installation
      • LOWER CONTROL ARM, BALL JOINT & BUSHINGS
        • Removal
        • Installation
      • TORSION BAR
        • Removal
        • Installation
      • UPPER CONTROL ARM, BALL JOINT & BUSHINGS
        • Removal
        • Installation
    • TORQUE SPECIFICATIONS
  • FIGURES
    • Fig. 1: Identifying Front Suspension Components
    • Fig. 2: Removing Axle Shaft From Hub Assembly
    • Fig. 3: Exploded View Of Torsion Bar Adjuster
    • Fig. 4: Left & Right Upper Control Arm Assemblies
  • TABLES
    • TORQUE SPECIFICATIONS

1996-97 SUSPENSION

Front - 4WD Torsion Bar - Explorer & Mountaineer

DESCRIPTION

Torsion bar suspension consists of torsion bars, upper and lower control arms with integral ball joints and bushings, adjusting cams, shock absorbers, wheel hubs, knuckles and stabilizer bar. See Fig. 1 .

Fig. 1: Identifying Front Suspension Components
Courtesy of FORD MOTOR CO.

NOTE: For information on 4WD drive axles, see appropriate article in DRIVE AXLES.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT

NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

WHEEL BEARINGS

Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support front of vehicle. Remove wheels. Reinstall 3 lug nuts to secure rotor to hub. Check hub nut for correct torque. See TORQUE SPECIFICATIONS table. Using a dial indicator, measure axial end play at hub. Maximum axial end play is .003" (.08 mm). If reading exceeds specification, replace wheel bearing assembly.

RIDING HEIGHT

NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

BALL JOINT CHECKING

Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Ensure wheel bearings are properly adjusted. See WHEEL BEARINGS . Hold wheel and move it in and out while watching knuckle and lower control arm. Knuckle movement must not exceed 1/32" (.80 mm) at upper or lower control arms. Replace ball joints if worn beyond limit.

REMOVAL & INSTALLATION

WHEEL HUB & BEARINGS

Removal

  1. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Remove wheel assembly. Remove hub nut and washer. Remove brake caliper and brake caliper bracket assembly. Remove brake rotor retaining screw (if equipped), and remove brake rotor. Remove 3 brake rotor shield retaining bolts, and remove brake rotor shield. Remove ABS sensor retaining bolt, and disconnect sensor. Reinstall rotor (without screw).
  2. Using Puller (T81P-1104-C), Metric Stud Adapter (T83P-1104-BH), Stud Adapter (T86P-1104-A1), Hub Remover Adapter (T81P-1104-A), separate axle shaft from wheel hub. See Fig. 2 . Remove brake rotor. Remove 3 wheel hub retaining bolts, and remove wheel hub and bearing assembly.

Fig. 2: Removing Axle Shaft From Hub Assembly
Courtesy of FORD MOTOR CO.

Installation

  1. Connect ABS sensor to wheel hub and position wheel hub assembly onto axle shaft and knuckle. Install hub retaining bolts and tighten to specification. See TORQUE SPECIFICATIONS table. Install washer and hub nut, and tighten to specification.
  2. Install ABS sensor bolt and tighten to specification. Install brake rotor shield and tighten bolts to specification. Install rotor. Install brake caliper and brake caliper bracket assembly. Tighten bolts to specification. Install wheel and lower vehicle.

WHEEL KNUCKLE

Removal

NOTE: Before disconnecting steering linkage from knuckle, always place steering system in the centered position.

  1. Place steering wheel and steering system in the centered position. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Remove wheel assembly. Remove brake caliper and brake caliper mounting bracket. Remove brake rotor retaining screw, and remove brake rotor.
  2. Remove 3 brake rotor shield retaining bolts, and remove brake rotor shield. Remove ABS sensor retaining bolt, and disconnect sensor. Remove hub nut and washer. Remove cotter pin and nut attaching tie rod end-to-knuckle. Using Pitman Arm Puller (T64P-3590-F), separate tie rod end from knuckle.
  3. Unload torsion bar using Torsion Bar Unloader (T95T-5310-A) and Torsion Bar Unloader Adapter (T96T-5310-A1). Support lower control arm with jack. Remove lower ball joint cotter pin, and loosen lower ball joint nut. Use pitman arm puller to loosen lower ball joint from knuckle. Remove puller and lower ball joint nut. Raise lower control arm and separate from lower ball joint. Reinstall rotor (without screw).
  4. Using Puller (T81P-1104-C), Metric Stud Adapter (T83P-1104-BH), Stud Adapter (T86P-1104-A1), Hub Remover Adapter (T81P-1104-A), separate axle shaft from wheel hub. See Fig. 2 . Remove brake rotor. Remove upper ball joint pinch bolt. Remove knuckle and hub assembly. Remove hub from knuckle (if necessary).
  5. Inspect upper and lower ball joints. Replace worn or damaged components as necessary. Upper and lower ball joints are an integral part of control arms, and must be replaced as an assembly. Installation

Installation

  1. Install wheel hub onto knuckle (if removed). Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Align axle shaft with knuckle and hub assembly, and position knuckle and hub assembly onto upper ball joint stud. Install upper ball joint pinch bolt and tighten to specification.
  2. Connect lower ball joint to knuckle. Ensure lower ball joint is seated into knuckle. Install lower ball joint nut, and tighten to specification. Install NEW cotter pin. Connect tie rod end to knuckle arm. Ensure tie rod end is seated in knuckle arm to prevent turning while tightening.
  3. Install tie rod end nut, and tighten to specification. Install NEW cotter pin. Install ABS sensor, and tighten bolt to specification. Install washer and hub nut, and tighten to specification. Install brake rotor shield, and tighten bolts to specification. Install brake rotor.
  4. Install brake caliper and brake caliper bracket assembly. Tighten bolts to specification. Remove torsion bar unloader. Check and set ride height. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Install wheel and lower vehicle.

SHOCK ABSORBERS

Removal (Automatic Ride Control)

  1. Place vehicle in 2-wheel drive. Turn off automatic ride control switch. Switch is located behind right rear quarter panel. Raise and support vehicle. Support lower control arm with jack. Disconnect automatic ride control electrical connector, and pry harness retainers from frame. Disconnect air line from shock absorber by pushing in on plastic ring, while pulling out on air line.
  2. If removing left shock absorber, release spring clip, and disconnect height sensor from upper bracket. Remove shock absorber upper nut, washer and bushing. Remove 2 lower shock absorber-to-lower control arm nuts. Compress shock absorber and remove from vehicle.

Installation

To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS table. Turn on automatic ride control.

Removal (Without Automatic Ride Control)

Raise and support vehicle. Support lower control arm with jack. Remove upper shock absorber nut, washer and bushing. Remove 2 lower shock absorber-to-lower control arm nuts. Compress shock absorber and remove from vehicle.

Installation

To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS table.

STABILIZER BAR

Removal

Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise and support vehicle. Remove stabilizer bar-to-stabilizer bar link nut, washer and bushing assembly. Remove stabilizer bar links from lower control arms (if necessary). Remove stabilizer bar-to-frame mounting brackets, and remove stabilizer bar from vehicle. Remove and replace stabilizer bar insulators (if necessary).

Installation

To install, reverse removal procedure. Tighten stabilizer bar-to-stabilizer bar links with vehicle lowered to curb height. Tighten nuts to specification. See TORQUE SPECIFICATIONS table.

LOWER CONTROL ARM, BALL JOINT & BUSHINGS

Removal

NOTE: Lower ball joints and bushings are an integral part of the lower control arm, and are replaced only as an assembly.

  1. Place steering wheel and steering system in the centered position. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise vehicle on hoist. Remove wheel assembly. Disconnect stabilizer link from lower control arm. Remove shock absorber. See SHOCK ABSORBERS . Place jackstands under jacking pads, and lower hoist while maintaining working room.
  2. Remove torsion bar. See TORSION BAR . Loosen lower control arm pivot bolts. Remove lower ball joint cotter pin and loosen lower ball joint nut. Using Pitman Arm Puller (T64P-3590-F), loosen lower ball joint in lower control arm. Remove puller and lower ball joint nut, while supporting lower control arm with jack.
  3. Raise lower control arm and separate knuckle from lower control arm. Remove lower control arm pivot bolts, and remove lower control arm from vehicle. Inspect lower ball joint and lower control arm bushings for wear and/or damage. If necessary, replace lower control arm assembly.

Installation

  1. Position lower control arm into crossmember. Install and snug lower control arm pivot bolts. Install torsion bar. See TORSION BAR . Raise lower control arm and engage lower ball joint into knuckle. Install lower ball joint nut, and tighten to specification. See TORQUE SPECIFICATIONS table. Install NEW cotter pin. Raise vehicle.
  2. Install shock absorber. Tighten upper and lower shock absorber nuts to specification. Install wheel assembly, and lower vehicle. Connect stabilizer bar link-to-lower control arm, and tighten nut to specification. Tighten lower control arm pivot bolts to specification. Check and set ride height and wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

TORSION BAR

Removal

  1. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise vehicle on hoist. Remove bolts attaching torsion bar protector-to-frame. See Fig. 3 . Remove bolt from torsion bar nut, noting number of turns required to remove bolt for installation.
  2. Using Torsion Bar Unloader (T95T-5310-A) and Torsion Bar Unloader Adapter (T96T-5310-A1), raise torsion bar adjuster. Remove torsion bar nut, and lower torsion bar adjuster. Slide torsion bar forward, and remove torsion bar adjuster. Remove torsion bar from vehicle.

Installation

  1. Slide torsion bar into lower control arm. Position torsion bar adjuster, and slide torsion bar into torsion bar adjuster. Raise adjuster using torsion bar unloader. Install torsion bar nut. Lubricate tip of torsion bar adjusting bolt. Install torsion bar adjusting bolt.
  2. Tighten torsion bar adjusting bolt same number of turns recorded during removal. Tighten bolt an additional 2 turns. Install torsion bar protector and tighten bolts to specification. See TORQUE SPECIFICATIONS table. Lower vehicle and check ride height. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Fig. 3: Exploded View Of Torsion Bar Adjuster
Courtesy of FORD MOTOR CO.

UPPER CONTROL ARM, BALL JOINT & BUSHINGS

NOTE: Upper ball joints and bushings are an integral part of the upper control arm, and are replaced only as an assembly.

Removal

  1. Place steering wheel and steering system in the centered position. Turn off air suspension switch (if equipped). Switch is located behind right rear quarter panel. Raise vehicle on hoist, and support lower control arm. Remove wheel and tire assembly. Secure knuckle from tilting, and remove upper ball joint-to-knuckle pinch bolt. Separate upper ball joint from knuckle.
  2. For removal of left upper control arm, remove nuts and cam bolts attaching upper control arm-to-frame, and remove upper control arm. See Fig. 4 .
  3. Right upper control arm is a 2 piece design. Remove 2 nuts attaching right upper ball joint assembly-to-adjusting arm, and remove right upper ball joint. Remove adjusting arm cam bolts, and remove adjusting arm.

Installation

  1. To install right upper control arm, position adjusting arm into frame. Install adjusting arm cam bolts, and tighten to specification. See TORQUE SPECIFICATIONS table. Install ball joint assembly onto adjusting arm, and tighten nuts to specification. Position upper ball joint into knuckle. Install upper ball joint pinch bolt, and tighten to specification.
  2. To install left upper control arm, position upper control arm into frame. Install upper control arm cam bolts, and tighten to specification. Connect upper control arm ball joint-to-knuckle. Install upper ball joint pinch bolt, and tighten to specification.
  3. Remove jackstand from under lower control arm. Install wheel and tire assembly. Lower vehicle and check wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Fig. 4: Left & Right Upper Control Arm Assemblies
Courtesy of FORD MOTOR CO.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Caliper Bracket Bolt 56-77 (76-104)
Hub Nut 157-213 (213-289)
Hub Retaining Bolts 74-96 (100-130)
Jounce Bumper Bolt 14-19 (19-26)
Lower Ball Joint Nut 83-113 (112-153)
Lower Control Arm Pivot Bolts 111-148 (150-201)
Lower Shock Absorber Nut
With Automatic Ride Control 18-24 (24-33)
Without Automatic Ride Control 39-53 (53-72)
Right Adjusting Arm Cam Bolts 83-113 (112-153)
Stabilizer Bar Bracket Bolts 65-87 (88-118)
Stabilizer Bar Link-To-Lower Control Arm Nut 10-13 (14-18)
Tie Rod End-To-Knuckle Nut 57-77 (77-104)
Torsion Bar Protector Bolts 25-34 (34-46)
Upper Ball Joint-To-Adjusting Arm Nut 95-128 (129-173)
Upper Ball Joint-To-Knuckle Pinch Bolt 30-40 (41-54)
Upper Control Arm Cam Bolts 83-113 (112-153)
Upper Shock Absorber Nut
With Automatic Ride Control 25-34 (34-46)
Without Automatic Ride Control 15-21 (20-28)
Wheel Lug Nuts (1) 100 (136)
INCH Lbs. (N.m)
ABS Sensor Bolt 62-97 (7-11)
Brake Rotor Shield bolt 89-124 (10-14)
(1) Failure to retighten wheel lug nuts at 500 miles after installation, may result in wheel coming loose and loss of vehicle control.

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