Lift Check; Bench Test; Rear Suspension - Ford 2002 Bantam Workshop Manual

204-00-4
DIAGNOSIS AND TESTING (CONTINUED)

Lift Check

1. Noise: Noise can be caused by loose
suspension or suspension unit attachments.
Verify that all attachments for the suspension
components are tight. If suspension units
have a damaged integral lower mounting
bushing, install new units. Check front and
rear suspension units for external damage.
2. Bottom/Hopping: Check condition of the
rubber suspension travel stops (front
suspension unit jounce bumper). Install new
parts if worn or missing. Examine for
evidence of previous overload, which may
have damaged components.
3. Only install one new unit in place of the worn
or damaged suspension unit. Suspension
units do not need to be installed in pairs,
unless both units are worn or damaged.

Bench Test

The suspension units are gas-pressurized which
results in them being fully extended when not
restrained. If a suspension unit does not fully
extend, it is damaged and a new unit should be
installed. Check the overall length (specification
±
478 3 mm).
If the suspension unit does not meet the overall
length requirements, there is a good indication
something internal is out of specification and a
new suspension unit should be installed.
With the suspension unit in the normal upright
position, compress it and allow it to extend three
times to purge the pressure chamber of any gas
that may have been introduced during handling.
Symptom Chart
Symptom Chart
Condition
• Wander/pull/drift
E1049 EN
Suspension — General Information
478 + - 3 mm
Possible Sources
• Excessive side to side differ-
ence in caster or camber an-
gles.
• Toe setting out of specification.
• Vehicle ride height incorrect
(front or rear, high or low).
CAUTION: If the combination dust
shield/jounce bumper has been removed
from the suspension unit, care must be
taken to avoid excessive bottoming of
the rod during the compression stroke to
avoid internal damage.
Place the suspension unit right side up in a vise.
Hand stroke the suspension unit as fast as
possible using as much travel as possible. Action
should become smooth and uniform throughout
each stroke. Higher resistance on extension than
on compression is normal.
The following conditions are abnormal:
• A lag or skip at reversal of travel near mid-
stroke when the suspension unit is correctly
aligned and in the installed position.
• Seizing.
• Noise, other than a faint swish, such as a
clicking upon fast stroke reversal.
• Excessive fluid leakage.
• With the rod fully extended, any lateral motion
of the rod in relation to outer suspension unit
body.
If the suspension unit action remains erratic after
purging air, install a new suspension unit.
REFER to Section 204-01. (front).
REFER to Section 204-02. (rear).

Rear Suspension

At regulator intervals, the following rear
suspension checks should be made:
1. Check for evidence of fluid leaks on rear
suspension units. (A light film of fluid is
permissible. Verify fluid is not from other
sources).
2. Check the rear leaf spring condition.
3. Check the condition of the upper and lower
rear suspension bushings.
• CARRY OUT wheel alignment.
Refer to General Procedures in
this section.
• CARRY OUT wheel alignment.
Refer to General Procedures in
this section.
• CHECK for abnormal loading,
spring sag or non-standard
springs.
204-00-4
Action
06/2001 2002 Bantam