Ford Falcon. Manual — part 407

501-04-2

Pickup Bed and Platform Body

501-04-2

GENERAL PROCEDURES

Hoisting the vehicle

Hoisting Area - Ute Rear

Item

Description

1

Hoisting area pad

2

Hoist arm

CAUTION: When Hoisting the vehicle the

unitized body-frame construction requires special

precautions and procedures when the vehicle is

jacked up or hoisted. In some cases, special hoist

adapters must be used as recommended by

specific hoist manufacturers. Refer to the Owner’s

Manuals when using the jack supplied with the

car.

CAUTION: Drive-on Type Hoist

To prevent possible damages to the underbody,

do not drive the vehicle on to any type hoist

without first checking for possible interference

between the upright flanges of the hoist rails and

the underbody. Should there be interference, the

hoist flanges should be modified as necessary

and/or the approach ramps built up to provide the

needed clearance.

CAUTION: Adapters

Front and rear adapters to hoist plates must be

carefully positioned in contact with the side rail to

ensure safe, accurate lifting.

CAUTION: Trolley Jack

When a trolley jack is used it is to be located in

the same position as for hoist lifting.

G34530 en

501-04-3

Pickup Bed and Platform Body

501-04-3

REMOVAL AND INSTALLATION

10. Remove eight bolts (Item 1 ) retaining the box to

Pickup Box

the chassis through floor cross members.

Removal
1. Remove

tonneau

cover.

2. Remove twelve M6 Bolts retaining bedliner load

tiedown brackets (Only 6 LH side ones shown).

11. Attach overhead lifting device by the means of

four equally spaced hooks located under the top

rail section at the position shown. Two on R/H

side of box and two on L/H of box.

3. Remove four screws retaining bedliner along the

WARNING: The inner angle section

rearsection in tailgate opening.

adjacent to the wheelarch must not be used to

lift the box.
NOTE: Ensure the chains / slings on the

overhead lifting device are near vertical when

viewed from the rear to minimize "pull-in" on the

bodysides.

4. Pull in both walls & bow floor section of bedliner

up to release locking tabs at wheel arch.

5. Remove bedliner from vehicle.
6. Remove two bolts that retain taillights ( LH and

RH ).

12. Remove scrivets retaining the plastic inner wheel

7. Remove taillights and allow globe holders to drop

arch mud deflector to chassis (LH and RH.).

back inside cavity.

8. Carefully remove the fir-tree clips retaining the

wiring for each taillight.

9. Disconnect reversing lamp/number plate

illumination connector.

G34531 en

501-04-4

Pickup Bed and Platform Body

501-04-4

REMOVAL AND INSTALLATION (Continued)

13. Raise the box, carefully manoeuvreing around the

fuel filler neck. Store the box on trestles locating

on cross beams under the floor.

Installation
1. Reverse removal procedure.

WARNING: Corflex bolts must be

re-started by hand. Attempting to restart a

corflex bolt with a rattle gun can result in

stripped threads.

CAUTION: Ensure rubber insulators have

been replaced on the vertical pins if dislodged

during removal.

G34531 en

501-04-5

Pickup Bed and Platform Body

501-04-5

REMOVAL AND INSTALLATION (Continued)

Aluminium Tray

Removal

Item

Description

1

Floor Assy. RR Flatbed

2

Bolt rear chasis mount

3

Bolt mid tray

4

Bolt front tray

1. Remove the four bolts retaining the front tray mounting brackets to the tray.

NOTE: To remove the actual tray mounting bracket from the x-member, the fuel tank must be removed to

access the lower bolt on the LH bracket.

2. Remove four bolts retaining the middle traymounting bracket to the chassis rail on both sides.
3. Remove the four bolts attaching the rearmounting brackets to the chassis rail on both sides.
4. Attach lifting device, ensuring the tray is lifted with

equal loading of all four corner points.

Installation
1. Reverse removal procedure.

WARNING: Corflex bolts must be

re-started by hand. Attempting to restart a

corflex bolt with a rattle gun can result in

stripped threads.

G34532 en