Ford Falcon. Manual — part 24

204-01-3 Front

Suspension 204-01-3

DESCRIPTION AND OPERATION

Item

Description

Front Suspension

4

Bracket Assy

Suspension

5

Insulator

The suspension is so designed that it allows an

6

Shock Absorber Frt

individual wheel to compensate for changes in the

7

Arm & Shaft Assy Frt Susp Upr

road’s surface level without considerably affecting the

8

Bolt Hex M14

opposite wheel. Each wheel is independently

9

Nut M14

connected to the frame and body by a spindle, ball

joint assemblies, and upper and lower control arms.

10

Arm Assy Frt Susp Lwr

The control arms are specifically designed and

11

Nut M10 Flange

positioned to allow the steering spindle to move in a

12

Spring Frt Susp Coil

prescribed three dimensional arc. The front wheels

13

Nut

are held in proper relationship to each other by two tie

rods that are connected to the steering rack and to

Side roll of the suspension is controlled by a spring

the spindles.

steel stabilizer bar. It is mounted in rubber bushings

held to the frame side rails by brackets.

Coil chassis springs are mounted between the spring

housings on the front end sheet metal and the spring

The ends of the stabilizer are connected to the lower

seats that are integral with the shock absorber body.

control arms. Rubber grommets at these connections

Ride control is provided by double, direct acting shock provide flexibility and ride features.

absorbers mounted inside the coil springs and

The upper control arm is attached to the body through

attached to the lower control arms by bolts. The upper isolating rubber bushings connected to brackets that

portion of each shock absorber extends through the

are bolted to the body.

dual path shear mount and is secured with two

The upper ball joint is a press fit into the upper control

grommets, two grommet retainers, and a nut.

arm, and the stud is fitted into the upper control end of

the spindle forging. A nylok nut and bolt clamps the

spindle to the ball joint.
The lower ball joint is a press fit into the lower arm,

and secures to the lower end of the spindle forging by

a tapered stud and nylok nut.
The inner ends of the lower control arms have

pressed in bushings and are attached to the cross

members by a single bolt through each bushing.
The suspension mounting points are all rubber

insulated to minimise the transmission of road noise

and vibration to the vehicle body.
Compliance in the lower arm bushes permits the

wheel a small amount of fore and aft movement and

so reduce the shock loading on the steering linkage

when the wheel hits a sudden irregularity in the road

surface.

Item

Description

1

Nut

2

Washer

3

Insulator

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204-01-4 Front

Suspension 204-01-4

DIAGNOSIS AND TESTING

Front Suspension

Refer to Section 204-00.

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204-01-5 Front

Suspension 204-01-5

REMOVAL AND INSTALLATION

7. Lower the vehicle and tighten the pivot bolts and

Lower Control Arm

shock absorber bolt with the vehicle at curb

attitude.

Special Tools

E9332

Removal
1. Raise the vehicle and support it under the body

rails.

2. Remove

the

wheel.

3. Loosen the ball joint nut. Using Tool No. E9332

free the taper. Remove the nut.

4. Disconnect the stabilizer bar link.
5. Loosen the hardware securing the front

crossmember and lower the crossmember

sufficiently to allow the front boss of the arm to be

withdrawn.

6. Remove the shock absorber bolt.

Item

Description

7. Remove the control arm pivot bolts and remove

1

Arm Assy Frt Susp Lower

the arm.

2

Nut Lock

Installation

3

Spindle Assy Frt Wheel

1. Fit the lower arm to the crossmembers.
2. Install but do not tighten the pivot bolts.

Lower Control Arm Ball Joint

3. Install the shock absorber bolt from the rear and

install the washer and a new nut on the strut. Do

Special Tools

not tighten either at this time.

204-236

4. Position the ball joint stud in the spindle. Tighten

with new nylok nut.

5. Install the wheel.
6. Tighten the hardware securing the front

crossmember.

204-230

Removal
NOTE: Eye protection must be worn during the

following procedures.

1. Place small end of Installer/Remover tool

204-236-Item 3 over shaft of ball joint.

2. Place Receiver 204-236-Item 2 above lower

control arm.

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204-01-6 Front

Suspension 204-01-6

REMOVAL AND INSTALLATION (Continued)

3. Using a hydraulic press, push ball joint out using

5. Press home using a hydraulic press using 6.5

6 tonne removal force.

tonne installing force.

Item

Description

Item

Description

1

Receiver 204-236-Item 2

1

An appropriate plate to support hydraulic

ram

2

204-236-Item 3

2

204-230-Item 8

Installation

3

Receiver 204-230-Item 3

1. Carefully remove rubber boot & retaining ring prior

to installation.

Upper Control Arm

2. Place ball joint into position in casting.

Removal

3. Place large end of installer/remover 204-230-Item

8 over butt of ball joint.

1. Raise the vehicle and support it under the body

rails.

4. Place receiver 204-230-Item 3 under lower control

arm.

2. Remove

the

wheel.

3. Separate the upper ball joint from the upper arm.

Tie the spindle to prevent it from failing away from

the body and straining the brake hose.

4. Remove the four nuts securing the upper arm

brackets to the suspension tower and remove the

assembly from the vehicle.

5. Remove the two bolts and the bracket assemblies

from the control arm.

Installation
1. Position the bracket assemblies on the upper arm

and loosely install new prevailing torque nuts.

2. Position the control arm on the suspension tower

and install and tighten the attaching nuts.

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