Ford Falcon. Manual — part 25
204-01-7 Front
Suspension 204-01-7
REMOVAL AND INSTALLATION (Continued)
3. Attach the ball joint to the spindle, tighten the
2. Using a hydraulic press with two tonne approx.
clamp joint. Remove the spindle tie.
force push out ball joint using tool 204-229-2,
small diameter down.
4. Install the wheel and lower the vehicle.
5. With the vehicle at curb attitude tighten the
spindle pivot bolts to specification.
Item
Description
1
Arm Assy Frt Susp Upper
2
Receiver Bolt
3
Spindle Assy
4
Nut
Upper Control Arm Ball Joint
Special Tools
204-229
Item
Description
1
204-229-Item 2
2
Ball Joint
3
204-229-Item 1 Receiver
4
Upper Control Arm
Removal
NOTE: Eye protection must be worn during the
Installation
following procedures.
1. Remove rubber boot from the new ball joint,
ensuring not to damage the boot or retainer ring
1. Place receiver 204-229-Item 1 large diameter
clip.
facing up, under upper arm casting.
2. Position ball joint over control arm.
3. Place receiver 204-229-Item 1, small end up,
under upper arm casting.
4. Using a hydraulic press push ball joint home with
tool 204-229-Item 2 large end facing down.
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204-01-8 Front
Suspension 204-01-8
REMOVAL AND INSTALLATION (Continued)
5. Reinstall protective rubber boot and retainer ring
3. Fit the bolt and nut securing the shock absorber
clip.
to the lower arm.
4. Fit the upper ball joint stud to the spindle and fit
the clamp bolt and nut.
5. Fit the insulators and brackets supporting the
stabilizer bar to the siderails ensuring that the bar
is cenrally located.
6. Attach the ends of the bar links, ensuring that the
insulators are correctly positioned.
7. Fit the wheel and lower the vehicle.
Item
Description
1
204-229-Item 2
2
Upper Control Arm
3
204-229-Item 1 Receiver
4
Ball Joint with Boot Removed
Stabilizer Bar
Stabilizer Bar Centre Bushing (Front
Removal
or Rear Bar)
1. Raise the vehicle supporting the body by the
side-rails.
Removal
2. Disconnect the stabilizer bar from each link.
NOTE: Damage to suspension and/or steering
Remove the retaining brackets.
components may occur if care is not exercised when
positioning hoist adaptors or jacks when lifting the
3. Remove the wheel and disconnect the upper ball
vehicle. Do not allow contact with the steering linkage.
joint stud from the spindle.
4. Remove the shock absorber lower bolt.
1. Raise the vehicle on a hoist positioning the
suspension in the curb load position.
5. Move the shock absorber to allow the end of the
stabilizer bar to be brought rearwards past it.
2. Remove the hardware and brackets attaching the
centre section of the stabilizer bar.
6. Remove the stabilizer bar.
3. Remove the insulators from the bar.
Installation
Installation
1. Place one end of the bar into position.
1. Position the insulators on the front bar. Position
2. Move the other side shock absorber to allow that
the insulator on the rear bar.
end of the bar to be brought into position in front
of the shock absorber.
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204-01-9 Front
Suspension 204-01-9
REMOVAL AND INSTALLATION (Continued)
2. Ensure that the links on each end of the bar are
Scenario 1-Replacement of small bush only
located at approximately the same angle relative
1. Clamp lower control arm in vice using soft jaws
to the centre line of the vehicle and install the
with both bushes at top.
attaching brackets.
2. Apply a graphite grease to forcing screw thread
3. Lower the vehicle.
before usage.
Stabilizer Bar Link Bushing
3. Screw the holding nut fully onto the forcing screw
204- 230-Item 5.
Removal
1. Raise the vehicle on a hoist positioning the
suspension in the curb load position.
2. Remove the nut, washers, spacer, insulators and
link bolt attaching the ends of the stabilizer bar.
Item
Description
1
Locating collar 204-230-Item 8
2
204-230-Item 9
3
Forcing screw 204-230-Item 5
Installation
4
Holding Nut
1. Install the bolt, washers, insulators, spacer and
5
204-230-Item 10 Orient anvil so stamping
nut as illustrated. Ensure that the insulators are
is to top (this positions eccentric hole)
correctly located in the respective mounting holes.
4. Slide large bush anvil 204-230-Item 10 onto the
2. Lower the vehicle.
threaded end of forcing screw.
5. Orient large bush anvil so part no stamping is on
Lower Arm Bushing
top.
Special Tools
6. Position assembly over the inside end of large
bush.
204-230
7. Place locating collar 204-230-Item 8 over
assembly.
8. Place small hole in small bush tool 204-230-Item
9 over forcing screw spigot.
9. Slide locating collar over small bush tool
204-230-Item 9 to prevent assembly slipping
during use.
Removal
10. Screw out holding nut to remove slack.
NOTE: Three scenarios exist for the replacement of
11. With suitable spanners, clamp holding nut and
lower control arm bushes. They are:
turn forcing screw using its hexagonal section
scenario 1 - replacement of the small bush only,
until small bush is removed.
scenario 2 - replacement of the large bush only,
NOTE: Beware, the unit will collapse as the bush
is removed.
scenario 3 - replacement of both bushes.
Refer to the applicable scenario numbers.
Removal
Scenario 2-Replacement of large bush only
Scenario 1 - Replacement of small bush only
NOTE: If both bushes are to be removed then remove 1. Apply a graphite grease to Forcing Screw thread
small bush first.
before usage.
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204-01-10 Front
Suspension 204-01-10
REMOVAL AND INSTALLATION (Continued)
2. Screw the Holding Nut fully on to the Forcing
Scenario 3-Replacement of both large and small
Screw (204-230-Item 5).
bushes
1. First follow procedure to remove small bush.
2. Slide Small Bush Anvil (204-230-Item 3) on the
threaded end of Forcing Screw (204-230-Item 5).
3. Slide Small Bush Anvil (204-230-Item 3) on the
threaded end of Forcing Screw.
4. Orient eccentric hole in Small Bush Anvil so part
stamping ‘UP’ is on Top.
3. Place narrow end of Small Bush Anvil Locator
5. Position assembly over the inside end of Small
(204-230-Item 4) in to empty small bush socket.
Bush.
4. Orient Small Bush Anvil so stamping ‘UP’ is on
6. Place Locating Collar (204-230-Item 1) over
Top.
assembly.
5. Position assembly over the exposed end of Small
7. Place small hole in Large Bush Tool
Bush Anvil Locator.
(204-230-Item 2) over Forcing Screw spigot.
6. Place Locating Collar (204-230-Item 1) over
assembly.
7. Place small hole in Large Bush Tool
(204-230-Item 2) over Forcing Screw spigot.
Item
Description
1
Locating collar 204-230-Item 1
2
204-230-Item 2
3
Forcing screw 204-230-Item 5
Item
Description
4
Holding Nut
1
Locating collar 204-230-Item 1
5
204-230-Item 3 Orient anvil so stamping is
2
204-230-Item 2
to top (this positions eccentric hole)
3
Forcing screw 204-230-Item 5
8. Slide Locating Collar over Large Bush Tool to
4
Holding Nut
prevent assembly slipping during use.
5
204-230-Item 3 Orient anvil so stamping is
9. With suitable spanners, clamp Holding Nut and
to top (this positions eccentric hole)
turn Forcing Screw using its hexagonal section
8. Slide Locating Collar over Large Bush Tool to
until large bush is removed.
prevent assembly slipping during use.
Removal
9. With suitable spanners, clamp Holding Nut and
NOTE: If both bushes are to be removed then remove
turn Forcing Screw using its hexagonal section
small bush first.
until large bush is removed.
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