1990 FORD SIERRA Suspension And Steering Workshop Manual

Front suspension
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent by MacPherson struts with coil springs and integral
telescopic shock absorbers. Anti-roll bar fitted to all models
Rear suspension
Type:
Saloon, Hatchback and Estate models . . . . . . . . . . . . . . . . . . . . . . . Independent by semi-trailing arms and coil springs with telescopic
shock absorbers mounted behind coil springs on Saloon and
Hatchback models but concentric with coil springs on Estate models.
Self-levelling rear shock absorbers on certain Estate models. Anti-roll
bar fitted to certain models
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Live beam axle with leaf springs and telescopic shock absorbers
Steering
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack-and-pinion steering gear linked to collapsible steering column by
flexible coupling and universal joint. Power steering available on
certain models
Front wheel alignment*
Production toe-setting:
Saloon, Hatchback and Estate models . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in) ± 1.0 mm (0.04 in) toe-in
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in) ± 2.0 mm (0.08 in) toe-in
Service tolerance before adjustment is required . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in) toe-out to 4.5 mm (0.18 in) toe-in
*Toe-setting figures are quoted for vehicle at kerb weight with 3.0 litres (0.66 gallons) of fuel in tank
Chapter 11
Suspension and steering
Front anti-roll bar - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .7
Front anti-roll bar-to-lower arm compliance bushes - renewal . . . . . .8
Front hub carrier - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .5
Front suspension crossmember - removal and refitting . . . . . . . . . . . .2
Front suspension lower arm - removal, overhaul and refitting . . . . . . .3
Front suspension lower arm inner pivot bush - renewal . . . . . . . . . . .9
Front suspension strut - removal, overhaul and refitting . . . . . . . . . . .4
Front wheel - alignment checking and adjusting . . . . . . . . . . . . . . . .34
Front wheel bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Manual steering gear - removal and refitting . . . . . . . . . . . . . . . . . . .27
Power steering fluid circuit - bleeding . . . . . . . . . . . . . . . . . . . . . . . .31
Power steering fluid hoses - removal and refitting . . . . . . . . . . . . . . .30
Power steering gear - removal and refitting . . . . . . . . . . . . . . . . . . . .28
Power steering pump - removal and refitting . . . . . . . . . . . . . . . . . . .29
Rear anti-roll bar (Saloon, Hatchback and Estate models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear coil spring (Saloon, Hatchback and Estate models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Rear shock absorber - removal and refitting . . . . . . . . . . . . . . . . . . .12
Rear suspension and axle assembly (P100 models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Rear suspension and final drive unit assembly (Saloon, Hatchback and
Estate models) - removal and refitting . . . . . . . . . . . . . . . . . . . . . .10
Rear suspension/final drive unit rear mounting (Saloon Hatchback and
Estate models) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Rear suspension front mounting (Saloon, Hatchback and Estate
models) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Rear suspension leaf spring (P100 models) - removal and refitting . .19
Rear suspension leaf spring bush (P100 models) - renewal . . . . . . .21
Rear suspension leaf spring shackle (P100 models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Rear suspension lower arm (Saloon, Hatchback and Estate models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Rear wheel bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Steering column adjuster - dismantling and reassembly . . . . . . . . . .25
Steering column - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .24
Steering gear rubber gaiter - renewal . . . . . . . . . . . . . . . . . . . . . . . . .32
Steering intermediate shaft and flexible coupling - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Steering wheel - centralising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .22
Tie-rod end - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .33
11•1
Specifications Contents
11
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

Wheels
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressed steel or alloy
Size:
Saloon, Hatchback and Estate models:
Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 x 4.50 in, 13 x 5.50 in, or 14 x 5.50 in
Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 x 5.50 in
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 x 5.50 in
Tyre sizes
Note: Manufacturers often modify tyre sizes and pressure recommendations. The following is intended as a guide only. Refer to your vehicle
handbook or a Ford dealer for the latest recommendations
Saloon and Hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 R 13H, 165 R 135, 165 R 13T, 185/70 R 13H, 185/70 R 135,
185/70 R13T, 195/60 R 14H, 195/60 VR 14 or 195/65 R 14T
Estate models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 R 13H, 175 R 135,175 R 13T, 195/70 R 13H, 195/65 R 14T,
195/60 R 14H or 195/60 VR 14 P100 models 185R 14 8PR
Tyre pressures (cold): lbf/in2
(bar):FrontRear
All Saloon, Hatchback and Estate models with normal load* . . . . . . .26 (1.8)26 (1.8)
All Saloon and Hatchback models with full load . . . . . . . . . . . . . . . .29 (2.0)36 (2.5)
Estate models with full load:
175 R 13H, 175 R 135,175 R 13T, 195/70 R 13H and 195/65 R14T .29 (2.0)48 (2.8)
195/60 R 14H and 195/60 VR 14 . . . . . . . . . . . . . . . . . . . . . . . . . .29 (2.0)36 (2.5)
P100 models with light load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 (1.8)36 (2.5)
P100 models with full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 (3.5)65 (4.5)
*Normal load is defined as up to three passengers (or equivalent). For sustained high speeds add 1.5 lbf/in2
(0.1 bar) for every 6 mph (10 km/h)
over 100 mph (160 km/h)
†A light load is defined as one passenger plus up to 100 kg (220 lb) payload
Torque wrench settingsNmlbf ft
Roadwheel nuts
Wheelnuts:
Saloon, Hatchback and Estate models (steel and alloy wheels) . . . .70 to 10052 to 74
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 to 9063 to 66
Hub nuts:
Saloon, Hatchback and Estate models . . . . . . . . . . . . . . . . . . . . . . .310 to 350229 to 258
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390 to 450288 to 332
Front suspension
Strut upper mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 5230 to 38
Hub carrier-to-strut pinch-bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 to 9257 to 68
Crossmember-to-underbody bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 9052 to 66
Engine mounting-to-crossmember nut:
Saloon, Hatchback and Estate models . . . . . . . . . . . . . . . . . . . . . . .50 to 7037 to 52
P100 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 to 5830 to 43
Anti-roll bar-to-lower arm nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 11052 to 81
Anti-roll bar U-clamp-to-underbody bolts . . . . . . . . . . . . . . . . . . . . . . .55 to 7041 to 52
Lower arm-to-hub carrier balljoint nut . . . . . . . . . . . . . . . . . . . . . . . . . .65 to 8548 to 63
Lower arm inner pivot bolt:
Stage 1 (“clamping”torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Loosen fully, then Stage 2 (“snug” torque) . . . . . . . . . . . . . . . . . . . . .1511
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten through a further 90º
Rear suspension
Saloon, Hatchback and Estate models:
Lower arm-to-crossmember pivot bolts . . . . . . . . . . . . . . . . . . . . . . .80 to 9559 to 70
Front guide plate-to-underbody bolts . . . . . . . . . . . . . . . . . . . . . . . .41 to 5130 to 38
Front guide plate-to-crossmember bolt . . . . . . . . . . . . . . . . . . . . . . .10074
Suspension/final drive unit rear mounting-to-underbody bolts (gold
coloured) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Suspension/final drive unit rear mounting-to-final drive unit rear cover
bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 5030 to 37
Anti-roll bar-to-underbody bracket bolts . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Hub carrier/brake backplate-to-lower arm bolts*:
Type X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 to 6438 to 47
Type Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 to 10059 to 74
Hub nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 290185 to 214
*See Section 15
11•2Suspension and steering

Torque wrench settings (continued)Nmlbf ft
P100 models:
Shock absorber-to-chassis crossmember bolt . . . . . . . . . . . . . . . . . . .60 to 7044 to 52
Leaf spring-to-front bracket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 to 196116 to 145
Leaf spring-to-spring shackle bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 to 196116 to 145
Spring shackle-to-underbody bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 to 8559 to 63
Axle-to-leaf spring U-bolt nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 to 5829 to 43
Manual steering
Steering gear-to-crossmember bolts:
Stage 1 (“clamping” torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Loosen fully, then Stage 2 (“snug” torque) . . . . . . . . . . . . . . . . . . . . .1511
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten through a further 90º
Steering column adjuster through-bolt . . . . . . . . . . . . . . . . . . . . . . . . . .6 to 84 to 6
Tie-rod end locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 to 6842 to 50
Tie-rod end-to-hub carrier nut* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 3215 to 24
Tie-rod-to-steering rack balljoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 to 8853 to 65
Steering wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 to 5533 to 41
Intermediate shaft-to-inner column clamp bolt . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Flexible coupling-to-steering gear clamp nut . . . . . . . . . . . . . . . . . . . . .24 to 2617 to 19
Column mounting pinch-bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 to 5533 to 41
Pinion retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 10052 to 74
Slipper plug† . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 to 53 to 4
*Tighten nut to specified torque and then tighten to next available split pin hole
†Tighten nut to specified torque and then loosen off 60º to 70º
Power steering (where different to manual steering)
Tie-rod to steering rack balljoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 7752 to 57
Flexible coupling-to-steering gear clamp bolt . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Intermediate shaft-to-inner column clamp bolt . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
Pinion locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 to 4727 to 35
Slipper plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 to 42 to 3
Pump rear support bar nut and bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 to 5130 to 38
Pump mounting bracket-to-engine bolts . . . . . . . . . . . . . . . . . . . . . . . .52 to 6438 to 47
Pump pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 127 to 9
Fluid hose-to-pinion housing bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2615 to 19
Fluid pressure hose-to-pump union . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 to 3119 to 23
Fluid return hose-to-pump union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 2012 to 15
The front suspension is of independent
MacPherson strut type incorporating coil
springs and integral telescopic shock
absorbers. The lower end of each strut is
attached to a hub carrier, which carries the
wheel hub and bearings, and the brake
assembly. The lower end of each hub carrier
is attached to a suspension lower arm by a
sealed balljoint. The inboard ends of the lower
arms are attached to the front suspension
crossmember and the lower arms thus
provide lateral location for the strut
assemblies. The upper end of each strut is
bolted to a suspension turret on the vehicle
body. An anti-roll bar is mounted to the rear of
the lower arms, and resists the roll tendency
of the front suspension.
On Saloon, Hatchback and Estate models,
the rear suspension is also of independent
type, incorporating semi-trailing arms, coil
springs and telescopic shock absorbers. The
semi-trailing arms are attached to the
suspension crossmember at their forward
ends, and to the hub carriers at the rear. Thecoil springs are located between the
semi-trailing arms and the vehicle underbody.
On Saloon and Hatchback models, the shock
absorbers are mounted behind the coil
springs, but on Estate models they are
concentric with the coil springs. On some
Estate models the shock absorbers are of the
self-levelling type. The suspension
crossmember is attached to the vehicle
underbody, and to the final drive unit. Certain
models are fitted with an anti-roll bar which is
mounted to the rear of the final drive unit, and
is attached to the semi-trailing arms by
connecting links.
The rear suspension on P100 models
consists of a beam axle located and
supported by a leaf spring on each side, and
utilizing telescopic shock absorbers to control
vertical movement. The hub and brake
assemblies are attached directly to each side
of the axle. The axle is bolted to the leaf
springs using U-bolts and counterplates, and
the shock absorbers are attached to the
counterplates at their lower ends and the
vehicle underbody at their upper ends.
The steering gear is of the conventional
rack and pinion type located ahead of the
front wheels. Movement of the steering wheelis transmitted to the steering gear by means
of a shaft containing a universal joint. The
front hub carriers are connected to the
steering gear by tie-rods, each having an inner
and outer balljoint. Power-assisted steering is
available on some models, assistance being
provided hydraulically by an engine-driven
pump.
Removal
1Remove the steering gear.
2Support the engine with a jack and
interposed block of wood under the sump.
3Unscrew and remove the engine mounting
nuts from the top of the mountings in the
engine bay (see illustration).
4Raise the engine slightly with the jack, and
ensure that it is safely supported, and just
clear of the engine mounting rubbers.
5Unscrew and remove the nuts, washers and
pivot bolts securing the lower arms to the
crossmember, and pull the arms from the
crossmember. Note that the pivot bolt heads
face to the rear of the vehicle.
2Front suspension crossmember
-removalandrefitting
1General information
Suspension and steering 11•3
11

6Where applicable, remove the brake pipes
from the clips on the crossmember, taking
care not to strain them, and detach any cables
or electrical leads which may be secured with
clips or cable-ties, noting their positions.
7Support the crossmember with a jack, then
unscrew and remove the four mounting bolts
(see illustration).
8Lower the crossmember and withdraw it
from under the vehicle.
9If desired, the engine mountings can now
be unbolted from the crossmember.
Refitting
10Refitting is a reversal of removal, but bear
in mind the following points.
11Do not tighten the lower arm pivot bolts
until the weight of the vehicle is resting on its
wheels. This is to prevent “wind up” of the
rubber bushes which will occur when the
vehicle is lowered if the bolts have been
tightened with no load on the suspension. The
following procedure must be used when
tightening the pivot bolts. Tighten the bolt to
the specified “clamping” torque, then loosen
the bolt fully. Re-tighten to the specified
“snug” torque and then further tighten the bolt
through the specified angle.
12Refit any cables or electrical leads in their
original positions, where applicable.
13When lowering the engine onto its
mountings, ensure that the locating pegs on
the mountings engage with the holes in the
mounting brackets.
Note: A balljoint separator tool will be
required for this operation.
Removal
1To improve access, raise the front of the
vehicle on ramps. Do not jack the vehicle up
at this stage. Apply the handbrake.
2Unscrew and remove the nut, washer and
pivot bolt securing the relevant lower arm to
the crossmember (see illustration).
3Remove the anti-roll bar-to-lower arm
securing nut and recover the dished washer
and plastic cover (where applicable) (see
illustration).4Ensure that the handbrake is applied, jack
up the front of the vehicle and support on axle
stands (see “Jacking and Vehicle Support”).
5Remove the split pin and unscrew the
castellated nut from the lower arm balljoint.
Using a balljoint separator tool, disconnect
the lower arm from the hub carrier. The lower
arm can now be withdrawn from the vehicle.
Recover the remaining dished washer and
plastic cover (where applicable) from the end
of the anti-roll bar.
Overhaul
6If the lower arm has been removed due to a
worn balljoint, the complete arm must be
renewed.
7The anti-roll bar compliance bushes can be
renewed as described in Section 8, but note
that the bushes on both sides of the vehicle
must be renewed at the same time. The lower
arm inner pivot bush can be renewed as
described in Section 9.
Refitting
8To refit the lower arm, proceed as follows.
9Fit the shallow dished washer (colour
coded black or green) and the plastic cover
(where applicable) to the end of the anti-roll
bar, then refit the lower arm to the anti-roll
bar. Fit the remaining plastic cover (where
applicable) and the deep dished washer
(colour coded yellow or black) and refit the
securing nut. Do not tighten the nut at this
stage. Note that the convex faces of the
dished washers must face the lower arm.10Reconnect the balljoint to the hub carrier,
refit the castellated nut and tighten to the
specified torque. Fit a new split pin.
11Locate the end of the lower arm in the
crossmember and refit the pivot bolt, washer
and nut. If necessary, push the outer rim of
the roadwheel in order to line up the holes in
the lower arm bush and the crossmember.
Note that the pivot bolt head should face to
the rear of the vehicle. Do not tighten the bolt
at this stage.
12Lower the vehicle so that its weight is
resting on the roadwheels, and bounce the
vehicle to settle the suspension.
13Tighten the lower arm pivot bolt, following
the procedure given in Section 2.
14Tighten the anti-roll bar-to-lower arm
securing nut to the specified torque.
15Lower the vehicle from the ramps, if not
already done.
Note: A spring compressor tool will be
required if the strut is to be dismantled.
Removal
1Loosen the relevant front roadwheel nuts,
apply the handbrake, jack up the front of the
vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
2Remove the roadwheel. On P100 models
mark the position of the roadwheel in relation
to one of the wheel studs before removal.
3Remove the front brake caliper but do not
disconnect the hydraulic hose. Support the
caliper on an axle stand to avoid straining the
hose.
4Where applicable, unbolt the ABS wheel
sensor from the hub carrier and detach the
wire from the clip on the strut. Unplug the
connector and place the sensor to one side.
5Unscrew and remove the pinch-bolt which
secures the hub carrier to the strut. Using a
suitable lever, such as a cold chisel, lever the
hub carrier clamp legs and wedge them apart.
6Lever the suspension lower arm
downwards to separate the hub carrier from
the bottom of the strut.
4Front suspension strut -
removal, overhaul and refitting
3Front suspension lower arm -
removal,overhaul and refitting
11•4Suspension and steering
2.3 Engine mounting nut (arrowed)
3.3 Front anti-roll bar-to-lower arm
securing nut (arrowed)3.2 Front suspension lower arm-to-
crossmember pivot bolt and nut
2.7 Front suspension crossmember
mounting bolts (arrowed)

7Working in the engine compartment,
unscrew the strut upper mounting nut, at the
same time supporting the strut from below.
Use a 6 mm Allen key inserted in the end of
the strut piston rod to prevent the rod from
turning as the upper mounting nut is
unscrewed (see illustration). On some
models, the upper mounting nut may be fitted
with a plastic cover. Note the upper mounting
cup under the nut.
8Withdraw the strut from under the wing of
the vehicle.
Overhaul
9To dismantle the strut, proceed as follows.
10Using spring compressors, compress the
coil spring. Do not attempt to compress the
spring without using purpose-made spring
compressors, as the spring is under
considerable tension, and personal injury may
occur if it is suddenly released (see
illustration).
11Hold the piston rod as described in
paragraph 7, unscrew the nut from the pistonrod and remove the lower cup, bearing, spring
seat, gaiter, coil spring and bump stop (see
illustration).
12Working in the engine compartment,
remove the upper cup and nylon spacer, and
if required prise out the rubber insulator.
13Clean all the components and examine
them for wear and damage. Check the action
of the shock absorber by mounting it vertically
in a vice and operating the piston rod several
times through its full stroke. If any uneven
resistance is evident, the shock absorber
must be renewed. Renew any worn or
damaged components as applicable.
Refitting
14Reassembly and refitting is a reversal of
dismantling and removal, bearing in mind the
following points.
15When reassembling, ensure that the gaiter
is fitted over the bump stop, and that the ends
of the coil spring are correctly located on the
spring seats. Also ensure that the bearing is
correctly located on the upper spring seat.
16Fit the nylon spacer over the piston rod
before fitting the strut to the top mounting.
17Tighten all fixings to the specified torque.
18On P100 models align the previously
made marks on the roadwheel and wheel
stud.Note: A balljoint separator tool will be
required for this operation.
Removal
1Loosen the relevant front roadwheel nuts,
apply the handbrake, jack up the front of the
vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
2Remove the roadwheel. On P100 models
mark the position of the roadwheel in relation
to one of the wheel studs before removal.
3Remove the front brake caliper but do not
disconnect the hydraulic hose. Support the
caliper on an axle stand, or suspend it with wire
from the coil spring to avoid straining the hose.
4Mark the position of the brake disc in
relation to the drive flange, and on Saloon,
Hatchback and Estate models, remove the
retaining screw or spire washer(s), as
applicable, and remove the disc. On P100
models, unscrew the five retaining nuts and
remove the wheel adapter plate and disc.
5Where applicable, unbolt the ABS wheel
sensor from the hub carrier and unplug the
wiring connector. Place the sensor to one side.
6Remove the split pin and unscrew the
castellated nut securing the tie-rod end to the
hub carrier. Using a balljoint separator tool,
disconnect the tie-rod end from the hub carrier.
7Repeat the procedure given in the previous
paragraph for the lower arm-to-hub carrier
balljoint.
8Unscrew and remove the pinch-bolt which
secures the hub carrier to the strut (see
illustration). Using a suitable lever, such as a
cold chisel, lever the hub carrier clamp legs
and wedge them apart. Withdraw the hub
carrier from the strut.
Refitting
9Refitting is a reversal of removal, but use
new split pins on the castellated nuts, and
align the previously made marks on the brake
disc and hub. Tighten all fixings to the
specified torque.
10On P100 models align the previously
made marks on the roadwheel and wheel
stud.
5Front hub carrier -removaland
refitting
Suspension and steering 11•5
11
5.8 Unscrewing the hub carrier-to-strut
pinch-bolt
4.11 Cross-section of the front strut upper mounting
A Bearing
B Nylon spacer
C Upper cupD Rubber insulator
E Lower cup
F Spring seatG Bump stop
H Gaiter
4.10 Suspension strut fitted with spring
compressors
4.7 Hold the strut piston rod with a 6 mm
Allen key when unscrewing the upper
mounting nut

1Remove the hub carrier.
2Reverse the roadwheel nuts and screw
them fully onto the studs to protect the
threads, then mount the hub carrier assembly
in a vice as shown (see illustration).
3Prise the dust cap from the rear of the hub
carrier, and unscrew the hub nut with a
suitable socket. Note that on all models
manufactured before late December 1982,
both left and right-hand nuts have a
right-hand thread, but as from this date,
left-hand thread assemblies were
progressively fitted to the right-hand hub
carrier. The modified right-hand hub can be
identified by the letter “R” stamped on its
outer face, or by the colour of the hub nut
nylon insert, blue indicates a normal
right-hand thread, and yellow indicates a
left-hand thread.
4Remove the splined washer, and tap the
hub carrier from the drive flange. Recover the
bearing inner race and rollers from the inner
end of the hub carrier (see illustration).
5Prise the oil seal from the outer end of the
hub carrier and remove the remaining bearing
inner race and rollers.
6Using a soft metal drift, drive the bearing
outer races from the hub carrier, taking care
not to damage the inner surface of the carrier.
7Clean the hub carrier and drive flange with
paraffin, wipe dry and examine for damage
and wear. Note that the components are
machined to very close tolerances, and the
bearings are supplied in matched pairs,
therefore scrupulous cleanliness must be
observed.
8Using a metal tube of suitable diameter,
drive the new bearing outer races fully into the
hub carrier. Ensure that the races are seated
correctly.
9Pack the inner bearing races and rollers
with high-melting-point lithium-based grease,
and locate the outer bearing assembly in the
hub camber.
10Fill the cavities between the sealing lips of
the oil seal with grease, then drive it fully into
the hub carrier using a block of wood or a
metal tube of suitable diameter. Note that onearly models the oil seal has a rubber casing,
and this early type of seal should be replaced
with the later type which has a metal casing.
The oil seal should be renewed regardless of
type, and a new seal of the correct type is
normally supplied with the new wheel bearings.
11With the drive flange mounted in a vice, as
during dismantling, tap the hub carrier onto
the drive flange.
12Fit the inner bearing assembly, tapping it
into place with a metal tube of suitable
diameter if necessary, and fit the splined
washer. Note that the bearings are self-setting
on assembly, and no subsequent adjustment
is required.
13Refit the hub nut and tighten it to the
specified torque.
14Tap the dust cap into position in the hub
carrier.
15Remove the assembly from the vice,
remove the roadwheel nuts, and refit the hub
carrier.
Removal
1To improve access, raise the front of the
vehicle on ramps. Do not jack the vehicle up
at this stage. Apply the handbrake.2Where applicable bend back the locktabs,
then unscrew the two bolts securing each of
the two anti-roll bar U-clamps to the vehicle
underbody (see illustrations).
3Ensure that the handbrake is applied, jack
up the front of the vehicle and support on axle
stands (see “Jacking and Vehicle Support”).
4Remove the anti-roll bar-to-lower arm
securing nuts and recover the dished washers
and plastic covers, where applicable (see
illustration).
5Unscrew and remove the nut, washer and
pivot bolt securing one of the lower arms to
the crossmember, and pull the end of the
lower arm from the crossmember.
6Pull the anti-roll bar from the bush in the
“free” lower arm then slide the anti-roll bar
from the remaining fixed lower arm. Recover
the remaining dished washers and plastic
covers (where applicable) from the ends of the
anti-roll bar.
7If necessary, the anti-roll bar compliance
bushes can be renewed as described in
Section 8, and the anti-roll bar U-clamp
bushes can be renewed by sliding them off
the ends of the bar. Note that although the
U-clamp bushes are of a split design, they
should not be levered open to aid fitting, and
the new bushes must be slid on from the ends
of the anti-roll bar. The bushes should always
be renewed in pairs.
7Front anti-roll bar - removal
and refitting
6Front wheel bearings - renewal
11•6Suspension and steering
6.2 Front hub carrier mounted in vice to
unscrew hub nut
7.2b . . . unscrew the bolts and remove the
anti-roll bar U-clamps7.2a Bend back the locktabs (arrowed) . . .
6.4 Front hub components
A Dust cap
B Hub nutC Splined washer
D Taper roller bearingE Bearing outer race
F Hub carrierG Oil seal
H Drive flange

Refitting
8To refit the anti-roll bar, proceed as follows.
9Fit the shallow dished washers (colour
coded black or green) and the plastic covers
(where applicable) to the ends of the anti-roll
bar, then push the anti-roll bar through the
bushes in the lower arms. Fit the remaining
plastic covers (where applicable) and the
deep dished washers (colour coded yellow or
black) and loosely fit the securing nuts. Note
that the convex faces of the dished washers
must face the lower arm. Do not tighten the
nuts fully at this stage.
10Locate the “free” lower arm inner pivot
bush in the crossmember, and refit the pivot
bolt, washer and nut. If necessary, push the
outer rim of the roadwheel in order to line up
the holes in the lower arm bush and the
crossmember. Note that the pivot bolt head
should face to the rear of the vehicle. Do not
tighten the bolt at this stage.
11Lower the vehicle so that its weight is
resting on the roadwheels.
12Refit the anti-roll bar U-clamps to the
vehicle underbody. Note that various different
types of clamping components have been
used during production, and if any of the
components are to be renewed, it is important
to retain the old components for identification
when ordering new parts. The same type of
clamp assembly must be used on both sides
of the vehicle. Tighten the bolts evenly on
each clamp to the specified torque. Where
applicable, secure the bolts with the locktabs.
13Bounce the vehicle to settle the
suspension, then tighten the lower arm pivot
bolt, following the procedure given in Section 2.
14Tighten the anti-roll bar-to-lower arm
securing nuts to the specified torque.
15Lower the vehicle from the ramps, if not
already done.Note: The compliance bushes must be
renewed in vehicle sets, therefore the bushes
on both sides of the vehicle must be renewed
at the same time. If plastic covers were not
originally fitted between the dished washers
and the bushes, suitable covers should be
obtained for fitting during reassembly.
1Remove the anti-roll bar.
2Using a thin-bladed chisel or screwdriver,
carefully prise out the compliance bushes
from the lower arms.
3Tap the new bushes into place using a
suitable socket or tube drift (see illustration).
4Some vehicles may have small rubber
spacer washers fitted to the ends of the
anti-roll bar, and these should be discarded
on reassembly.
5Refit the anti-roll bar.
1To improve access, raise the front of the
vehicle on ramps. Apply the handbrake.
2Unscrew and remove the nut, washer and
pivot bolt securing the relevant lower arm to
the crossmember.
3Remove the anti-roll bar-to-lower arm
securing nut and recover the dished washer
and plastic cover (where applicable).
4Ensure that the handbrake is applied, jack
up the front of the vehicle and support on axle
stands (see “Jacking and Vehicle Support”).
5Pull the inner end of the lower arm from the
crossmember.
6The pivot bush can now be removed from
the lower arm using a long bolt with nut,
washers and a suitable metal tube.
7Lubricate the new bush with soapy water,
and fit with a single continuous action to avoiddeformation of the bush, again using the bolt,
nut, washers and tube.
8Locate the end of the lower arm in the
crossmember, and refit the pivot bolt, washer
and nut. If necessary, push the outer rim of
the roadwheel in order to line up the holes in
the lower arm bush and the crossmember.
Note that the pivot bolt head should face to
the rear of the vehicle. Do not tighten the bolt
at this stage.
9Refit the plastic cover, dished washer
(where applicable), and nut to the end of the
anti-roll bar. Do not tighten the nut at this
stage.
10Lower the vehicle so that its weight is
resting on the roadwheels, and bounce the
vehicle to settle the suspension.
11Tighten the lower arm pivot bolt, following
the procedure given in Section 2.
12Tighten the anti-roll bar-to-lower arm
securing nut to the specified torque.
13Lower the vehicle from the ramps, if not
already done.
Note: From May 1986, revised final drive unit
rear mounting bolts have been used in
production. Whenever the earlier type of bolts
are removed, they should be discarded and
the later type fitted. The earlier bolts are
coloured blue, and the later type bolts are
coloured gold.
Removal
1Jack up the vehicle and support on axle
stands (see “Jacking and Vehicle Support”). It
is only strictly necessary to jack up the rear of
the vehicle, but this provides only limited
access. Note that the axle stands should be
positioned under the side members.
2Remove the rear section of the exhaust
system - ie. from the joint.
3Remove the propeller shaft.
4Disconnect the handbrake equaliser from
the operating rod by removing the circlip and
10Rear suspension and final
drive unit assembly (Saloon,
Hatchback and Estate
models) - removal and refitting
9Front suspension lower arm
inner pivot bush - renewal
8Front anti-roll bar-to-lower arm
compliance bushes - renewal
Suspension and steering 11•7
11
8.3 Tapping a front anti-roll bar-to-lower
arm compliance bush into position
7.4 Front anti-roll bar-to-lower arm mounting
A Rear (black or green) shallow dished
washer
B Plastic cover (where applicable)
C Compliance bushes
D Plastic cover (where applicable)
E Front (yellow or black) deep dished
washer

pivot pin. Take care not to lose the
components (see illustration).
5Remove the brake cable sheaths from their
brackets on the vehicle underbody.
6Unscrew the brake pipes from the brake
hoses at the brackets on the vehicle
underbody. Plug the ends of the pipes and
hoses to prevent leakage and dirt ingress,
then detach the hoses from the brackets by
removing the U-shaped retaining clips (see
illustration).
7Where applicable, disconnect the ABS
sensors, and detach the leads from the clips
on the lower arms.
8Place suitable blocks beneath the rear
wheels, then lower the vehicle so that the rear
coil springs are lightly loaded. Reposition the
axle stands under the side members.
9Support the final drive unit with a jack,
using an interposed block of wood to spread
the load.
10Where applicable, unscrew and remove
the two anti-roll bar mountings from the
underbody.
11Unscrew and remove the three bolts
securing each of the front guide plates to the
underbody and the suspension crossmember
(see illustration). Where applicable, bend
back the lockwasher tabs on the larger bolts.
12Unscrew and remove the four bolts
securing the final drive unit rear mounting to
the underbody. Note the location and number
of any shims which may be fitted (see
illustration).
13Working inside the rear of the vehicle,
disconnect the shock absorber upper
mountings. On Saloon and Hatchbackmodels, access is gained by removing the
trim covers behind the side cushions. Each
cover is secured by two self-tapping screws,
and the shock absorber is secured by a bolt
and nut. On Estate models, fold down the rear
seat backrest, fold back the floor covering
and remove the front section of the luggage
compartment floor, which is secured with 12
self-tapping screws. Remove the nut and
washer from the shock absorber.
14Using a jack and a wooden beam
positioned beneath the longitudinal
underbody side members, raise the rear of the
vehicle until the rear suspension and final
drive unit assembly can be withdrawn from
under the vehicle.
15If desired, the assembly can be
dismantled with reference to the relevant
Sections of this Chapter and Chapter 9.
Refitting
16Refitting is a reversal of removal, bearing
in mind the following points.
17Where applicable, secure the larger front
guide plate bolts by bending up the
lockwasher tabs.
18Ensure that the coil springs are located
correctly on their seats on the vehicle
underbody.
19When refitting the final drive rear mounting
to the underbody, refit any shims in their original
noted positions, and fit the bolts with reference
to the note at the beginning of this Section.
20Tighten all fixings to the specified torque.
21On completion, bleed the brakes and
adjust the handbrake. With the vehicle level,
check the final drive unit oil level.
Models with rear drum brakes
Removal
1Chock the front wheels, jack up the rear of
the vehicle and support on axle stands placed
under the side members.
2Remove the relevant driveshaft.
3Remove the handbrake cable from the clip
on the lower arm.
4Unscrew the brake pipe from the brake
hose at the bracket on the lower arm. Plug the
ends of the pipe and hose to prevent leakage
and dirt ingress, then detach the hose from
the bracket by removing the U-shaped
retaining clip (see illustration).
5Unscrew the brake pipe from the wheel
cylinder on the brake backplate and plug the
end of the pipe and the cylinder to prevent
leakage and dirt ingress.
6Unscrew the bolts securing the brake
backplate to the lower arm and tie the
backplate to one side.
7Where applicable, prise the anti-roll bar
connecting strap from the lower arm.
8Support the lower arm on a jack, and raise
it slightly to place the coil spring under load.
9Remove the shock absorber.
10Unscrew and remove the three bolts
securing the front guide plate to the
underbody and the suspension crossmember
(see illustration). Where applicable, bend
back the lockwasher tab(s) on the larger bolt.
11Lower the lower arm, and remove the coil
spring and rubber cup.
12Note the orientation of the two lower
arm-to-crossmember pivot bolts and nuts,
then unscrew and remove them and withdraw
the lower arm from under the vehicle (see
illustration).
13If the lower arm is to be renewed, unclip
the brake pipe, and refit to the new arm.
14If required, the pivot bushes may be
renewed using a long bolt, nut, washers and a
suitable metal tube. Lubricate the new bushes
with soapy water before fitting.
11Rear suspension lower arm
(Saloon, Hatchback and
Estate models) -removaland
refitting
11•8Suspension and steering
10.4 Handbrake equaliser-to-operating rod
circlip and pivot pin (arrowed)10.11 Rear suspension front guide plate -
lockwasher arrowed
11.4 Brake pipe bracket on lower arm. U-
shaped retaining clip arrowed10.12 Final drive unit-to-underbody rear
mounting
10.6 Rear underbody brake pipe bracket -
U-shaped hose retaining clip arrowed