Ford Falcon. Manual — part 100

211-04-12 Steering

Column 211-04-12

DISASSEMBLY AND ASSEMBLY

1. The clockspring is clipped into the multi-function

Setting the Steering Column

switch, and can be removed by deflecting and

Adjustment Clamp

releasing the three retaining clips. Remove the

two electrical connectors from the wire harness

Assembly

bracket.

1. Remove the bolt and washer securing the black

plastic adjustment lever to the serrated clamping

nut.

2. Remove the lever from the clamp nut.

2. Remove the three screws which secure the

multi-function wash/wipe/indicator/headlight

switch. Slide the lever-lock connector off the tag

of the wire harness bracket.

Item

Description

1

Serrated Clamping Nut

2

Bolt

3

Adjustment Lever

3. Slacken off and re-tighten the clamp nut to 11Nm

torque.

4. Reposition the lever on the clamp-nut ensuring

the serrations mesh correctly, and the lever is in

the fully closed position. i.e. the main arm of the

lever is parallel to the centreline of the steering

column

5. Hold the lever and replace the washer and bolt.

Tighten the bolt to 11Nm torque.

3. Remove the electrical connector from the PATS

unit.

Adjustable Steering Column

4. Remove the screw that attaches the PATS unit to

Disassembly

the ignition lock housing. Slide the PATS unit off

the ignition lock housing.

NOTE: The degree of disassembly required will

NOTE: The ignition illumination globe in the PATS

depend on the nature of the repair or the component

unit is not serviceable as a separate item.

which is to be replaced. Disassembly instructions are

given below, but it may not be necessary to carry out

5. Remove the bolt and washer securing the

all steps to effect the required repairs. These

adjustment lever, and remove the lever. Undo

instructions refer to a steering column that has been

serrated clamping nut and remove the plastic

completely removed from the vehicle.

thrust washer.
NOTE: The bolt, serrated clamp nut, and clamp

bolt use a special double start thread, and cannot

be replaced with conventional metric fasteners.

6. Remove the counter balance spring, clamp bolt

and clamping spacer.

7. Remove the alloy mounting bracket.The column is

now completely disassembled.

NOTE: The upper and lower steering shafts and

bearings are not serviceable. The upper shaft and

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211-04-13 Steering

Column 211-04-13

DISASSEMBLY AND ASSEMBLY (Continued)

bearing is staked into position. It has to sustain the

5. Fit the lever, washer and bolt.

impact of the driver in a severe accident, and must

not be disassembled.

NOTE: The upper & lower sections of the telescoping

steering shafts are made as an assembly, and can

only be assembled in one orientation. Carefully mark

the lower bearing carrier (white plastic) and alloy shaft

before disassembly, to ensure correct alignment. The

two flats on the lower alloy shaft are aligned to the

two LONG flats on the upper steering shaft.

NOTE: The locking mechanism for the steering

column is not serviceable. It is fully secured to provide

maximum anti-theft protection.

NOTE: The ignition switch for the steering column is

fully integrated into the lock housing, and is not

6. Fit the multi-function switch, ensuring that centre

serviceable. It is integrated to provide maximum

drive hub is aligned to the two flats of the steering

anti-theft protection.

shaft. Fit the three screws. Torque to 1.3Nm.
NOTE: If a new steering column is fitted, the

Assembly

screws used to attach the multi-function switch

1. Assemble the alloy mounting bracket over the

and lower shroud will cut their own thread into the

column. Lightly smear the working surfaces with a

lock housing. A torque higher than 1.3Nm may be

general purpose grease.

experienced while cutting these threads.

7. Ensure the wiring is correctly routed, then secure

the lever-lock connector to the wire harness

bracket.

Fixed Steering Column

Disassembly
1. The degree of disassembly required will depend

on the nature of the repair or the component

which is to be replaced. Complete disassembly

instructions are given below, but it may not be

necessary to carry out all steps to effect the

required repairs.

2. These instructions refer to a steering column that

2. Fit the clamping spacer, bolt and counterbalance

has been completely removed from the vehicle.

spring.

3. Disassembly of the fixed steering column is

3. Fit the plastic thrust washer, ensuring that the

identical to the adjustable steering column, except

protruding face of the washer is fitted into the

for gear shift module.

vertical slot in the alloy bracket.

Assembly

4. Fit the serrated clamping nut, and tighten to finger

1. Assembly of the fixed steering column is the same

tight.

as adjustable column, expect for the clamping

NOTE: DO NOT tighten the clamp nut at this

mechanism.

stage, this will be done after the column is fitted to

the vehicle, and the lever will be set at the same

2. Install the column as described in Section

time.

211-04-9.

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211-04-14 Steering

Column 211-04-14

DISASSEMBLY AND ASSEMBLY (Continued)

3. To set the steering column correct height, slacken 2. New Clockspring

the serrated nut on the clamping bolt, and drop

Remove the grenade pin.

the column 12mm from its top position. Torque

Rotate the centre hub clockwise 1/4 of a turn,

the clamp nut to 11Nm.

relative to the body of the clockspring.

Gear Shift Module

Item

Description

1

Remove grenade pin before installing

Disassembly and Assembly

onto column

1. Remove the M12 nut on the shift shaft.

3. Existing

Clockspring

Rotate the centre hub fully anticlockwise

relative to the body of the clockspring. The

green and yellow wire harnesses should be

almost aligned to the "TOP" marking on the

body.
Rotate the centre hub clockwise 3 1/2 turns

clockwise.

Item

Description

1

Selectorgate screw

2

Shift lever retaining nut - M12

2. Remove the shift lever and ball stud assembly.
3. Remove the three screws which secure the gear

shift selector gate. The column is now completely

disassembled.Further disassembly is not

4. The clockspring is now suitable for installation on

recommended.

a column that is installed into a vehicle with the

4. Assembly is the reverse of the above procedure

road wheels in a straight ahead position.

5. Torque the selector gate screws to 2Nm.

5. Ensure that the two flats on the lower alloy

6. Torque the shift lever retaining nut to 18Nm.

steering shaft are vertical, with the pip at the

bottom.

Centralizing the Clockspring

6. Slide the clockspring over the upper steering

shaft, and clip it to the multifunction switch.

Assembly

NOTE: This clockspring is used in another vehicle

1. Before fitting the clockspring it must be

application. When installed in a Falcon it is rotated

centralized.

180 degrees, and the "TOP" mark should be

located at the bottom.

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211-04-15 Steering

Column 211-04-15

DISASSEMBLY AND ASSEMBLY (Continued)

7. Route the wiring and attach the two connectors to

the wire harness bracket.

8. Fit the PATS unit. See Section 211-04-6.
9. Install the column. See Section 211-04-7.
10. Re-set the steering column adjustment clamp

load. See Section 211-04-11.

11. Refit the shrouds. See Section 211-04-5 &

Section 211-04-6

Floor Plate and Intermediate Shaft

Disassembly
1. It is recommended the floor plate and

intermediate shaft should not be disassembled.

2. If it is deemed necessary to separate the upper

and lower sliding halves of the intermediate shaft,

then it is vital that an alignment mark is made on

the shafts, to ensure correct orientation on

reassembly. It is recommended that this sliding

joint is NOT disassembled.

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