Ford Falcon. Manual — part 7
100-02-2
Jacking and Lifting
100-02-2
DESCRIPTION AND OPERATION
Jacking/Lifting Points - Ute
Jacking
WARNING: Do not run the engine when
jacking the vehicle. The wheels contacting the
ground could cause the vehicle to move. Failure
to follow these instructions may result in personal
injury.
WARNING: Make sure the jack and jack
stands are correctly located to prevent the vehicle
from falling. Failure to follow these instructions
may result in personal injury.
WARNING: Wheel chocks should be used to
prevent the vehicle from rolling and falling off the
jack. Failure to follow these instructions may
1. The front jacking\lifting point for the ute is on the
result in personal injury.
sill at the point where the rocker moulding has
been cut away to expose the sill.
CAUTION: The service jack provided with the
2. The rear jacking\lifting point for the ute is on the
vehicle is only intended to be used in an
leaf spring hanger bracket.
emergency for changing a deflated tire. Never use
the service jack to hoist the vehicle for any other
service. Refer to the Owner Guide when using the
jack supplied with the vehicle.
Jacking/Lifting Points - Sedan/Wagon
1. The front jacking\lifting point for sedan and wagon
is on the sill at the point where the rocker
moulding has been cut away to expose the sill.
2. The rear jacking\lifting point for the sedan and
wagon is on the sill at the point where the rocker
moulding has been cut away to expose the sill.
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100-04-1
Noise, Vibration and Harshness
100-04-1
SECTION : 100-04 Noise, Vibration and Harshness
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) . . . . . . . . . . . . . . . . . . . . 100-04-2
Acceptable Noise, Vibration and Harshness . . . . . . . . . . . . . . . . . ...100-04-2
Diagnostic
Theory
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-04-2
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-04-2
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH) . . . . . . . . . . . . . . . . . . . . 100-04-7
1: Customer Interview . . . . . . . . . . . . . . . . . . . . . . . . . . 100-04-10
2: Pre-Drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .100-04-10
3: Preparing for the Road Test . . . . . . . . . . . . . . . . . . . . . . ..100-04-10
4: Verify the Customer Concern . . . . . . . . . . . . . . . . . . . . . . 100-04-10
5: Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..100-04-10
6: Check OASIS/TSBs/Repair History . . . . . . . . . . . . . . . . . . . ...100-04-12
7: Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .100-04-12
NVH Condition and Symptom Categories . . . . . . . . . . . . . . . . . . .100-04-13
Symptom
Charts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-04-14
Pinpoint
Tests
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-04-35
Component
Tests
. . . . . . . . . . . . . . . . . . . . . . . . . . . ...100-04-49
GENERAL PROCEDURES
Brake Disc Machining . . . . . . . . . . . . . . . . . . . . . . . . . . .100-04-55
Powertrain/Drivetrain Mount Neutralizing . . . . . . . . . . . . . . . . . . ...100-04-55
Exhaust System Neutralizing . . . . . . . . . . . . . . . . . . . . . . . ..100-04-55
Wheel Bearing Check . . . . . . . . . . . . . . . . . . . . . . . . . . .100-04-56
100-04-2
Noise, Vibration and Harshness
100-04-2
DESCRIPTION AND OPERATION
within an acceptable range.
Noise, Vibration and Harshness (NVH)
Glossary of Terms
Noise is any undesirable sound, usually unpleasant in
nature. Vibration is any motion, shaking or trembling,
Acceleration-Light
that can be felt or seen when an object moves back
An increase in speed at less than half throttle.
and forth or up and down. Harshness is a ride quality
issue where the vehicle’s response to the road
Acceleration-Medium
transmits sharply to the customer. Harshness
An increase in speed at half to nearly full throttle,
normally describes a firmer than usual response from
such as 0-97 km/h (0-60 mph) in approximately 30
the suspension system. Noise, vibration and
seconds.
harshness (NVH) is a term used to describe these
conditions, which result in varying degrees of
Acceleration-Heavy
dissatisfaction. Although, a certain level of NVH
An increase in speed at one-half to full throttle, such
caused by road and environmental conditions is
as 0-97 km/h (0-60 mph) in approximately 20
normal. This section is designed to aid in the
seconds.
diagnosis, testing and repair of NVH concerns.
Acceptable Noise, Vibration and
Ambient Temperature
Harshness
The surrounding or prevailing temperature.
All internal combustion engines and drivelines
Amplitude
produce some noise and vibration; operating in a real
The quantity or amount of energy produced by a
world environment adds noise that is not subject to
vibrating component (G force). An extreme vibration
control. Vibration isolators, mufflers and dampers
has a high amplitude. A mild vibration has a low
reduce these to acceptable levels. A driver who is
amplitude.
unfamiliar with a vehicle can think that some sounds
are abnormal when actually the sounds are normal for Backlash
the vehicle type. For example, Traction-Lok®
Gear teeth clearance.
differentials produce a slight noise on slow turns after
extended highway driving. This is acceptable and has
Boom
no detrimental effect on the locking axle function. As a
Low frequency or low pitched noise often
technician, it is very important to be familiar with
accompanied by a vibration. Also refer to Drumming.
vehicle features and know how they relate to NVH
concerns and their diagnosis. If, for example, the
Bound Up
vehicle has automatic overdrive it is important to test
An overstressed isolation (rubber) mount that
drive the vehicle both in and out of overdrive mode.
transmits vibration/noise instead of absorbing it.
Diagnostic Theory
Brakes Applied
The shortest route to an accurate diagnosis results
When the service brakes are applied with enough
from:
force to hold the vehicle against movement with the
system knowledge, including comparison with a
transmission in gear.
known good system.
system history, including repair history and usage Buffet/Buffeting
patterns.
Strong noise fluctuations (less than 1000 Hz) caused
condition history, especially any relationship to
by gusting winds. An example would be wind gusts
repairs or sudden change.
against the side glass.
knowledge of possible sources.
Buzz
using a systematic diagnostic method that divides
A low-pitched sound (200-5000 Hz) like that from a
the system into related areas.
bee. Often a metallic or hard plastic humming sound.
The diagnosis and correction of noise, vibration and
Also describes a high frequency (200–800 Hz)
harshness concerns requires:
vibration. Vibration feels similar to an electric razor.
a road or system test to determine the exact
Camber
nature of the concern.
The angle of the wheel in relation to the true vertical
an analysis of the possible causes.
as measured looking from the front of the vehicle.
testing to verify the cause.
Camber is positive when the wheel angle is offset so
repairing any concerns found.
that the top of the wheel is positioned away from the
a road test or system test to make sure the
vehicle.
concern has been corrected or brought back to
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100-04-3
Noise, Vibration and Harshness
100-04-3
DESCRIPTION AND OPERATION (Continued)
Clonk
A hydraulic knocking sound. Sound occurs with air
pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-duration, low-frequency sound.
Occurs mostly on a vehicle that is accelerating or
decelerating abruptly. Also described as a thunk.
Coast/Deceleration
Releasing the accelerator pedal at cruise, allowing the
engine to reduce vehicle speed without applying the
brakes.
Caster
Coast/Neutral Coast
The angle of the steering knuckle in relation to the
Placing the transmission range selector in NEUTRAL
true vertical as measured looking from the side of the
(N) or depressing the clutch pedal while at cruise.
vehicle.
Constant Velocity (CV) Joint
A joint used to absorb vibrations caused by driving
power being transmitted at an angle.
Controlled Rear Suspension Height
The height at which a designated vehicle element
must be when driveline angle measurements are
made.
Coupling Shaft
The shaft between the transfer case and the front
drive axle or, in a two-piece rear driveshaft, the front
section.
CPS
Cycles per second. Same as hertz (Hz).
Item
Description
Cracks
1
True vertical
A mid-frequency sound, related to squeak. Sound
2
Positive caster
varies with temperature conditions.
3
Steering axis
Creak
Chatter
A metallic squeak.
A pronounced series of rapidly repeating rattling or
Cruise
clicking sounds.
Constant speed on level ground; neither accelerating
Chirp
nor decelerating.
A short-duration high-pitched noise associated with a
Cycle
slipping drive belt.
The process of a vibrating component going through a
Chuckle
complete range of motion and returning to the starting
point.
A repetitious low-pitched sound. A loud chuckle is
usually described as a knock.
Decibel
Click
A unit of measurement, referring to sound pressure
level, abbreviated dB.
A sharp, brief, non-resonant sound, similar to
actuating a ball point pen.
Drive Engine Run-Up (DERU) Test
The operation of the engine through the normal rpm
range with the vehicle standing still, the brakes
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