Ford Falcon. Manual — part 39

204-04-9

Wheels and Tyres

204-04-9

REMOVAL AND INSTALLATION

3. Stand the wheel and tyre upright with the tyre

Wheel

inner bead in the drop centre well at the

bottom of the wheel. Insert the tyre iron

Removal

between the bead and the edge of the wheel

1. Remove the wheel cover by inserting the small

rim, and pry the wheel out of the tyre.

end of a wheel nut removal tool inside the outer

Installation

edge of the cover and progressively prying off the

cover (steel wheels only).

1. If a used tyre is being installed remove all dirt

from the tyre. If a tyre is being mounted to the

2. Loosen the wheel nuts one turn.

original wheel, check the tyre bead seat on the

3. Raise the vehicle until the tyre clears the floor.

rim for imperfections and rectify same before

4. Remove the wheel nuts and the centre cap

installing the tyre. If a new tyre or wheel is being

(where fitted).

installed coat a new valve with lubricant and

Installation

position the valve to the wheel. Use a valve

replacing tool to seat the valve in the rim.

1. Clean all dirt from the hub.

2. Apply lubricant to the sealing surface on both tyre

2. Position the wheel on the hub. Install the wheel

beads and wheel. With the outer side of the wheel

centre cap (where fitted) on the wheel bolts.

up, install the beads one at a time over the wheel

3. Install the wheel nuts and tighten them alternately

rim, by using a rubber mallet or a tyre mounting

in order to draw the wheel evenly against the hub.

machine.

4. Lower the vehicle to the floor, and tighten the

3. Remove the valve core and give the tyre a few

nuts.

quick bursts of air to seal the beads.

5. Position the wheel cover recess for the valve,

4. If the beads do not seal, hold the beads against

symmetrically around the valve and using a

the rim by positioning a tyre mounting band over

rubber mallet gently knock the cover onto the

the tyre. If a mounting band is not available, tie a

wheel, hitting on the outer edge. (Steel wheels

tourniquet of heavy cord around the

only.)

circumference of the tyre. Tighten the cord with a

tyre iron. Centre the tyre on the wheel with a

Tyre

rubber mallet. Repeat item 3. Remove the

mounting band.

Removal

5. Install the valve core then inflate the tyre to 275

NOTE: When fitting a new tubeless tyre, a new

kPa pressure to seat the beads against the rim

snap-in valve should also be fitted. The valve is made

flanges.

to last the life of the tyre, but beyond that time fatigue

of the valve body rubber is likely to impair the air-seal 6. Check to see that the bead positioning rings (rings

at the rim hole.

on the side walls near the rim) are evenly visible

just above the rim flanges all the way around the

NOTE: The tyre can be demounted or mounted on a

tyre. If the rings are not even, deflate the tyre

machine. A machine should always be used on

completely and inflate it again.

aluminium alloy wheels.

7. When the rings are properly positioned, deflate

NOTE: Be sure that outer side of the wheel is

the tyre to the recommended pressure.

positioned upward. It is acceptable to use tyre irons

8. Dynamically balance the wheel and tyre

on steel wheels using the following procedure.

assembly.

1. Remove the valve cap and core, and deflate the

tyre completely.

2. With the bead loosening tool, break loose the tyre

beads from the wheel.

3. Remove the wheel weights (if fitted).

1. With the outer side of the wheel upward,

insert two tyre irons about 200 mm apart

between the tyre outer bead and the wheel

rim. Use only tyre irons with rounded edges or

irons designed for demounting tubeless tyres.

2. Lever the tyre bead over the wheel rim with

one iron and hold it in this position. Pry the

rest of the bead over the rim with the other

iron. Take small "bites" with the iron around

NOTE: Ensure correct rotational direction when fitting

the tyre in order to avoid damaging the

a directional tyre to a rim.

sealing surface of the tyre bead.

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205-00-1

Driveline System — General Information

205-00-1

SECTION : 205-00 Driveline System — General

Information

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205-00-2

DESCRIPTION AND OPERATION

Driveline System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-00-3

General

Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . .205-00-3

Run

in

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...205-00-5

Towing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..205-00-5

Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-00-5

DIAGNOSIS AND TESTING

Driveline System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-00-5

In Vehicle Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . ..205-00-5

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-00-5

Bearing

Noise

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...205-00-7

Gear Tooth Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . .205-00-7

Shim and Backlash Changes . . . . . . . . . . . . . . . . . . . . . . . ...205-00-8

Driveline

Vibration

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-00-9

Limited Slip Differentials (M78 & M86) . . . . . . . . . . . . . . . . . . . ...205-00-9

Inspection after Removal & Dismantling . . . . . . . . . . . . . . . . . . . 205-00-10

205-00-2

Driveline System — General Information

205-00-2

SPECIFICATIONS

Torque Specifications

Refer to, Specifications and Special Tools of Section

205-02 for all Torque Specifications.

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205-00-3

Driveline System — General Information

205-00-3

DESCRIPTION AND OPERATION

Conventional M86 differentials are not fitted with a

Driveline System

metal tag. For LSD units, a metal tag marked

“SPIN RESISTANT DIFF. USE APPROVED

General Specifications

LUBRICANT ONLY” is attached under the filler

M78 & M86 IRS (Sedan)

plug on the rear cover.

M78 & M86 Beam Axle (Wagon & Ute)

M78 IRS

M78 Beam axle

M86 IRS

M86 Beam axle

A label identifying the drive unit assembly part

number, serial number, final drive ratio and model is

A label identifying the beam axle assembly part

fixed to the carrier casting. Two different model final

number, serial number, and final drive ratio is fixed to

drive units are used in sedan vehicles:

the axle tube adjacent to the carrier.

1. M78 final drive units are fitted with 3.23 or 3.45

Two different model beam axles are used on wagon

7.75" (197mm) diameter gear sets, with or without

and utility vehicles:

LSDs. All M78 final drive units should be filled

with synthetic oil as per Section 205-02

1. M78 beam axles are fitted with 3.23 or 3.45 7.75"

Specifications. Conventional M78 differentials are

(197mm) diameter gear sets, with or without ABS

fitted with a metal tag marked “HIGH

and with or without LSDs. All M78 beam axles

PERFORMANCE. USE APPROVED LUBRICANT

should be filled with synthetic oil as per Part 4-5

ONLY” that is attached under the filler plug on the

Specifications. Conventional M78 differentials are

rear cover. For Limited Slip Differentials (LSD)

fitted with a metal tag marked “HIGH

units, the metal tag is marked “LSD - HIGH

PERFORMANCE. USE APPROVED LUBRICANT

PERFORMANCE. USE APPROVED LUBRICANT

ONLY” that is attached under the filler plug on the

ONLY”.

rear cover. For LSD units, the metal tag is marked

“LSD - HIGH PERFORMANCE. USE APPROVED

2. M86 final drive units are fitted with 3.23 or 3.46

LUBRICANT ONLY”.

8.6" (220mm) diameter gear sets, with or without

LSDs. M86 final drive units are fitted to all sedan

2. M86 beam axles are fitted with 3.23 or 3.46 8.6"

vehicles powered by a V8 or turbo I6 engine. All

(220mm) diameter gear sets, with or without ABS

M86 final drive units should be filled with mineral

and with or without LSDs. M86 axles are fitted to

oil as per Section 205-02 Specifications.

1 tonne rated utilities, and all vehicles powered by

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