204-00 DIAGNOSTYKA I TESTOWANIE
Układ zawieszenia
UID=G37351

2002.50 Mondeo

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical damage.

Mechaniczny
Tire pressure
Wheel and tires
Wheel knuckles
Tie-rod ends
Front suspension lower arm ball joints
Front suspension lower arm bushings
Front strut and spring assemblies
Front and rear stabilizer bar and connecting links
Rear springs
Rear shock absorbers
Rear suspension lower arms

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Usterka	Prawdopodobne przyczyny	Zalecane czynności
Drift left or right	*Vehicle attitude incorrect (front or rear is high or low).	*CHECK for abnormal loading, coil spring sag, or non-standard springs.
	*Steering gear or linkage worn or damaged.	*CHECK the steering system. Patrz rozdział 211-00.
	*Brake system.	*CHECK the brakes. Patrz rozdział 206-00.
	*Incorrect wheel alignment.	*ADJUST the wheel alignment.
	*Worn front wheel bearings.	*CHECK the front wheel bearings. REFER to Wheel Bearing Inspection in this Section.
	*Wheel and tires.	*Go to Pinpoint Test A.
Steering wheel off center	*Vehicle attitude incorrect (front or rear is high or low).	*CHECK for abnormal loading, coil spring sag or non-standard springs.
	*Steering gear or linkage.	*CHECK the steering system. Patrz rozdział 211-00.
	*Suspension lower arm ball joint.	*CARRY OUT the Ball Joint Component Test in this section.
	*Incorrect wheel alignment.	*ADJUST the wheel alignment.
Tracks incorrectly	*Incorrect castor angle.	*GO to Pinpoint Test B.
	*Rear suspension damage.	*GO to Pinpoint Test B.
Rough ride	*Front or rear stabilizer connecting bar, links or bushings.	*CHECK or INSTALL new suspension components as necessary. Patrz rozdział 204-01 / 204-02.
	*Front suspension lower arm bushing.	*CHECK or INSTALL new suspension components as necessary. Patrz rozdział 204-01.
	*Rear suspension arm bushing.	*CHECK or INSTALL new components as necessary. Patrz rozdział 204-02.
	*Front strut and spring assemblies.	*GO to Pinpoint Test C.
	*Rear shock absorbers.	*GO to Pinpoint Test C.
Excessive noise	*Worn front wheel bearings.	*CHECK the wheel bearings. REFER to Wheel Bearing Inspection in this Section.
	*Suspension lower arm ball joint.	*CARRY OUT the Ball Joint Component test in this Section
	*Suspension damage.	*GO to Pinpoint Test D
Incorrect tire wear	*Incorrect tire pressure.	*ADJUST the tire pressure. REFER to the Owner's Guide.
	*Incorrect wheel alignment.	*ADJUST the wheel alignment.
Vibration	*Damaged or worn front wheel bearings.	*CHECK the front wheel bearings. REFER to Wheel Bearing Inspection in this Section.
	*Wheels and tires.	*CHECK the tires. BALANCE or INSTALL new tires as necessary. Patrz rozdział 204-04.
	*Incorrect wheel alignment.	*ADJUST the wheel alignment.
	*Steering system inoperative.	*CHECK the steering system. Patrz rozdział 211-00.
	*Front strut and spring assemblies.	*GO to Pinpoint Test C.
	*Damaged front suspension lower arm(s).	*GO to Pinpoint Test D.
	*Wheel and tire excessive runout.	*GO to Pinpoint Test E.

Pinpoint Tests

OSTRZEŻENIE: To avoid personal injury due to the loss of vehicle control, the inspection should be carried out by two people to maintain safe driving conditions. Adequate grip should always be maintained on the steering wheel. Failure to follow these instructions may result in personal injury.

WSKAZÓWKA: The following conditions must be met when evaluating the vehicle.

WSKAZÓWKA: The tire swapping procedures are for bi-directional rotating tires only.

test styków A : DRIFT LEFT OR RIGHT

WARUNKI

SZCZEGÓŁY/WYNIKI/CZYNNOŚCI

A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES

Raise and support the vehicle. Patrz rozdział 100-02.

Swap the front left-hand wheel and tire assembly with the front right-hand wheel and tire assembly.

Road test the vehicle.

Does the vehicle drift?

Tak

PRZEJDŹ do A2.

Nie

The concern has been corrected.

A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES

Raise and support the vehicle. Patrz rozdział 100-02.

Swap the rear left-hand wheel and tire assembly with the rear right-hand wheel and tire assembly.

Road test the vehicle.

Does the vehicle drift?

Tak

PRZEJDŹ do A3.

Nie

The concern has been corrected.

A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES

Raise and support the vehicle. Patrz rozdział 100-02.

Swap the front left-hand wheel and tire assembly with the rear left-hand wheel and tire assembly.

Road test the vehicle.

Does the vehicle drift?

Tak

PRZEJDŹ do A4.

Nie

The concern has been corrected.

A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES

Raise and support the vehicle. Patrz rozdział 100-02.

Swap the front right-hand wheel and tire assembly with the rear right-hand wheel and tire assembly.

Road test the vehicle.

Does the vehicle drift?

Tak

PRZEJDŹ do A5.

Nie

The concern has been corrected.

A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY

Raise and support the vehicle.

Swap the front left-hand wheel and tire assembly with the rear right-hand wheel and tire assembly.

Road test the vehicle.

Does the vehicle drift?

Tak

PRZEJDŹ do A6.

Nie

The concern has been corrected.

A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY

Raise and support the vehicle. Patrz rozdział 100-02.

Swap the front right-hand wheel and tire assembly with the rear left-hand wheel and tire assembly.

Road test the vehicle.

Does the vehicle drift?

Tak

PRZEJDŹ do A7.

Nie

The concern has been corrected.

A7: INSTALL NEW TIRES

WSKAZÓWKA: Install new tires only once.

Install new tires to the four road wheels. TEST the system for normal operation.

Does the vehicle drift?

Tak

Verify possible sources, refer to the Symptom Chart.

Nie

The concern has been corrected.

test styków B : TRACKS INCORRECTLY

WARUNKI

SZCZEGÓŁY/WYNIKI/CZYNNOŚCI

B1: CHECK THE CASTOR

Check the vehicle wheel alignment.

Is the castor angle within specification?

Tak

PRZEJDŹ do B2.

Nie

INSTALL new suspension components as necessary. ADJUST alignment to specification. TEST the system for normal operation.

B2: CHECK THE REAR SUSPENSION

Measure the vehicle wheel base left-hand and right-hand side.

Compare the measurements.

Are the measurements the same?

Tak

VERIFY the customer concern.

Nie

INSPECT the rear suspension components for wear or damage. INSTALL new components as necessary. Patrz rozdział 204-02. TEST the system for normal operation.

test styków C : ROUGH RIDE

WARUNKI

SZCZEGÓŁY/WYNIKI/CZYNNOŚCI

C1: CHECK THE FRONT STRUT AND SPRING ASSEMBLIES

Raise and support the vehicle. Patrz rozdział 100-02.

Inspect the front strut and spring assemblies for oil leaks or damage.

Are the front strut and spring assemblies damaged or leaking?

Tak

INSTALL new components as necessary. Patrz rozdział 204-01. TEST the system for normal operation.

Nie

PRZEJDŹ do C2.

C2: CHECK THE REAR SHOCK ABSORBERS

Raise and support the vehicle. Patrz rozdział 100-02.

Inspect the rear shock absorbers for oil leaks or damage.

Are the rear shock absorbers damaged or leaking?

Tak

INSTALL new components as necessary. Patrz rozdział 204-02. TEST the system for normal operation.

Nie

VERIFY the customer concern.

test styków D : EXCESSIVE NOISE

WARUNKI

SZCZEGÓŁY/WYNIKI/CZYNNOŚCI

D1: INSPECT THE SUSPENSION

Raise and support the vehicle. Patrz rozdział 100-02.

Inspect the suspension mounting bolts.

Are the mounting bolts loose or broken?

Tak

TIGHTEN or INSTALL new suspension mounting bolts. Patrz rozdział 204-01. (Front). Patrz rozdział 204-02. (Rear). TEST the system for normal operation.

Nie

PRZEJDŹ do D2.

D2: INSPECT THE SPRINGS

Inspect the springs for damage.

Are the springs damaged?

Tak

INSTALL new springs. Patrz rozdział 204-01. (Front). Patrz rozdział 204-02. (Rear). TEST the system for normal operation.

Nie

PRZEJDŹ do D3.

D3: INSPECT THE FRONT SUSPENSION LOWER ARM

Inspect the front suspension lower arm bushings for excessive wear or damage.

Are the front suspension lower arm bushings worn or damaged?

Tak

INSTALL new lower arm. Patrz rozdział 204-01. TEST the system for normal operation.

Nie

PRZEJDŹ do D4.

D4: INSPECT THE TIRES

Inspect the tires for uneven wear.

Is there uneven wear?

Tak

INSTALL new tires. ADJUST the wheel alignment to specification. TEST the system for normal operation.

Nie

VERIFY the customer concern.

test styków E : VIBRATION

WARUNKI

SZCZEGÓŁY/WYNIKI/CZYNNOŚCI

E1: INSPECT THE TIRES

Raise and support the vehicle. Patrz rozdział 100-02.

Inspect the tires for damage or excessive wear.

Are the tires damaged or worn?

Tak

INSTALL new tires. TEST the system for normal operation.

Nie

PRZEJDŹ do E2.

E2: MEASURE THE WHEEL AND TIRE RUNOUT ON THE VEHICLE

Measure the wheel and tire runouts on the vehicle using suitable equipment. Assembly runout should be less than 1.14 mm (0.045 inch) radial and lateral.

Is the measurement within specification?

Tak

PRZEJDŹ do E8.

Nie

PRZEJDŹ do E3.

E3: MEASURE THE WHEEL AND TIRE RUNOUT OFF THE VEHICLE

Measure the wheel and tire from any position that exceeds 1.14 mm (0.045 inch) radial or lateral. Before removing the wheel, mark a wheel stud and corresponding stud hole so the wheel can be installed in same position. Remove the wheel and mount on a wheel balancer. Measure the runout. Wheel and tire runout should be less than 1.14 mm (0.045 inch) radial and lateral.

Is the measurement to specification?

Tak

PRZEJDŹ do E6.

Nie

PRZEJDŹ do E4.

E4: MATCH MOUNTING

Mark the high runout location on the tire and also on the wheel. Deflate the tire and rotate the tire 180 degrees on the wheel. Inflate the tire and measure the runouts.

Are the wheel and tire balanced?

Tak

INSTALL the wheel to the vehicle. TEST the system for normal operation.

Nie

If the high spot is not within 101.6 mm (4 inches) of first high spot on the tire, PRZEJDŹ do E5.

E5: MEASURE WHEEL RUNOUT

Remove the tire and mount the wheel on a wheel balancer. Measure the runout on both flanges. Runout should be less than 1.14 mm (0.045 inch) radial and lateral.

Is the runout to specification?

Tak

LOCATE and MARK the low spot on wheel and INSTALL the tire matching the high spot on the wheel. BALANCE the wheel and tire assembly. TEST the system for normal operation.

Nie

INSTALL a new wheel. CHECK the runout on the new wheel. If the new wheel is within limits, LOCATE and MARK the low spot. INSTALL the tire, matching the high spot of the tire with the low spot of the wheel. BALANCE the wheel and tire assembly. INSTALL the wheel and tire to the vehicle. TEST the system for normal operation.

E6: REAR HUB AND STUD PITCH CIRCLE DIAMETER RUNOUT

Remove the rear wheel and brake drum or disc.

Measure the hub flange face runout (greater than 0.254 mm (0.010 inch)), stud circle runout (greater than 0.08 mm (0.003 inch)) and radial runout (greater than 0.05 mm (0.002 inch)).

Are the measurements correct?

Tak

PRZEJDŹ do E7.

Nie

INSTALL a new rear hub. Patrz rozdział 204-02.

E7: FRONT HUB AND STUD PITCH CIRCLE DIAMETER RUNOUT

Remove the front wheel and brake disc.

Measure the stud circle runout (greater than 0.06 mm (0.002 inch)).

Are the measurements correct?

Tak

PRZEJDŹ do E8.

Nie

INSTALL a new hub. Patrz rozdział 204-01.

E8: WHEEL BALANCE

Balance all wheels. Road test the vehicle.

Is a vibration felt?

Tak

Patrz rozdział 100-04.

Nie

VERIFY the customer concern.

Component Tests

Ball Joint Inspection

1. Raise and support the vehicle. Patrz rozdział 100-02.

2. Firmly grasp the outer end of the suspension lower arm and try to move it up and down, watching and feeling for any movement. Free movement will usually be accompanied by an audible "click''. There should be no free movement.

3. If there is any free movement install a new lower arm. Patrz rozdział 204-01.

4. If a new lower arm is installed it will be necessary to check and adjust the front wheel alignment. For additional information, refer to Specifications in this Section.