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Page 1 of 8204-02 Rear SuspensionREMOVAL AND INSTALLATION2008 Taurus/Taurus X/SableProcedure revision date: 04/14/2010Upper ArmSpecial Tool(s)2-Jaw Puller205-D072 (D97L-4221-A) orequivalentAdapter204-039, Part of 205-813Adapter for 204-592204-592/1Forcing Screw204-356Puller, Bearing205-D063 (D84L-1122-A) orequivalentRemover/Installer, Bushing204-357 or equivalentSeparator, Ball Joint204-592http://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 2 of 8All-Wheel Drive (AWD) VehiclesItemPart NumberDescription1W520214Upper arm ball joint nut25A649Upper arm3W520213Stabilizer bar link upper nut4W709443Upper arm-to-subframe rear bolt55A638Upper arm-to-subframe bushing6W710020Upper arm-to-subframe front bolt75K7898Upper arm front bushingFront Wheel Drive (FWD) Vehicleshttp://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 3 of 8ItemPart NumberDescription15A649Upper arm25A638Upper arm rear bushing3W709443Upper arm-to-subframe rear bolt45A638Upper arm-to-wheel knuckle bushing5W709443Upper arm-to-wheel knuckle bolt6W520213Stabilizer bar link upper nut7W710024Upper arm-to-subframe front bolt85K7898Upper arm front bushinghttp://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 4 of 8RemovalNOTICE: Suspension fasteners are critical parts because they affect performance of vitalcomponents and systems and their failure may result in major service expense. New parts must beinstalled with the same part numbers or equivalent part, if replacement is necessary. Do not use areplacement part of lesser quality or substitute design. Torque values must be used as specifiedduring reassembly to make sure of correct retention of these parts.NOTE: The forward and rearward upper arm bushings are removed and installed as a pair.All vehicles1. Remove the rear subframe. For additional information, refer to Section 502-00.2. Place a suitable support under the wheel knuckle.3. Remove and discard the stabilizer bar link upper nut and separate the link from the upper arm.4. Remove and discard the upper arm-to-subframe bolts.Front Wheel Drive (FWD) vehicles5. Remove and discard the upper arm-to-knuckle bolt and separate the upper arm from the wheelknuckle.All-Wheel Drive (AWD) vehicles6. Remove and discard the wheel knuckle ball joint nut.7. NOTE: It may be necessary to tap the knuckle to disconnect the upper arm.Using the Ball Joint Separator and Adapter, separate the wheel knuckle from the upper arm.All vehicles8. Using the Bushing Remover/Installer, separate the upper arm and front bushing from the rearbushing. Once the upper arm and front bushing are separated from the rear bushing, use the BushingRemover/Installer to pull the arm and bushing out of the bushing bore.http://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 5 of 89. Using the 2-Jaw Puller and Bearing Puller, separate the upper arm front bushing from the upper arm.10. Remove the upper arm from the subframe.11. Using the Forcing Screw and Adapter, remove the upper arm rear bushing from the subframe.InstallationAll vehicles1. NOTICE: Use only liquid soap, if necessary, to lubricate the bushing. Do not use any othertypes 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 ininstallation, a small amount of liquid soap may be applied to the outer diameter of the bushing.Position the upper arm rear bushing into the bushing bore from the rear of the subframe and, usingthe Forcing Screw and Adapter, install the bushing into the subframe.Use the opposite side bushing as a guide to install the bushing to the correct depth in the subframe.http://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 6 of 8AWD vehicles2. NOTICE: Do not fully tighten the nut at this time or incorrect clamp load or bushing damagemay occur.Position the upper arm into the forward bushing bore and into the rear bushing, then position theupper arm onto the wheel knuckle ball joint stud and install the ball joint nut. Tighten the new nut until snug.FWD vehicles3. NOTICE: Do not fully tighten the bolt at this time or incorrect clamp load or bushing damagemay occur.Position the upper arm into the forward bushing bore and into the rear bushing, then position theupper arm onto the wheel knuckle and install the upper arm-to-knuckle bolt. Tighten the new bolt until snug.All vehicles4. Loosely install the new upper arm-to-subframe rear bolt.5. NOTE: The upper arm height setting is measured from the top of the subframe to the bottom of theupper arm.While an assistant holds the upper arm, adjust it to the correct height. Refer to the table below forcorrect upper arm height setting specifications.VehicleUpper Arm Height SettingsTaurus X Front Wheel Drive (FWD)163 mm (6.4 in)Taurus/Sable FWD147 mm (5.7 in)Taurus X All-Wheel Drive (AWD)158 mm (6.2 in)Taurus/Sable AWD138 mm (5.4 in)http://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 7 of 86. Tighten the upper arm-to-subframe rear bolt to 110 Nm (81 lb-ft).7. While an assistant holds the upper arm in the center of the bushing bore, use the BushingRemover/Installer and the Ball Joint Separator to install the upper arm front bushing into thesubframe.8. Install the forward upper arm bushing to the correct depth in the subframe. Use the opposite sidebushing as a guide.9. Install the upper arm-to-subframe front bolt. Tighten to 110 Nm (81 lb-ft).AWD vehicles10. Tighten the upper arm ball joint nut to 110 Nm (81 lb-ft).FWD vehicles11. Tighten upper arm-to-wheel knuckle bolt to 105 Nm (77 lb-ft).http://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
Page 8 of 8All vehicles12. Position the stabilizer bar link and install the stabilizer bar link upper nut. Tighten to 55 Nm (41 lb-ft).13. Install the rear subframe. For additional information, refer to Section 502-00.Copyright 2015 Ford Motor Companyhttp://www.fordservicecontent.com/Ford Content/vdirsnet/workshop/GSI/ WS8F/US/EN/. 4/11/2015
4 5A638 Upper arm-to-wheel knuckle bushing 5 W709443 Upper arm-to-wheel knuckle bolt 6 W520213 Stabilizer bar link upper nut 7 W710024 Upper arm-to-subframe front bolt 8 5K7898 Upper arm front bushing Pa 3f 8 htt //www er ˇcecte ˆ /F Cte /irs t/w GSI/ WS /U S/EN/. /
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