Ford Fusion: Front Suspension / Front Wheel Bearing and Wheel Hub. Removal and Installation

Special Tool(s) / General Equipment

	204-161 (T97P-1175-A) Installer, Halfshaft TKIT-1997-LM2 TKIT-1997-F/FM2 TKIT-1997-FLM2
	205-D070 (D93P-1175-B) Remover, Front Wheel Hub

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 and discard the halfshaft nut.
   

1. Remove the brake hose bracket bolt.
   

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. NOTICE: Do not bend the inner joint more than 18 degrees and the outer joint more than 45 degrees. Damage to the shaft will occur.

   Press the halfshaft from the hub.
   Use Special Service Tool: 205-D070 (D93P-1175-B)  Remover, Front Wheel Hub.

1. Remove the brake disc.
   Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
   

1. Remove and discard the 4 wheel bearing and wheel hub bolts and remove the wheel bearing and wheel hub.
   

Installation

1. NOTE: Tighten bolts in a criss-cross pattern.

   Position the wheel bearing and wheel hub and install the 4 new wheel bearing and wheel hub bolts.
   Torque:
      1:   98 lb.ft (133 Nm)
      2:   98 lb.ft (133 Nm)
      3:   98 lb.ft (133 Nm)
      4:   98 lb.ft (133 Nm)

1. Install the brake disc.
   Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
   

1. Pull the halfshaft into the hub.
   Use Special Service Tool: 204-161 (T97P-1175-A)  Installer, Halfshaft.

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. Install the brake hose bracket bolt.
   Torque: 159 lb.in (18 Nm)

1. NOTICE: Do not tighten the front 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.

   NOTICE: 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 components may occur.

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

   With the help of an assistant holding the brake pedal, install the new halfshaft nut.
   Torque: 148 lb.ft (200 Nm)

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

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