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    2006 Ford Five Hundred

    Upper Control Arms

    Print

    Removal & Installation




    WARNING
    Always use new bolts and nuts on the suspension components.

    1. Measure the distance between the top of the wheel and the bottom of the wheel opening. This is the trim height.
    2.  
    3. Remove the rear wheels.
    4.  
    5. With a wax pencil, mark the relational alignment of the rear subframe to the underbody at the mounting locations.
    6.  
    7. Remove the 2 catalytic converter nuts.
    8.  
    9. Disconnect the muffler and tailpipe assembly from the isolators.
    10.  
    11. Remove the catalytic converter, muffler and tailpipe assembly.
      NOTE
      Index the driveshaft before disconnecting from the rear drive axle. It is necessary to install new driveshaft bolts during installation. Reuse of the driveshaft bolts is not recommended.

    12.  
    13. Remove the 6 driveshaft bolts.
    14.  
    15. Loosen the trailing link-to-subframe bolts.
    16.  
    17. Support and raise the knuckle with a suitable jack.
    18.  
    19. Raise the knuckle until the tilt angle of the trailing link is horizontal to the body.
    20.  
    21. Remove the trailing link-to-knuckle bolts.
    22.  
    23. Position the trailing link aside.
    24.  
    25. Remove the rear shock-to-lower control arm bolts.
    26.  
    27. Disconnect the rear wheel speed sensor electrical connectors.
    28.  
    29. On AWD vehicles, remove the rear axle assembly.
    30.  
    31. Release the park brake cable tension.
    32.  
    33. Disconnect the intermediate park brake cable from the front park brake cable.
    34.  
    35. Disconnect the intermediate cable from the body bracket.
    36.  
    37. Remove the park brake cable-to-body bracket.
    38.  
    39. Disconnect the rear park brake cables at the equalizer.
    40.  
    41. Disconnect the rear park brake cables from the park brake levers at the rear calipers.
    42.  
    43. Disconnect the rear park brake cables from the park brake brackets.
    44.  
    45. Remove the rear brake caliper pins.
    46.  
    47. Remove the rear calipers and the rear caliper brackets and attach aside to the body with mechanic's wire. It is not necessary to disconnect the hydraulic brake lines.
    48.  
    49. On AWD vehicles remove the 4 rear subframe bracket bolts.
      CAUTION
      When positioning the lifting table, be sure to support the rear subframe on the subframe rails. Do not lift on the rear differential or rear control arms, damage may occur.

    50.  
    51. Position a lifting table.
    52.  
    53. Remove the 4 rear subframe bolts.
    54.  
    55. On AWD vehicles remove the 2 rear subframe brackets.
    56.  
    57. Remove the rear subframe assembly.
    58.  
    59. Place a suitable support under the wheel knuckle.
    60.  
    61. Remove and discard the stabilizer bar link upper nut and separate the link from the upper arm.
    62.  
    63. Remove and discard the upper arm-to-subframe bolts.
    64.  
    65. On FWD vehicles, remove and discard the upper arm-to-knuckle bolt and separate the upper arm from the wheel knuckle.
    66.  
    67. On AWD vehicles , remove and discard the wheel knuckle ball joint nut.
      NOTE
      It may be necessary to tap the knuckle to disconnect the upper arm.

    68.  
    69. Using the tools shown, separate the wheel knuckle from the upper arm.

      Click image to see an enlarged view

      Fig. Using the tools shown, separate the wheel knuckle from the upper arm

    70.  
    71. Using the tool shown, separate the upper arm and front bushing from the rear bushing. Once the upper arm and front bushing are separated from the rear bushing, use the special tool to pull the arm and bushing out of the bushing bore.

      Click image to see an enlarged view

      Fig. Using the tools shown, separate the upper arm and front bushing from the rear bushing

    72.  
    73. Using the tool shown, separate the upper arm front bushing from the upper arm.

      Click image to see an enlarged view

      Fig. Using the tools shown, separate the upper arm front bushing from the upper arm

    74.  
    75. Remove the upper arm from the subframe.
    76.  
    77. Using the tools shown, remove the upper arm rear bushing from the subframe.

      Click image to see an enlarged view

      Fig. Using the tools shown, remove the upper arm rear bushing from the subframe

    78.  

    To install:

    1. Use only liquid soap, if necessary, to lubricate the bushing. Do not use any other types of lubricants or damage to the bore or bushing may occur.
      NOTE
      Make sure the bushing bore on the subframe is clean and free of foreign materials. To aid in installation, a small amount of liquid soap may be applied to the outer diameter of the bushing.

    2.  
    3. Position the upper arm rear bushing into the bushing bore from the rear of the subframe and, using the special tools, install the bushing into the subframe.
    4.  
    5. Use the opposite side bushing as a guide to install the bushing to the correct depth in the subframe.
      CAUTION
      Do not fully tighten the nut at this time or incorrect clamp load or bushing damage may occur.

    6.  
    7. On AWD vehicles, position the upper arm into the forward bushing bore and into the rear bushing, then position the upper arm onto the wheel knuckle ball joint stud and install the ball joint nut. Tighten the nut until snug.
    8.  
    9. On FWD vehicles, position the upper arm into the forward bushing bore and into the rear bushing, then position the upper arm onto the wheel knuckle and install the upper arm-to-knuckle bolt. Tighten the bolt until snug.
    10.  
    11. Loosely install the upper arm-to-subframe rear bolt.
      NOTE
      The upper arm height setting is measured from the top of the subframe to the bottom of the upper arm. While an assistant holds the upper arm, adjust it to the correct height. On FWD models the measurement is 5.7 inches (147 mm). On AWD models the measurement is 5.4 inches (138 mm).

    12.  
    13. Tighten the upper arm-to-subframe rear bolt to 81 ft. lbs. (110 Nm).
    14.  
    15. While an assistant holds the upper arm in the center of the bushing bore, use the tools to install the upper arm front bushing into the subframe.
    16.  
    17. Install the forward upper arm bushing to the correct depth in the subframe. Use the opposite side bushing as a guide.

      Click image to see an enlarged view

      Fig. Install the forward upper arm bushing to the correct depth in the subframe. Use the opposite side bushing as a guide

    18.  
    19. Install the upper arm-to-subframe front bolt and tighten to 81 ft. lbs. (110 Nm).
    20.  
    21. On AWD vehicles, tighten the wheel knuckle ball joint nut to 81 ft. lbs. (110 Nm).
    22.  
    23. On FWD vehicles, tighten upper arm-to-wheel knuckle bolt to 81 ft. lbs. (110 Nm).
    24.  
    25. Position the stabilizer bar link and install the stabilizer bar link upper nut. Tighten to 28 ft. lbs. (38 Nm).
      NOTE
      Install new suspension fasteners during assembly.


      NOTE
      Before tightening the upper control, toe link, trailing arm and lower control arm bolts, use a jackstand to raise the rear suspension to ride height.

    26.  
    27. Install the subframe in the reverse order of removal keeping in mind the following:
      1. Align the subframe to the body following the alignment specification.

        Click image to see an enlarged view

        Fig. Subframe to body alignment

      2.  
      3. Install the 4 rear subframe bolts and tighten to 85 ft. lbs. (115 Nm).
      4.  
      5. On AWD vehicles install the 4 rear subframe bracket bolts and tighten to 41 ft. lbs. (55 Nm).
      6.  
      7. Install the rear shock-to-lower control arm bolts. On AWD models tighten to 105 ft. lbs. (142 Nm) or 81 ft. lbs. 110 Nm) on FWD models.
      8.  
      9. Install the trailing link-to-knuckle bolts and tighten to 77 ft. lbs. (105 Nm).
      10.  
      11. Install the trailing link-to-subframe bolts and tighten to 77 ft. lbs. (105 Nm).
      12.  
      13. Install the 6 driveshaft bolts and tighten to 18 ft. lbs. (25 Nm)
      14.  
      15. Install the 2 catalytic converter nuts and tighten to 30 ft. lbs. (40 Nm).
      16.  

    28.  

     
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