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Many thanks to Chris Birkbeck Rally Sport for supplying the kit to us for this guide.
Ford Racing Suspension Kits up to 1998 and 1998 onwards kits now available for around £250 + VAT and postage. Contact Darren Wilcox (Telephone +44 (0) 1287 677 512 E-mail: sales@gorallyschool.co.uk) |
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FRONT SUSPENSION (torque setting for refitting in brackets)
1. Loosen the wheel bolts. (85 NM) |
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2. Jack up the car and place it on axle stands. |
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| 4. Remove the brake pipe from the suspension mounted bracket. |
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| 5. Loosen the anti roll bar drop link. This will need holding from behind with a spanner to prevent the ball joint moving in the socket. Be careful not to damage the drop link. (52 NM)
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6. Remove the brake caliper by undoing the two mounting bolts on the rear of the caliper. Also, remove the brake disc. (58 NM)
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7. Remove the nut holding the track rod end into the hub carrier. Tap the rod end upwards with a hammer to release it. (26 NM)
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8. Remove the lower suspension arm ball pinch bolt and lever the lower arm downwards. (51 NM)
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9. Unbolt the lower suspension retaining bolt and hammer the hub carrier downwards to release the suspension from the hub carrier.
(51 NM) |
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10. Undo the suspension topmount nut using an allen key to hold the piston rod in place and a spanner to undo the nut. (50 NM) |
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11. Remove the suspension out through the wheelarch. |
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| 12. Compress the front springs
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13. Remove the rubber topmount and undo the large nut holding the spring retainer in place.
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14. Place the spring retainer onto the new spring and damper. Refit the thrust bearing and then fasten the large nut back down on top of them. |
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15. Refit the rubber top mount and place back into the wheel arch. Refit the upper part of the top mount and put the new bolt on finger tight. |
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| 16. Refit the hub carrier to the lower part of the suspension, lower arm into the hub carrier, track rod end, brake disc, brake caliper, and wheel. |
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REAR SUSPENSION (torque setting for refitting in brackets)
17. Loosen the wheel bolts. (85 NM) |
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| 18. Jack up the car and place it on axle stands. |
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| 19. Remove the wheel |
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| 20. Remove the parcel shelf |
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21. Using suitable size spanners remove the upper suspension retaining nuts. (22 NM)
Working under the car, unbolt the suspension from the rear beam. (120 NM)
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22. Compress the rear springs
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23. Using a small screw driver, remove the top mount circlip carefully.
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24. Remove the topmount and fit it to the new damper and spring. Fit the circlip to the new suspension
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25. Refit the suspension back onto the car replacing the top nuts and bottom bolts tightened to the specific torque setting. |
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