!Guide! Replacing Or Rebuilding Front Struts - MK7 2011

----------------------------------------------------------

-Ford Fiesta Zetec JA8  08-13

----------------------------------------------------------

Misc:
-If you aren't replacing the full strut assembly then check the top mounts, coil springs, and shock absorbers individually to see what needs replacing
-Struts/springs/mounts/shocks should IDEALLY be replaced in pairs
-Suspension nuts/bolts should IDEALLY be replaced

-This guide is for replacing either the full strut, just the shock absorber, or just the spring, or just the shock absorber

----------------------------------------------------------

-Crack off the wheel which accompanies the strut(s) which need to be repaired or replaced (19mm)
-Put the relevant corners of the car on axle stands
-Remove the  wheels that need to come off (19mm)
-Spray penetrating oil & wire brush the top drop link nut, the brake hose bracket bolt & also the 2 bolts that secure the strut to the steering knuckle
-Open the bonnet & spray penetrating oil & wire brush the large piston rod nut & the 3 nuts that secure the top mount to the car

-Hold the top drop link nut with a 15mm spanner & turn the ball joint stud with a 5mm hex key to remove the nut
-Unclip the ABS wire from the 2 points on the strut
-Unbolt the 10mm brake hose bracket bolt with a SOCKET and move the hose to one side
-Remove the 2 bolts that fasten the strut to the steering knuckle (Hold the nuts with a 18mm spanner & turn the bolts with a 15mm SOCKET)
-Remove the 3 13mm nuts that are securing the top mount in place (13mm ratchet spanner is ideal)
-Push the strut back to free it from the steering knuckle
-Manoeuvre the strut until to comes away from the car

-SKIP THIS NEXT 4 SECTIONS IF YOU ARE REPLACING THE FULL STRUT ASSEMBLY:

1.
-Spray the top piston rod nut with penetrating oil again & give it a brush
-Clean out the hex key ball stud
-Place an 18mm pass through socket on the top nut & pass a 5mm hex key through it. Lock the socket in place with a 21mm spanner & turn the hex key with a ratchet to crack the nut off slightly. (DO NOT FULLY UNDO THIS NUT YET!!) (This is to make it easier/safer to remove once the coil spring is compressed as you are not fighting with it as much)
-Clamp a coil spring compressor to each side of the coil spring. Try to keep the compressors as evenly spaced apart and symmetrical as possible.
-Make sure that both coil spring compressors are seated properly over the coils at all points
-Compress each coil spring compressor evenly, a bit on each side at a time, with a 1/2" drive until the top mount can spin easily (DON'T POINT THE COIL TOWARDS YOURSELF AT ANY POINT) (DONT COMPRESS MORE THAN 10mm ON EACH SIDE AT ANY ONE TIME)
-Place an 18mm pass through socket back on the top nut & pass a 5mm hex key through it. Lock the socket in place with a 21mm spanner & turn the hex key with a ratchet to fully remove the nut.

2.
-Remove the top mount and clean & re-grease the bearings with moly grease (Skip this if you are replacing the top mount)
-Remove the shock absorber dust cover & bump stop
-Slowly back off each coil spring compressor 10mm each side until the spring is released (DON'T POINT THE COIL TOWARDS YOURSELF AT ANY POINT) (Leave the coil spring in a compressed state if you are not replacing it)
-Assess the top mount & shock absorber & coil spring for any defects

3.
(IF YOU ARE REPLACING THE COIL SPRING)
-Clamp a coil spring compressor to each side of the new coil spring. Try to keep the compressors as evenly spaced apart and symmetrical as possible.
-Make sure that both coil spring compressors are seated properly over the coils at all points
-Compress each coil spring compressor evenly, a bit on each side at a time, with a 1/2" drive until the top mount can be fully seated & fastened in place (DON'T POINT THE COIL TOWARDS YOURSELF AT ANY POINT) (DONT COMPRESS MORE THAN 10mm ON EACH SIDE AT ANY ONE TIME)

4.
-Put the new coil spring over the shock absorber so that the bottom spring butts up into the recess in the shock absorber base
-Reattach the shock absorber dust cover & bump stop
-Attach the top mount & screw the nut on until it is secure
-Slowly back off each coil spring compressor 10mm each side until the spring is released (DON'T POINT THE COIL TOWARDS YOURSELF AT ANY POINT) (Leave the coil spring in a compressed state if you are not replacing it)
-Remove the spring compressors
-Put an 18mm pass through socket on the top nut & pass a 5mm hex key through it. Lock the socket in place with a 21mm spanner & turn the hex key with a ratchet & torque it down to 48Nm

-Orient the strut the correct way and position it into the wheel well, and seat the top mount
-Mate the steering knuckle with the shock absorber and feed the 2 bolts through to secure it in place (Ideally replace the 2 bolts & nuts)
-Tighten the top 3 13mm nuts for the top mount @ 30Nm (Ideally replace the 3 nuts)
-Tighten the 2 18mm steering knuckle nuts to 82Nm & then an additional 90 degrees whilst holding the bolts with a 15mm spanner

-Secure the brake hose bracket with a 10mm bolt until it is reasonably tight
-Tighten the top drop link to the strut with a 19mm socket
-Once the drop link ball joint starts to spin then hold it with a 19mm spanner and tighten the ball joint stud with a 5mm hex key to 48Nm
-Clip the ABS wire in at the 2 fastening points

-Apply a conservative amount of aluminium anti seize to the hat of the rotors
-Fasten the wheel back on (19mm)
-Lower the car back down
-Tighten the wheel nuts to 110Nm (19mm)

----------------------------------------------------------

Useful sources:

How to change a front shock strut on FORD FIESTA JA8 [TUTORIAL AUTODOC]

----------------------------------------------------------