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Ford Fusion - Rear wheel bearing replacement - rustonboy

2003 model, no ABS, drum brake. Optimistically (encouraged by Haynes manual) making some progress (got the brake drum off and the circlip out) but now a bit stuck (like the old bearing). Does any one have a favourite trick which does not need specialist equipment for getting the old bearing out? Is brute force the main ingredient? It seems like I need a circular drift of about 49 mm - any idea how I could get such a thing easily? And getting the new one in? Have heard about ovens and freezers - any truth in that? An old problem - but new to me - please give some advice if you can - many thanks :-)

Ford Fusion - Rear wheel bearing replacement - bathtub tom

Is the bearing in the removed drum, or on the stub shaft?

If the former, then a cold chisel and hammer (it doesn't matter what damage you do to the old one). If the latter then you'll need something like a puller.

If you need to put the new bearing back in the drum, then put the drum in the oven and the bearing in the freezer - don't tell the missus!

ISTR the method to remove the drum, was to unbolt the backplate? If you're stuck, then you can always tke the parts to a local garage. I've had very good help from such sources for the price of a couple of pints.

Edited by bathtub tom on 21/08/2021 at 22:52

Ford Fusion - Rear wheel bearing replacement - rustonboy

Many thanks for your advice. Yes the whole bearing is still in the drum - none left on the stub shaft. Removal of the drum from the stub shaft was pretty straightforward - a single 30mm nut in the middle. Apparently this will require 235 Nm torque when I put it back together (a new nut was supplied with the new bearing). I guess I have nothing to lose in this situation - will try your suggestions and take the bits to a garage if I get completely stuck. Thanks again :-)

Ford Fusion - Rear wheel bearing replacement - rustonboy

A quick update for those who might have to tread this path in the future or who are just interested in stuff :-) The old bearing is firmly wedged in the hub (brake drum), by what I now understand is called an "interference fit". Well it certainly interfered with my plans for DIY! The bearing can only be removed from one side (after removing a circlip), so it has to be driven out from the other side. Unfortunately, due to the internal contours fo the hub on the other side, it is not possible to apply any pressure to the outer race of the bearing. So it is only possible to push against the inner race. I cleaned everything up and applied WD 40 liberally beforehand. As a drift, I used a large 1/2" socket (extended by a 6" extension bar) and started tapping on the inner race. No joy. Tapped harder, no joy, etc. etc. Eventually the inner race on the tapped side broke (plenty of roller bearings) and the innder race on the exit side also fell out. So now I have a hub with a very snug outer race shell, and a 1/2" socket which is permanently attached to an extension bar! Happy days :-) Plan C will be a visit to my local garage to ask for some help. This was a job I should not have started.

Ford Fusion - Rear wheel bearing replacement - Chris M

I applaud you for having a go. I'd do the same myself, but I assume Haynes gave some instruction on how to remove the bearing? Also worth having a look on YouTube to get a better idea, although some of the numpties on there shouldn't be allowed near DIY maintenance. I found this one from a chap that appears to know what he's doing.

youtu.be/dD2y-Hi0nfI

Good luck and please report back.

Ford Fusion - Rear wheel bearing replacement - rustonboy

Before concluding this mini-saga, many thanks for your encouragement and advice :-)

The Haynes manual says"Press or drive out the bearing using a length of metal tube of diameter slightly less than the bearing outer race." Well the outer race is invisible from the driving side, so you have to press on the inner race. I guess the pressure I applied was not distributed uniformly enough and the inner race eventually disintegrated under my hammer taps. The recommended youtube video is very good - that is the professional way to do it, but does need professional equipment.

A friend with a brainwave took the offending hub away to apply heat, but got not joy that way and brought it back.

So I went to my local garage and they kindly put the hub in a huge press with a special disc of the right diameter inserted into the narrow part of the outer race and, with much huffing and puffing and raised eyebrows, eventually drove out the outer race. They then kindly pushed the new bearing in for me using the same massive press and even fitted the new circlip. I offered to pay but was charged nothing for this - just shows how staying on good terms with a local garage as a long-term customer is worthwhile. As I left, the owner told me: the torque setting is "FT". In response to my raised eyebrow, he clarified "f**king tight". I tightened the single centre nut as far as I could until the socket started slipping off. I would feel happier with a crowned nut and a split pin, but that is progress for you. If the wheel falls off, at least it is the rear one :-)

Ford Fusion - Rear wheel bearing replacement - Big John

As I left, the owner told me: the torque setting is "FT".

Might be worth revisiting - socket should not slip off? On a straight rear bearing pressed in (Ford Zodiac - I know OLD) I used a 3/4 drive socket, T bar and a long extension tube. Can't remember the torque figure but it was also "FT". I tried a 1/2 socket and ratchet but it struggled and ratchet wouldn't fit back in the case afterwards - I'd had a bit too much spinach that day.

Hopefully on a smaller Fusion a 1/2 drive socket should be enough but I would recheck or ask said garage to do so as it is a wheel coming off job. Although I presume it's a different direction thread each side(NS/OS) so it doesn't tend to loosen in forward motion.

Edited by Big John on 23/08/2021 at 21:59

Ford Fusion - Rear wheel bearing replacement - Chris M

Well done!

We learn through experience and you will have greater knowledge to call upon in the future. The tool shown in the video and the press at the garage apply steady pressure. I doubt trying to knock it out with a drift was ever going to work.

Haynes will be a bit more specific than Fing tight and if you don't have access to a torque wrench, a trip to your tame garage would be advisable. Maybe take some doughnuts if they don't take cash :)

Ford Fusion - Rear wheel bearing replacement - galileo

Well done!

We learn through experience and you will have greater knowledge to call upon in the future. The tool shown in the video and the press at the garage apply steady pressure. I doubt trying to knock it out with a drift was ever going to work.

Haynes will be a bit more specific than Fing tight and if you don't have access to a torque wrench, a trip to your tame garage would be advisable. Maybe take some doughnuts if they don't take cash :)

I did my Hillman Imp rear bearings, the recommended torque for the nut was 250 lb ft. Tightened as much as I could and once I got to work borrowed a long torque wrench from the test-bed technicians.

Ford Fusion - Rear wheel bearing replacement - Oli rag

I remember doing a rear wheel bearing on a renault megane I had. It felt like I was too late to think " why did I ever start this" after taking a couple of hours to drift out the old bearing. Never again springs to mind!

Ford Fusion - Rear wheel bearing replacement - rustonboy

Thank you Big John and Chris M for your concern about the wheel coming off. Not just clever folks on here but people who actually care :-)

The Haynes manual says 235 Nm, which is off the scale on my torque wrench and that of my mate! So I just used a long-handled bar and did the best I could. I am not sure why the socket started slipping off after a certain point. Maybe because I was using a socket with 12 internal faces (CR-V and less than £3 from B&Q). I will invest in a socket with only 6 faces and try again. I am using 1/2" drive though it does make sense that 3/4" would be better. Mine was the offside bearing, so the wheel turns in the same direction as tightening - at least have that small element of reassurance. I am confident it's "PDT" (pretty damn tight), but will definitely have another go at achieving "FT" :-)

Ford Fusion - Rear wheel bearing replacement - rustonboy

Sorry to bore most of you with the end of this tale, but there might be a poor soul like me out there who will benefit. The 30 mm socket which was sliipping off the hub nut had 12 faces as I said before. Well I fretted a bit then went to Halfords and bought a 30 mm socket with only six faces and the label "HUB NUT SOCKET". That cost £11, but it did the job - no hint of slipping at all - and my 1/2" drive felt perfectly adequate in this case. My torque bar only goes up to 200 Nm, so I measured the calibration gaps and wound it up to where 235 would be. When that clicked I was happier, but just to make sure, I then applied a little more pressure using a long extension handle. I now feet pretty confident I have achieved FT. Thanks again for advice and encouragement :-)

Ford Fusion - Rear wheel bearing replacement - Andrew-T

The Haynes manual says ....

One snag with a Haynes manual is that (apart perhaps from being cloned from versions for other models) is that it is compiled from dismantling and reassembling a fairly young car. It usually makes little allowance for such as your case, where the car has 'matured' for 18 years ... :-)