Ford Falcon. Manual — part 23

204-00-8

Suspension System — General Information

204-00-8

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Incorrect Tyre Pressure

Sag at One Wheel

Remove/Repair as required

Tyre Sizes Not Uniform
Overloaded or Unevenly Loaded
Vehicle
Sagging or Broken Spring
Loose or Worn Suspension Arm
Bushings

Incorrect Tyre Pressure

Hard or Rough Ride

Remove/Repair as required

Overloaded or Unevenly Loaded
Vehicle
Sagging or Broken Spring
Lack of Lubrication
Loose or Weak Shock Absorber
Loose or Worn Suspension Arm
Bushings
Binding Front Suspension Ball Joints
or Steering Linkage
Wheel Out of Balance
Out-of-Round Wheel

Rear Suspension Misalignment (Dog-

Rear Spring Tie Bolt Off Centre

Remove/Repair as required

(Wagon/Ute)

Tracking)

Broken Rear Spring Tie Bolts (Wagon)
Rear Spring Front Hanger Mislocated
(Wagon/Ute)
Loose or Worn Suspension Arm
Bushings
Frame or Underbody Out of Alignment
Bent Rear Axle Housing

Hand Test

Shock Absorbers

1. With the shock absorber removed from the

On Vehicle Tests

vehicle, hold the shock absorber such that it is in

1. Grasp the vehicle bumper bar and bounce the

a vertical position, as it would be installed in the

corner of the vehicle up and down. If the shock

vehicle. Fully compress and extend the shock

absorbers are in serviceable condition the vehicle

absorber unit three times to bleed the shock

will settle to it’s original position within two

absorber. Compress the unit and observe that the

bounces after the bumper is released.

piston rod extends under it’s own internal gas

2. Check the shock absorber to be sure that it is

pressure. There should be a smooth movement of

securely and properly installed on the vehicle.

the shock absorber rod over the complete stroke

Check the shock absorber mounting bushes and

as the shock extends. Any noticeable slowing of

body insulators for damage and / or wear.

the rod, loss of movement or drag, especially as

Replace any defective body insulators and tighten

the piston rod nears the top of its stroke, will

attachments to the specified torque. If wear or

indicate low internal gas pressure, loss of shock

damage is visible on shock absorber mounting

fluid or faulty internal valve operation.

bushes, the entire shock absorber should be

2. Extend and compress the shock as fast as

replaced.

possible, using as much travel of the shock as

3. Check the compression rubbers or bumpers fitted

possible. The action of the shock should become

on the shock rod for signs of damage. Replace if

smooth and uniform throughout each stroke. It is

necessary.

normal for the shock to have higher resistance to

extension than compression. Faint fluid "swishing"

4. Inspect the shock absorber for evidence of fluid

noises are also normal during extension and

leakage. It is important to be sure that any fluid

compression of the shock.

observed is from the shock absorber and not from

any other source.

3. If the action is smooth, but the shock absorbers

are suspected of being weak, repeat Step 2 on a

5. If the leakage is severe, replace the shock

new shock absorber or on the mating shock

absorber if leakage. (Some evidence of fluid

absorber fitted to the opposite side of the vehicle.

weepage on the shock body is not considered

Compare the results of both tests.

harmful to the shock provided that the on-vehicle

and hand tests described below are acceptable).

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204-00-9

Suspension System — General Information

204-00-9

GENERAL PROCEDURES

Toe Adjustment

Front Wheel Lock Angle Adjustment

1. Toe is the inward point of both front wheels at the 1. When the inside wheel is turned 20

°, the turning

front. The checking and optimum resetting toe-in

angle of the outside wheel should be specified in

in specifications are specified in the Description

the Description and Operation section.

and Operation section.

2. If the turning angles are incorrect or uneven when

2. Check the toe with the steering wheel in the

compared with the figures obtained on the other

straight-ahead position.

lock, first check the toe. If this is correct, examine

the tie rods which should be approximately the

3. On vehicles with power steering, the steering

same length. It they are appreciably different (i.e.

wheel must be in the straight-ahead position when

3.0mm) the turning angles will be adversely

the engine is switched off.

affected. It should be noted that minor differences

4. If it is necessary to again move the steering wheel

in tie rod length are acceptable and, in fact,

on a power steering vehicle the engine must be

sometimes necessary to compensate for

restarted.

production tolerances in the build up of the

5. Measure the angle of each front wheel from the

suspension and steering assembly.

straight-ahead position and add the angles

3. If the toe and the tie rod lengths are satisfactory

together.

examine the tie rods for distortion. The tie rod ball

joints should also be checked for wear or

Front Wheel Alignment

looseness.

1. The Caster, Camber and King Pin Inclination

Upper & Lower Ball Joint Inspection

angles are set in production and are not

adjustable.

1. Raise

the

vehicle.

2. The tie rods, part of the steering rack assembly,

2. Grasp the tyre at the top and bottom and try to

are adjustable for length to permit the setting of

move it in and out.

Toe and wheel lock angles.

3. There should be no perceptible movement in

3. Do not attempt to carry out alignment checks

either joint. If movement is detected in either joint,

without first making a preliminary check of the

that joint should be replaced.

serviceability of the front end components.

XR Rear Camber Adjustment

Toe & Steering Wheel Spoke

1. Measure ride height. Refer to wheel Alignment

Adjustments

charts in this section for ride heights vs. camber.

NOTE: Check the steering wheel spoke position when

Select appropriate camber setting.

the front wheels are in the straight-ahead position. If

2. Complete RLCA (Rear Lower Control Arm) to

the spoke is not in its correct position, it can be

subframe cam bolt adjustment (set Toe).

corrected while toe is being adjusted.

3. With toe set and locked in position, adjust left

1. Clean and lubricate the exposed threads on the

camber to specification using the cambolt.

tie-rods. Loosen the clips on the outer ends of the 4. Adjust the right camber to specification using the

rack bellows and ensure that the bellows are free

cambolt.

on the tie-rods.

5. Re-adjust left camber if necessary. Tighten both

2. Hold the tie-rod and loosen the lock nut on each

nuts to the specified torque (126

± 24 Nm).

rod.

6. Take care during the above procedure to ensure

NOTE: Both rods have right hand threads.

the brake hose bracket is located correctly.

3. Adjust toe-in. If the steering wheel spokes are in

RLCA (Rear Lower Control Arm) to

their correct position, lengthen or shorten both

rods equally to obtain correct toe. If the steering

Subframe Cambolt Adjustment

wheel spoke is not in its correct position, make

1. Loosen both bolts and adjust as required to reach

the necessary rod adjustments to obtain correct

spesified toe.

toe and steering wheel spoke alignment.

2. Tighten both nuts to the specified torque

4. When the toe and steering wheel spoke alignment

(105

± 10 Nm).

are both correct tighten the lock nut on each rod.

5. Position each tie-rod end ball joint at the centre of

its articulation and tighten the clips on the rack

bellows.

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204-01-1 Front

Suspension 204-01-1

SECTION : 204-01 Front Suspension

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-01-2

DESCRIPTION AND OPERATION

Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-01-3

Suspension

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-01-3

DIAGNOSIS AND TESTING

Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-01-4

REMOVAL AND INSTALLATION

Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-01-5

Lower Control Arm Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . .204-01-5

Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-01-6

Upper Control Arm Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . .204-01-7

Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-01-8

Stabilizer Bar Centre Bushing (Front or Rear Bar) . . . . . . . . . . . . . . . ...204-01-8

Stabilizer Bar Link Bushing . . . . . . . . . . . . . . . . . . . . . . . . . 204-01-9

Lower Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-01-9

Lower Arm - Large Bushing . . . . . . . . . . . . . . . . . . . . . . . . .204-01-11

Upper Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-01-11

Front Wheel Spindle and Hub . . . . . . . . . . . . . . . . . . . . . . . ..204-01-13

Spring and/or Shock Absorber Assembly . . . . . . . . . . . . . . . . . . . 204-01-15

204-01-2 Front

Suspension 204-01-2

SPECIFICATIONS

Torque Specifications

Description

Nm

Upper Arm to Mounting Bracket

50

Upper Arm Mounting Bracket to Body

35

Lower Control Arm to Sub-frame

115

Shock Absorber to Upper Attachment

35

Shock Absorber to Lower Control Arm

80

Spring Seat to Body

35

Ball Joint to Spindle

90

Stabilizer Bar Bracket

35

Stabilizer Bar Link Nuts

55

Wheel Bearing Nut

300

Wheel Nut

125

Brake Caliper to Spindle

115

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