Mercury 2002 Cougar Instruction manual

Wheel Knuckle
Removal
1. CAUTION: Use a socket to remove the nut to prevent damage.
Loosen the wheel hub nut.
2. Loosen the wheel nuts.
3. CAUTION: Use an Allen key to prevent the piston rod from rotating and causing damage.
Loosen the strut tower nut by five turns.
4. Raise and support the vehicle. For additional information, refer to Section 100-02.
5. Remove the wheel.
6. Remove the tie-rod end nut.
7. CAUTION: Protect the ball joint seal to prevent damage.
Using the special tool, detach the tie-rod end from the wheel knuckle.
Special Tool(s)
Separator, Ball Joint
211-001 (TOOL-3290-D)
Remover/Installer, Front Hub
204-069 (T81P-1104-C)
Remover, Hub (Metric Stud)
204-085 (T83P-1104-BH)
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8. Remove the anti-lock brake system (ABS) sensor and cable.
9. Detach the caliper and anchor plate assembly.
 Secure the caliper and anchor plate assembly out of the way to prevent damage to the flexible brake hose.
10. Remove the brake disc.
 Remove the retainers (if equipped).
11. CAUTION: Use a socket to remove the nut to prevent damage.
Remove the wheel hub nut.
12. Remove the lower arm to wheel knuckle pinch nut and bolt.
13. CAUTION: Protect the ball joint seal to prevent damage.
Detach the lower arm from the wheel knuckle.
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14. Remove the wheel knuckle strut and spring assembly pinch bolt.
15. Using the special tools, detach the halfshaft from the wheel hub using the special tools.
16. Remove the wheel knuckle.
 Secure the halfshaft out of the way.
Installation
1. Position the wheel knuckle on the strut and spring assembly.
2. Position the halfshaft to the wheel hub.
 Install the wheel hub retaining nut finger-tight.
3. Install the lower arm to the wheel knuckle.
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4. Install the pinch bolt and nut.
5. Install the pinch bolt.
6. Install the ABS sensor.
7. Install the brake disc.
 Install the retainers (if equipped).
8. Install the caliper and anchor plate assembly.
9. Install the tie-rod end.
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10. Install the wheel.
11. Lower the vehicle.
12. Tighten the wheel nuts.
13. CAUTION: Use a socket to install the nut to prevent damage.
Tighten the wheel hub retaining nut.
14. CAUTION: Use an Allen key to prevent the piston rod from rotating and causing damage.
Install the strut tower nut.
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2002 Cougar Workshop Manual
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