Ford Fiesta (1989-1995). Instruction — part 49

mountings for signs of wear. Test the
operation of the unit, 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, the shock
absorber should be renewed. Note that if
either unit is to be renewed, it is good practice
to renew both together as a matched pair.

Refitting

4 Locate the unit in position and refit the
mounting bolts and nut. Do not fully tighten
the mountings at this stage.
5 Lower the vehicle to the ground and rock it
to settle the suspension. Raise the vehicle
again, as necessary, until the shock absorber
is at an angle of 50° ± 5° to the horizontal.
With the shock absorber in this position,
tighten the upper and lower mountings to the
specified torque.

17 Rear suspension assembly

(Courier models) -
removal and refitting

Removal

1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the rear roadwheels.
2 Refer to Chapter 9 for details, and
disconnect the handbrake cable equaliser
from the primary cable. Remove the
handbrake rear cable from its adjuster and its
fixed body locations. Release the exhaust
system mountings as necessary to allow the
handbrake cable to be withdrawn over the
rear of the exhaust.
3 Disconnect the rear brake flexible hydraulic
brake hoses from their rigid line connections
(see illustration). Clamp the hoses before
disconnecting them, to minimise the fluid loss
and air entry into the hydraulic system (see
Chapter 9 for details).
4 Detach the light-laden valve linkage from
the bracket on the suspension assembly.

5 Locate suitable jacks under the suspension
assembly to support its weight (not to lift it).
6 Unscrew the shock absorber lower
mounting bolts on each side.
7 Unscrew the two mounting bracket bolts
each side (see illustration), check that all
associated fittings are clear, then lower the
suspension assembly and remove it from
under the vehicle.

Refitting

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

a) Refit the front mounting brackets first,

and tighten the retaining bolts to the
specified torque.

b) Reconnect the shock absorber lower

mountings, but do not fully retighten the
securing bolts until after the vehicle is
lowered to the ground and is standing on
its wheels.

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, adjusting the light laden valve,
and reconnecting and adjusting the
handbrake cable.

d) Once the vehicle is standing on its

wheels, raise it again, as necessary, until
the shock absorbers are at an angle of
50° ± 5° to the horizontal. With the shock
absorbers in this position, tighten the
lower mountings to the specified torque.

18 Rear suspension ride height

(Courier models) - adjustment

Checking of the ride height requires the use

of Ford special tools to accurately compress
the suspension to a pre-determined value.
Further special tools are then required to
reposition the torsion bars to the new setting.

This operation should be entrusted to a

Ford dealer, as it is not possible to carry out
the procedure accurately without the use
of the appropriate tools.

19 Steering wheel -

removal and refitting

Removal

Models without air bag

1 Drive the vehicle in a straight line onto a
level surface, so that the roadwheels are
pointing straight ahead.
2 Carefully prise the motif from the centre of
the steering wheel (see illustration).
3 Mark the relative positions of the steering
wheel and steering column shaft.
4 Unscrew the retaining bolt from the centre
of the steering wheel, then insert the ignition
key and turn it to position “I”. Grip the wheel
each side, then pull and withdraw it from the
column shaft.

Models with air bag

Warning: Handle the air bag with
extreme care as a precaution
against personal injury, and
always hold it with the cover

facing away from your body. If in doubt
concerning any proposed work involving
the air bag or its control circuitry, consult a
Ford dealer or other qualified specialist.
5 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, 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.
6 Undo the screws, and remove the steering
column lower shroud.
7 Undo the two external screws and the two
internal screws and remove the steering
column upper shroud.

10•12 Suspension and steering

19.2 Removing the motif from the steering

wheel

17.7 Courier rear suspension pivot

brackets locate on dowels in underbody

17.3 Brake hose and rigid pipe connection

on Courier rear suspension assembly

1595Ford Fiesta Remake

If the wheel is tight, tap it up
near the centre, using the
palm of your hand, or twist it
from side to side, whilst

pulling upwards to release it from the
shaft splines.

8 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.
9 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.
10 Disconnect the multi-plug from the rear of
the module, and remove the module from the
vehicle.

Warning: Position the air bag
module in a safe place, with the
mechanism facing downwards
as a precaution against
accidental operation.

11 Release the wiring harness from the side
of the steering column and disconnect the air
bag module wiring multi-plug (yellow lead).
12 Where applicable, undo the single screw
and withdraw the Passive Anti-Theft System
(PATS) transceiver from the ignition
switch/steering lock barrel (see illustration).
13 Turn the steering wheel so that the
roadwheels are in the straight-ahead position,
then remove the ignition key to lock the
steering.
14 Unscrew the retaining bolt from the centre
of the steering wheel, then insert the ignition

key and turn it to position “I”. Grip the steering
wheel each side, then pull and withdraw it
from the column shaft.

Refitting

All models

15 Refit in the reverse order of removal.
Make sure that the wheel is centralised, as
noted on removal and turn the ignition key so
that it is in position “I” (steering unlocked).
Tighten the retaining bolt to the specified
torque setting.

20 Steering column (instruction

steering) -
removal and refitting

Removal

Models without air bag

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the instruction choke control knob,
where fitted, by depressing the lug securing it,
and pulling it from its shaft (see illustration).
The lug is found on the side of the control
knob shank.
3 Remove the lower steering column shroud
by undoing its four retaining screws, then
detach the choke warning light switch/pull
control assembly from the lower shroud by
unscrewing its retaining collar (bayonet-type

fixing), using a suitable tool to locate in the
collar recesses (see illustration).
4 Remove the two screws securing the upper
steering column shroud from above, and the
two screws securing it from below, the latter
accessible only with the lower shroud
removed.
5 Disconnect the wiring multi-plugs from the
steering column multi-function switch
assembly, then remove the single screw
securing the multi-function switch assembly
to the steering column lock housing. This
retaining screw is located directly forward of
the hazard warning light switch (see
illustration). Remove the multi-function
switch assembly.
6 Disconnect the ignition switch wiring multi-
plug connector and remove the loom plate
from its location on the left-hand side of the
steering column (see illustration).
7 Unclip the bonnet release cable abutment
from its location in the steering column lock
housing, then detach the cable from the
bonnet release lever by aligning the cable
core with the slot on the release lever and
withdrawing it through that slot. Detach the
spring from the release lever arms, then
disengage the arms from the steering column
lock housing and remove the bonnet release
lever (see illustration).

Suspension and steering 10•13

20.3 Removing the instruction choke control

assembly retaining collar

20.2 Instruction choke control knob and its

locating lug (arrowed)

19.12 Undo the screw (arrowed) and

withdraw the Passive Anti-Theft System

(PATS) transceiver from the ignition

switch/steering lock barrel

20.7 Bonnet release lever and cable

A Bonnet release cable abutment
B Bonnet release cable slot on release lever
C Bonnet release lever return spring
D Steering column to mounting bracket

retaining nuts

20.6 Removing ignition loom plate from

steering column lock housing (steering

wheel removed for clarity)

20.5 Steering column multi-function

switch retaining screw (arrowed) (steering

wheel removed for clarity)

1595Ford Fiesta Remake

8 Remove the nuts securing the steering
column mounting bracket.
9 Remove the pinch-bolt securing the lower
steering shaft universal joint to the steering
rack pinion splined shaft, located at the rear of
the engine compartment (see illustration),
and separate the two as far as possible.
10 Pull the steering column assembly from its
bulkhead location and withdraw it from the
vehicle, ensuring that the lower steering shaft
universal joint and the steering rack pinion
splined shaft separate fully. The effort
required to remove the column assembly may
be quite high, due to the close tolerance of
the lower column tube support bush in its
location.

Models with air bag

Warning: Handle the air bag
with extreme care as a
precaution against personal
injury, and always hold it with

the cover facing away from your body. If in
doubt concerning any proposed work
involving the air bag or its control circuitry,
consult a Ford dealer or other qualified
specialist.

11 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, 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.

12 Undo the screws, and remove the
steering column lower shroud.
13 Undo the two external screws and the two
internal screws and remove the steering
column upper shroud.
14 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.
15 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.

16 Disconnect the multi-plug from the rear of
the module, and remove the module from the
vehicle.

Warning: Position the air bag
module in a safe place, with the
mechanism facing downwards
as a precaution against
accidental operation.

17 Turn the steering wheel so that the
roadwheels are in the straight-ahead position,
then remove the ignition key to lock the
steering.
18 Release the wiring harness from the side
of the steering column and disconnect the air
bag module wiring multi-plug (yellow lead).
19 Disconnect the wiring multi-plugs from
the steering column multi-function switch
assembly.
20 Disconnect the ignition switch wiring
multi-plug connector and remove the loom
plate from its location on the left-hand side of
the steering column.
21 Where applicable, undo the single screw
and withdraw the Passive Anti-Theft System
(PATS) transceiver from the ignition
switch/steering lock barrel (see illus-
tration 19.12).
22 Unclip the bonnet release cable abutment
from its location in the steering column lock
housing, then detach the cable from the
bonnet release lever by aligning the cable
core with the slot on the release lever and
withdrawing it through that slot. Detach the
spring from the release lever arms, then
disengage the arms from the steering column
lock housing and remove the bonnet release
lever.
23 Remove the nuts securing the steering
column mounting bracket.
24 Remove the pinch-bolt securing the lower
steering shaft universal joint to the steering
rack pinion splined shaft, located at the rear of
the engine compartment, and separate the
two as far as possible.
25 Pull the steering column assembly from its

bulkhead location and withdraw it from the
vehicle, ensuring that the lower steering shaft
universal joint and the steering rack pinion
splined shaft separate fully. The effort
required to remove the column assembly may
be quite high, due to the close tolerance of
the lower column tube support bush in its
location.

Refitting

All models

26 Ensure that the roadwheels are in the
straight-ahead position. With the help of an
assistant, insert the steering column assembly
into the vehicle so that the lower steering
shaft universal joint and the pinion splined
shaft on the steering rack locate correctly,
with the steering wheel centralized. Loosely
refit the pinch-bolt to secure. Ensure that the
steering shaft bulkhead seal seats correctly in
its location.
27 With the column assembly located loosely
in position, refit the nuts securing it to its
mounting bracket, taking care to ensure that
the lower column tube support bush seats
correctly as the nuts are tightened to the
specified torque.
28 Refit the steering column ancillary
components, reversing the removal procedure
given in paragraphs 2 to 7 (for models without
air bag) or 12 to 22 (for models with air bag).
29 Tighten the pinch-bolt securing the lower
steering shaft universal joint to the pinion
splined shaft to the specified torque. Ensure
that the pinch-bolt sits in the annular groove
on the pinion splined shaft (see illustration).
30 Reconnect the battery negative lead.

21 Steering column (power

steering) -
removal and refitting

Removal

Warning: Handle the air bag
with extreme care as a
precaution against personal
injury, and always hold it with

the cover facing away from your body. If in
doubt concerning any proposed work
involving the air bag or its control circuitry,
consult a Ford dealer or other qualified
specialist.
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, 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.
2 Undo the screws, and remove the steering
column lower shroud.
3 Undo the two external screws and the two
internal screws and remove the steering
column upper shroud.
4 Turn the steering wheel as necessary so

10•14 Suspension and steering

20.29 Steering rack-to-column

engagement

A Steering rack pinion splined shaft
B Annular groove to ensure correct location

of pinch-bolt

C Pinch-bolt
D Lower steering shaft universal joint

20.9 Pinch-bolt securing lower steering

shaft universal joint to pinion splined shaft

(arrowed)

1595Ford Fiesta Remake

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.
5 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.
6 Disconnect the multi-plug from the rear of
the module, and remove the module from the
vehicle.

Warning: Position the air bag
module in a safe place, with the
mechanism facing downwards
as a precaution against
accidental operation.

7 Turn the steering wheel so that the
roadwheels are in the straight-ahead position,
then remove the ignition key to lock the
steering.
8 Release the wiring harness from the side of
the steering column and disconnect the air
bag module wiring multi-plug (yellow lead).
9 Disconnect the wiring multi-plugs from the
steering column multi-function switch
assembly.
10 Disconnect the ignition switch wiring
multi-plug connector and remove the loom
plate from its location on the left-hand side of
the steering column.
11 Undo the single screw and withdraw the
Passive Anti-Theft System (PATS) transceiver
from the ignition switch/steering lock barrel
(see illustration 19.12).
12 Unclip the bonnet release cable abutment
from its location in the steering column lock
housing, then detach the cable from the
bonnet release lever by aligning the cable
core with the slot on the release lever and
withdrawing it through that slot. Detach the
spring from the release lever arms, then
disengage the arms from the steering column
lock housing and remove the bonnet release
lever.
13 Remove the C-clip at the base of the
steering column shaft, below the universal
joint.
14 Remove the nuts securing the steering
column mounting bracket.
15 Pull the steering column assembly from its
bulkhead location and withdraw it from the
vehicle, ensuring that the steering column
shaft and flexible coupling separate fully.

Refitting

16 Ensure that the roadwheels are in the
straight-ahead position and the steering
column is locked. With the help of an
assistant, insert the steering column assembly
into the vehicle so that the steering column
shaft engages with the flexible coupling.
17 Refit the steering column shaft C-clip.
18 With the column assembly located loosely
in position, refit and tighten the nuts securing
it to its mounting bracket.
19 Refit the steering column ancillary

components, reversing the removal procedure
given in paragraphs 2 to 12.
20 Reconnect the battery negative lead.

22 Steering gear rubber gaiters

- renewal

1 Remove the track rod end balljoint as
described in Section 28.
2 Remove the one-piece undertray where
fitted, by turning its bayonet-type fasteners,
and on XR2i models, remove the front
suspension crossmember as described in
Section 7.
3 Count the number of exposed threads
visible, from the end of the track rod to the
track rod end balljoint locknut, and record this
figure. Now unscrew the locknut from the
track rod.
4 Release the clip(s), and slide the gaiter off
the rack-and-pinion housing and track rod.
5 Scrape off all grease from the old gaiter,
and apply to the track rod inner joint. Wipe
clean the seating areas on the rack-and-
pinion housing and track rod.
6 Slide the new gaiter onto the housing and
track rod, and secure with the retaining clips.
Ensure that the narrow neck locates correctly
in the track rod groove.
7 Screw the track rod end balljoint locknut
back onto the track rod until the same number
of threads, as counted on removal, are visible.
8 Refit the track rod end balljoint as
described in Section 28.
9 Refit the front suspension crossmember
and one-piece undertray, as applicable.

23 Steering gear

(instruction steering) -
removal and refitting

Removal

taking care to disengage the pinion splined
shaft from the lower steering shaft universal
joint as the assembly is moved.

Refitting

8 Centralize the rack and steering wheel, then
engage the pinion splined shaft to the lower
steering shaft universal joint.
9 Refit the steering rack assembly mounting
bolts to the bulkhead and tighten to the
specified torque, ensuring that the servo
support bracket is correctly held.
10 Refit the pinion splined shaft-to-lower
steering shaft universal joint pinch-bolt and
nut and tighten to the specified torque,
ensuring that the pinch-bolt locates to the
annular groove as the pinion splined shaft.
11 Refit the track rod end balljoints to the
steering arms, as detailed in Section 28. As
long as the track rod end-to-track rod relative
positions have not been disturbed, it will not
be necessary to reset the front wheel
alignment.
12 Refit the front suspension crossmember
and one-piece undertray, as applicable.
13 Refit the roadwheels, then lower the
vehicle to the ground. Tighten the roadwheel
nuts to the specified torque with the vehicle
on its wheels.

24 Steering gear

(power steering) -
removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the front roadwheels.
3 Remove the one-piece undertray where
fitted, by turning its bayonet-type fasteners,
and on XR2i models, remove the front
suspension crossmember as described in
Section 7.
4 Remove the pinch-bolt securing the pinion
splined shaft to the lower steering shaft
flexible coupling, located at the rear of the
engine compartment.
5 Undo the retaining screws, and detach the
clips securing the power steering hydraulic
pressure pipes to the steering gear.
6 Position a suitable container under the
hydraulic pipe connections to the steering
gear. Unscrew the pipe unions, then detach
the pipes from the valve body. Withdraw the
pipes from the steering gear, and drain the
hydraulic fluid into the container.
7 Plug the exposed ends of the hydraulic line
connections, to prevent the ingress of dirt and
further fluid loss. Note that new O-ring seals
will be needed for the pressure and return
hose connections when reconnecting.
8 Slacken the upper bolts securing the
steering gear support brackets. On left-hand

Suspension and steering 10•15

1595Ford Fiesta Remake

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Ford Fiesta (1989-1995). Instruction — part 49

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