Ford Falcon. Manual — part 99
211-04-8 Steering
Column 211-04-8
REMOVAL AND INSTALLATION (Continued)
6. Disconnect the 2 wire harnesses from the
9. Remove the four bolts retaining the alloy steering
clockspring.
column mounting bracket onto the instrument
panel, and completely remove the column from
the vehicle.
NOTE: The four bolts are retained in the alloy
mounting bracket using special fibre retaining
washers. Make sure all these washers are in
place before re-installing the steering column. If
one or more of the washers are missing, the alloy
mounting bracket may become distorted,
adversely affecting the column adjustment
mechanism and column break-away mechanism .
Delete all the washers from the installation if one
or more of the fibre washers are missing.
Installation
1. Before re-installing the steering column, check
that the front wheels are in the straight ahead
position.
2. Check that the clockspring has been centralized
on the steering column. See Section 211-04-13.
3. Fit the lower steering column shaft into the
connector tube on the floor plate. Loosely fit the
M8 flanged head bolt.
4. To align the alloy mounting bracket to the steering
column, close the adjustment lever so that the
clamping mechanism is just nipped up. The alloy
bracket should still be able to rotate by hand so
that it can align to the instrument panel. Secure
the four M8 mounting bracket bolts to the
instrument panel and torque to 18Nm.
NOTE: The four bolts are retained in the alloy
mounting bracket using special fibre retaining
Item
Description
washers. Make sure all these washers are in
1
Four mounting bolts. Torque to 18 Nm.
place before re-installing the steering column. If
2
Two clockspring connectors
one or more of the washers are missing, the alloy
mounting bracket may become distorted,
3
One release tab for lever lock connector
adversely affecting the column adjustment
4
Pull back safety clip before removing the
mechanism and column break-away mechanism .
aluminum shaft
Delete all the washers from the installation if one
5
Torque bolt to 25 Nm
or more of the fibre washers are missing.
6
Two release tabs for ignition wiring lever
5. Torque the M8 flanged head bolt in the lower
lock connector
steering column shaft to 25Nm.
7. Disconnect the ignition wire harness lever-lock
6. Connect the lever lock connectors for the multi
connector. The lever has two retaining tabs that
function switch, and ignition wiring.
keep the lever locked in place. These must be
7. Connect the two clockspring connectors.
disengaged before the lever can be rotated.
8. Refit the shrouds. See Section 211-04-5.
8. Disconnect the multi-function switch wire harness
9. Refit the steering wheel and Driver Air Bag. See
lever-lock connector. The lever has a single
Section 211-04-09 & Section 211-04-10.
retaining tab that keeps the lever locked in place.
This must be disengaged before the lever can be
10. Adjust the steering column through its full range to
rotated.
ensure the movement is smooth.
11. Re-connect the battery.
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211-04-9 Steering
Column 211-04-9
REMOVAL AND INSTALLATION (Continued)
2. In the driver’s foot well, remove the M8 flanged
Fixed Steering Column (Column Shift
head bolt that joins the steering column shaft to
automatic)
the floor plate connector tube. Carefully lift the
plastic safety clip and pull the steering shaft
Removal and Installation
rearwards out of the connector tube.
1. The removal and installation of the Column Shift
3. In the engine bay remove the three nuts securing
Automatic steering column is identical to the
the floor plate to the dash panel.
adjustable steering, but requires one additional
operation.
2. Put the gear shift lever into "Park". Underneath
the instrument panel on the LHS of the steering
column, is the cable that operates the automatic
transmission. Remove the cable end (ball socket)
from the steering column by levering it off with a
screwdriver.
Item
Description
1
Floor plate securing nut
2
Intermediate nut to steering rack nut
4. Remove the bolt that secures the lower end of the
intermediate shaft to the steering rack. Slide the
intermediate shaft rearwards to collapse it,
3. To assemble the cable end ball socket, pull it
removing the universal joint from the steering rack
rearwards onto the ball stud, which is fitted to the
input shaft.
steering column shift mechanism.
5. The intermediate shaft and floor plate assembly
can now be removed from the vehicle.
Floor Plate & Intermediate Shaft
CAUTION: Be carefull collapsing steering
NOTE: The apperance of the intermediate shaft in
shaft .
XR6 Turbo and XR8 will vary from that shown in that
Installation
the shaft will be fitted with a reflective sheath and in
that no ’bell’ will be fitted over the lower universal
1. Ensure that the front wheels and steering wheel
joint. Removal of this type of intermediate shaft is as
are in the straight ahead position.
described below with the exception that the body
2. Before installation of the floor plate assembly,
mounted intermediate shaft heat shield may need to
check that the rubber gasket face on the floor
be removed to obtain adequate access to the
plate, and the mating sealing surface on the dash
intermediate shaft.
panel are clean and dry. Ensure that the threads
of the three studs on the dash panel are clean,
Removal
and that the nuts are free running.
1. Ensure that the front wheels and steering wheel
3. Position the floor plate over the three studs of the
are in the straight ahead position. Tape the
dash panel, and loosely attach the three nuts.
steering wheel to the upper and lower shrouds so
that the steering wheel cannot be inadvertently
4. From the driver’s foot well, extend the steering
rotated during this procedure. This protects the
shaft by hand and guide it into the floor plate
clockspring from being over-wound at full left
connector tube. Install the M8 flanged head bolt
hand or right hand steering wheel lock.
shaft and torque to 25Nm.
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211-04-10 Steering
Column 211-04-10
REMOVAL AND INSTALLATION (Continued)
5. Torque the three M6 nuts on the floor plate to
deformation. Install and correctly position the new
7Nm.
sensor or any other damaged supplemental
restraint system (SRS) components whether or
WARNING: Over torquing could result in
not the air bag is deployed.
the stud snapping off.
WARNING: To avoid accidental deployment
and possible personal injury, the backup power
supply must be depleted before repairing or
installing a new front or side supplemental
restraint system (SRS) components and before
repairing, installing new, adjusting or striking
components near the front or side air bag
sensors, such as doors, instrument panel,
console, door latches, strikers, seats and
hoodlatches.
Please refer to the appropriate workshop manual
to determine the location of the front air bag
sensors.
To deplete the backup power supply energy,
disconnect the battery ground cable and wait at
least one minute. Be sure to disconnect auxiliary
Item
Description
batteries and power supplies (if equipped).
1
Floor plate securing nut
2
Intermediate nut to steering rack nut
WARNING: The restraint system diagnostic
tool is for restraint system repair only. Remove
6. Slide the intermediate shaft lower universal joint
from vehicle prior to road use. Failure to remove
yoke onto the steering rack input shaft. Note that
could result in injury and possible violation of
the spline is keyed so that it can only be
vehicle safety standards.
assembled in one orientation.
1. Disconnect the battery. Wait at least one minute
7. Insert the M8 bolt into the yoke and torque to
to deplete the backup power supply energy.
22Nm.
2. Rotate the steering wheel 90
° from straight
Driver Air Bag
ahead, to access one of the Driver Air Bag
retaining screws on the front face of the steering
NOTE: Also refer to Section 501-20B.
wheel.
Removal
WARNING: Always wear safety glasses when
repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag
module. This will reduce the risk of injury in the
event of an accidental deployment.
WARNING: Never probe the connectors on
the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Vehicle sensor orientation is
critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint
3. Rotate the steering wheel 180
° to access the
system (SRS) is involved in a collision, inspect
other screw.
the sensor mounting bracket and wiring pigtail for
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211-04-11 Steering
Column 211-04-11
REMOVAL AND INSTALLATION (Continued)
4. Gently pull the Driver Air Bag away from the
2. Unscrew the retaining bolt using a Torx T50
steering wheel.
driver. To stop the steering wheel rotating,
remove the key from ignition barrel, and rotate the
steering wheel to the left until the steering column
lock engages.
Item
Description
1
Horn/Cruise/Audio Connector
2
Inflator Connectors
3. Install the steering wheel puller, Ford service tool
No. J-1859-A (09561-11002).
5. Disconnect the wiring to the Driver Air Bag inflator
Ensure that the pusher block is used so that the
by depressing the retaining clips on either side of
thread in the end of the steering column is not
the connector.
damaged. Loosen the wheel from the column.
6. Remove the horn/audio wiring connector.
4. Carefully feed the clockspring wire harnesses
7. Remove the Driver Air Bag from the vehicle.
through the hub of the steering wheel, and
remove the steering wheel from the vehicle.
Installation
5. Installation of the steering wheel is a reverse of
1. Disconnect the battery. Wait at least one minute
the above procedure. Torque the M10 steering
to deplete the backup power supply energy.
wheel attachment bolt to 38Nm.
2. Connect the wiring to the Driver Air Bag inflators.
The connectors are mechanically keyed to fit in
only one orientation.
3. Ensure the inflator wire harness is clipped into
position.
4. Connect the horn/audio wiring. Ensure the wire
harness is clipped into position.
5. Gently push the Driver Air Bag into the steering
wheel. Ensure all wiring is clear of the Driver Air
Bag attachment screws.
6. Rotate the steering wheel 90
° from straight
ahead, to access the one of the Driver Air Bag
retaining screws on the front face of the steering
wheel. Torque the screw with a Torx T30 bit, to
5Nm.
7. Rotate the steering wheel 180
° to access the
other screw.
8. Reconnect the battery.
Steering Wheel
Removal and Installation
1. Remove the Driver Air Bag. See Section
211-04-09.
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