Ford Orion. Manual - part 53

Dismantling

1 With the strut removed from the vehicle,
clean away all external dirt, then secure it in a
vice.
2 Fit the spring compressor tool (ensuring
that it is fully engaged) and compress the coil
spring until all tension is relieved from the
upper mounting.
3 Unscrew and remove the upper mounting
through-bolt and nut (see illustration).
4 Withdraw the upper mounting cup and the
spring seat.
5 The suspension strut and coil spring can
now be separated. If the coil spring or strut is
to be renewed, the original coil spring must be
released from the compressor. If it is to be re-
used, the coil spring can be left in
compression.

Examination

6 With the strut assembly now completely
dismantled, examine all components for wear,
damage or deformation, and check the
bearing for smoothness of operation. Renew
any of the components as necessary.
7 Examine the strut for signs of fluid leakage.
Check the strut piston for signs of pitting
along its entire length, and check the strut
body for signs of damage or elongation of the
mounting bolt holes. Test the operation of the
strut, holding it in an upright position, by
moving the piston through a full stroke, and
then through short strokes of 50 to 100 mm.
In both cases, the resistance felt should be
smooth and continuous. If the resistance is
jerky, or uneven, or if there is any visible sign
of wear or damage to the strut, renewal is
necessary.

Reassembly

8 Reassembly is a reversal of the dismantling
procedure but note the following points:
a)

When the spring is located over the
suspension strut, the spring seat, cup and
through-bolt fitted, tighten the retaining
bolt to the specified torque setting.

b)

When reassembled, check that the upper
and lower spring tails are correctly
engaged with their spring seats before
removing the spring compressor.

14 Rear axle (Hatchback,

Saloon and Estate models) -
removal and refitting

3

Removal

1 Chock the front wheels, then raise and
support the vehicle at the rear on axle stands.
Unbolt and remove the roadwheels.
2 Refer to Chapter 9 for details, and
disconnect the handbrake cable equaliser
from the primary cable. Detach the non-
adjustable cable circlip and the cable from the
underbody fastenings.
3 Disconnect the rear brake flexible hydraulic
brake hoses from their rigid line connections.
Clamp the hoses before disconnecting them,
to minimise the fluid loss and air entry into the
hydraulic system (see Chapter 9 for details).
4 On ABS-equipped models, undo the
retaining nut and detach the ABS load-
apportioning valve from the axle beam. Do not
remove the load-apportioning valve (see
Chapter 9).

Hatchback and Saloon models

5 Locate suitable jacks or axle stands under
the axle beam to support its weight (not to lift
it), then unscrew the mounting bracket bolts
each side (see illustration).
6 Unscrew and remove the strut-to-axle
mounting bolt each side.
7 Check that all associated fittings are clear,
then lower the axle and remove it from under
the vehicle.
8 If the twist beam axle has been damaged, it
must be renewed. Refer to Chapter 9 for
details on removing the rear brakes from the
axle. To remove the front mounting/pivot
brackets from the axle, unscrew the pivot bolt.

Estate models

9 Position a jack under the coil spring area of
the suspension arm (not under the axle beam)
each side, and raise them so that they just
take the weight of the trailing arms.
10 Unscrew and remove the shock absorber
retaining bolt from the lower attachment point
to the rear axle each side.
11 Slowly lower the jack under the
suspension arm each side, and allow the

trailing arms to drop and the compression in
the coil springs to be released.
12 With the coil springs fully relaxed,
withdraw them from their mounting locations
between the body and the suspension arms.
As they are removed, mark each for its
direction of fitting and side so that they are
refitted to their original locations.
13 Reposition the jacks, or place axle stands
under the axle beam to support its weight (not
to lift it), then unscrew the mounting bracket
bolts each side.
14 Check that all associated fittings are clear,
then lower the axle and remove it from under
the vehicle.
15 If the twist beam axle has been damaged,
it must be renewed. Refer to Chapter 9 for
details on removing the rear brakes from the
axle. To remove the front mounting/pivot
brackets from the axle, unscrew the pivot 
bolt.

Refitting

All models

16 Refitting is a reversal of the removal
procedure, but note the following:
a)

Reconnect the axle at the front floor
mountings first, and tighten the retaining
bolts to the specified torque setting.

b)

On Hatchback and Saloon models,
reconnect the axle to the suspension
struts, but do not fully retighten the
securing bolts until after the vehicle is
lowered to the ground and is standing on
its wheels.

c)

On Estate models, when relocating the
coil springs between the body and the
suspension arm each side, ensure that
they are correctly orientated, and that
their tails abut against the stops. When
the coil springs are correctly located,
raise the jacks under the suspension
arms, and reconnect the shock absorber
each side.

d)

Ensure that all brake fluid line connections
are clean before reconnecting them. Refer
to the appropriate Sections in Chapter 9
for specific details on reconnecting the
brake lines, bleeding the brake hydraulic
system, and for reconnecting the
handbrake cable and its adjustment.

e)

When the vehicle is lowered and is
standing on its wheels, tighten the
suspension fastenings to the specified
torque wrench settings.

15 Rear axle pivot bushes

(Saloon and Estate models) -
renewal

3

1 Chock the front roadwheels, then raise and
support the vehicle at the rear on axle stands.
2 Position a suitable support (preferably
adjustable) under the axle twist beam so that
it is capable of carrying the weight of the axle
(not the weight of the vehicle).

10•10 Suspension and steering systems

14.5  Rear axle forward mounting bolts

(arrowed)

A

Upper mounting
cup

B Spring seat

C Suspension strut
D Spring

13.3  Rear suspension strut components

as fitted to Hatchback and Saloon models

3 Unscrew the nuts and pivot bolts, then
lower the rear axle so that the bushes are
clear of their mounting brackets. Take care
not to allow the brake pipes to become
distorted and stretched - if necessary,
disconnect the hydraulic lines (see Chapter 9
for details).
4 Using a steel tube of suitable diameter,
various flat washers and a long bolt and nut,
draw the bush out of its location in the axle
arm.
5 Clean the bush eye in the axle arm;
lubricate it, and the new bush, with a soapy
solution (washing-up liquid, for example) prior
to installation.
6 Locate the new bush in position, together
with the steel tube, washers, bolt and nut as
used for removal. Ensure that the bush flange
is positioned on the outside, then draw the
bush fully into position so that its lip is
engaged.
7 Raise the axle to reposition the bush pin
bores in line with the bolt holes in the
mounting brackets, then insert the pivot bolts.
Screw the retaining nuts into position on the
pivot bolts, but do not fully tighten them at
this stage.
8 If necessary, reconnect the brake lines,
then top-up and bleed the braking system as
described in Chapter 9.
9 Lower the vehicle to the ground, then
tighten the rear axle pivot bolts nuts to the
specified torque wrench setting to complete.

16 Rear shock absorber (Estate

and Van models) - removal,
testing and refitting

3

Removal

1 Chock the front wheels, then jack up the
rear of the vehicle and support it on axle
stands. Remove the appropriate roadwheel.
2 On Estate models, position a jack under the
coil spring area of the suspension arm (not
under the axle beam), and raise it to just take
the weight of the suspension.
3 Unscrew and remove the shock absorber
retaining bolt from the lower mounting (see
illustration).

4 On Estate models, unscrew the retaining
nuts securing the shock absorber top
mounting on the underside of the body (from
underneath) and withdraw the shock absorber
(see illustration).
5 On Van models, unscrew and remove the
four shock absorber upper mounting bracket-
to-body retaining bolts (see illustration).
Remove the shock absorber and its upper
mounting bracket from the vehicle. To
disconnect the shock absorber from the
mounting bracket, unscrew the retaining nut,
withdraw the through-bolt and remove the
shock absorber from the bracket.

Testing

6 Mount the shock absorber in a vice,
gripping it by the lower mounting. Check the
mounting rubbers for damage and
deterioration. Examine the shock absorber for
signs of fluid leakage. Extend the shock
absorber, then check the piston for signs of
pitting along its entire length. Check the body
for signs of damage or elongation of the
mounting bolt holes. Test the operation of the
shock absorber, by moving the piston through
a full stroke, and then through short strokes of
50 to 100 mm. In both cases, the resistance
felt should be smooth and continuous. If the
resistance is jerky, or uneven, or if there is any
visible sign of wear or damage to the strut,
renewal of the complete is necessary.

Refitting

7 Refitting is a reversal of removal procedure.
Tighten the retaining nuts and bolts to the
specified torque wrench settings (where
given), then lower the vehicle to the ground.

17 Rear coil springs 

(Estate models) - 
removal and refitting

3

Removal

1 Chock the front wheels, then jack up the
rear of the vehicle and support it on axle
stands. Remove the rear roadwheels.
2 Position a jack under the coil spring area of
the suspension arm (not under the axle beam)

each side, and raise them so that they just
take the weight of the trailing arms.
3 Unscrew and remove the shock absorber
retaining bolt from the lower attachment point
to the rear axle each side.
4 Slowly lower the jack under the suspension
arm each side, and allow the trailing arms to
drop and the compression in the coil springs
to be released. Check that no excessive strain
is imposed on the handbrake cables and/or
the hydraulic hoses to the rear brakes.
Disconnect them as described in Chapter 9 if
necessary.
5 With the coil springs fully relaxed, withdraw
them from their mounting locations between
the body and the suspension arms. As they
are removed, mark each for its direction of
fitting and side, so that they are refitted to
their original locations (where applicable).

Refitting

6 Refitting is a reversal of the removal
procedure but note the following special
points:
a)

When relocating the coil springs between
the body and the suspension arm each
side, ensure that they are correctly
orientated, and that their tails abut against
the stops.

b)

When the coil springs are correctly
located, raise the jacks under the
suspension arms, and reconnect the
shock absorber each side.

c)

Tighten the retaining bolts to the specified
torque setting.

d)

If the brake cables and/or the hydraulic
hoses were detached, refer to Chapter 9
for the reconnecting details, and to bleed
the hydraulic system.

18 Rear leaf spring, shackle and

bushes (Van models) -
removal, inspection and refitting

3

Removal

1 Chock the front wheels, then jack up the
rear of the vehicle and support it on axle
stands. To allow improved access, unbolt and
remove the rear roadwheel on the side
concerned.

Suspension and steering systems  10•11

16.5  Shock absorber upper (A) and 

lower (B) mountings on Van models

16.4  Rear shock absorber upper mounting

(Estate models)

16.3  Rear shock absorber-to-axle

mounting (Estate models)

10

2 With the rear of the vehicle supported on
stands, move the jack under the rear axle.
Raise it to support the weight of the axle, and
to take the loading from the front and rear
spring mountings.
3 Unscrew and remove the shock absorber
lower mounting bolt, and detach the shock
absorber from its mounting bracket (see
illustration).
4 Unscrew and remove the spring-to-axle U-
bolt retaining nuts, and remove the U-bolts.
Remove the counterplate and the bump stop
from the top of the spring.
5 Unscrew and remove the mounting bolt and
nut from the rear spring shackle (see
illustration).

6 Unscrew and remove the retaining nut or
bolt (as applicable) from the front mounting.
Withdraw the mounting bolt (noting the flat
washer fitted under the bolt head), then lower
the jack under the axle just enough to allow
the spring to be removed. Carefully withdraw
the spring from the vehicle.

Inspection

7 If the spring mounting (shackle) bolts are
noticeably worn, they must be renewed. If the
spring eye bushes are worn and in need of
replacement, they can be withdrawn using a
suitable drawbolt and spacer. New bushes
can be pressed into position in the spring eye
using a vice (or press).
8 If required, the rear spring shackle can be
removed by unscrewing the retaining nut,
removing the inboard shackle plate and
withdrawing the outboard shackle plate
complete with the upper shackle stud. The
upper split type bushes must be renewed if
they are worn.

Refitting

9 Refit the rear shackle, and initially hand-
tighten the shackle bolt and nut.
10 Relocate the spring over the axle, align
the front spring eye with the mounting, and
insert the bolt. Loosely secure the bolt (and
where applicable, the nut) at this stage.
11 Align the rear spring eye with the shackle
at the rear, and loosely fit the mounting bolt
and nut.
12 Locate the counterplate and bump stop
on the top of the spring over the axle, then
refit the U-bolts and fit the retaining nuts. The
jack under the axle may need to be raised to
enable the U-bolt assemblies to be relocated.
13 Reconnect the shock absorber to the rear
axle, then tighten the various fixings to their
specified torque wrench settings.
14 Refit the roadwheel, and lower the vehicle
to the ground to complete.

19 Rear axle (Van models) -

removal and refitting

3

Removal

1 Chock the front wheels, then jack up the
rear of the vehicle and support it on axle
stands. To allow improved access, unbolt and
remove the rear roadwheels.
2 With the rear of the vehicle supported on
stands, position a single jack centrally (or
preferably, two jacks each side of centre)
under the axle beam, and raise to take the
weight of the axle - do not lift the vehicle.
3 Clamp the hydraulic hoses of the light-
laden valve, to prevent excessive fluid loss
and the ingress of air and dirt into the
hydraulic system, then disconnect the
hydraulic lines to the light-laden valve and
remove the clips.
4 Refer to Chapter 9 for details, and remove

10•12 Suspension and steering systems

18.5  Leaf spring rear (A) and front (B)

locations and securing bolts

1

Axle

2

Rear leaf spring

3

Shock absorber

4

Bracket

5

Counterplate

6

Bump stop

7

Shackle plate and stud

8

Inboard shackle plate

9

Rear shackle bushes

10 U-bolt
11 Front spring eye bush
12 Rear spring eye bush
13 Spring mounting (shackle)

bolt

14 Spring mounting (shackle)

bolt

15 Shock absorber lower

mounting bolt

16 Shock absorber upper

mounting bolt

17 Bolt
18 Nut
19 Nut
20 Washer

18.3  Rear leaf spring, axle and associated components on Van models

the brake drum/hubs and then the backplate
from the rear axle on each side. The
backplates may be left attached to the axle,
but it will still be necessary to detach the
wheel cylinder brake line, and also to
disconnect and withdraw the handbrake cable
from each rear brake backplate. As each
assembly is removed, keep them separated,
and mark them to identify the right- and left-
hand assemblies. Note that they are
“handed”, and must not be confused or they
could be incorrectly refitted later.
5 Unscrew and remove the shock absorber
lower fixing bolts, and detach them from the
rear axle.
6 Unscrew and remove the axle-to-leaf spring
U-bolt retaining nuts, remove the U-bolts,
then carefully lower the axle and remove it
from under the vehicle.

Refitting

7 Refitting is a reversal of the removal
procedure, but note the following:
a)

Reconnect the axle to the spring,
reconnect the U-bolts and the shock
absorbers to the axle on each side, and
then tighten the retaining bolts to the
specified torque wrench settings.

b)

Refer to the appropriate Sections in
Chapter 9 to refit the brake backplate and
brake assemblies, and ensure that they
are correctly located according to side.

c)

Ensure that all brake fluid line connections
are clean before reconnecting them. Refer

to the appropriate Sections in Chapter 9
for specific details on reconnecting the
brake lines, bleeding the brake hydraulic
system, and reconnecting the handbrake
cable. Details of handbrake adjustment
will be found in Chapter 1.

20 Steering wheel - 

removal and refitting

1

Removal

Models without air bag

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Turn the ignition key to release the steering
lock, then set the front roadwheels in the
straightahead position. With the steering
centralised, the steering wheel should be
positioned as shown (see illustration). Move
the ignition key to the OFF position.
3 Prise free the outer pad from the centre of
the steering wheel (see illustration).
4 Prise free the inner horn pad (see
illustration), then note the connections and
detach the horn wiring at the spade
connectors (these differ in size to ensure
correct refitting). Once the wiring is free,
withdraw the inner horn pad. As it is
withdrawn, note that it has a directional arrow
mark which points up when the steering wheel
is in the straightahead position.

5 Unscrew the retaining bolt from the centre
of the steering wheel, then gripping the wheel
each side, pull and withdraw it from the
column shaft (see illustrations).
6 If the wheel is reluctant to budge, give it a
sharp tap on the underside of the spoke (as
near to the hub as possible) with the palm of
your hand.

Models with air bag

Warning: On models equipped
with an air bag system, refer to the
safety precautions in Section 27 of
Chapter 12 before starting work.

7 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).

Warning: Before proceeding, wait
a minimum of 15 minutes, as a
precaution against accidental
firing of the air bag. This period

ensures that any stored energy in the
back-up capacitor is dissipated.
8 Undo the two screws, and remove the
steering column upper shroud.
9 Turn the steering wheel as necessary so
that one of the air bag module retaining bolts
becomes accessible from the rear of the
steering wheel. Undo the bolt, then turn the
steering wheel again until the second bolt is
accessible. Undo this bolt also.
10 Withdraw the air bag module from the
steering wheel far enough to access the
wiring multi-plug. Some force may be needed
to free the module from the additional steering
wheel spoke retainers.

Suspension and steering systems  10•13

20.4  Prise free the inner horn pad and

detach the wires . . .

20.3  Remove the outer horn pad from the

centre of the steering wheel

20.2  Steering wheel alignment -

centralised within a tolerance of 30º each

side of vertical

20.13  Undo the screws (arrowed) and

withdraw the detachable lower facia panel

from beneath the steering column

20.5B  . . . and withdraw the steering wheel

20.5A  . . . unscrew the retaining bolt . . .

10