Ford Falcon. Manual — part 27

204-01-15 Front

Suspension 204-01-15

REMOVAL AND INSTALLATION (Continued)

Installation

Spring and/or Shock Absorber

1. Ensure that the bumpstop, washer and dirtshield

Assembly

fitted are correctly fitted onto the shock absorber;

compress the spring in the spring compressor and

Removal

assemble the shock absorber into it.

1. Remove the coolant bottle or the air cleaner box

2. Set the stop of the shock absorber spring seat,

depending upon which side is to be removed.

against the spring lower end, fit the upper spring

seat insulator and rotate it’s stop against the

upper end of the spring. Fit the spring cap with

any of the three studs at the specified angle

relative to the centre line of the shock absorber

assembly to lower control arm mounting bolt

(lower spring seat stop end).

3. Assemble the dual path shear mount and nut onto

the shock absorber piston rod.

4. Partly release the spring compressor and torque

the nut to specification whilst preventing the

spring cap from rotating by use of a soft lever (eg:

piece of wood) against two of the three studs.

5. Fully release the spring compressor.
6. Install the shock absorber/spring assembly into

Item

Description

the vehicle. The lower spring tail is to be to the

1

Shock Absorber Ftr

front on LHS and to the rear on RHS. Take care

2

Bolt Hex Hd M14

not to damage boot of the lower ball joint, or the

ABS wire (where fitted) and loosly fit one of the

3

Nut M14

nuts supporting the assembly to suspension

4

Arm Assy Frt Susp Lwr

tower.

2. Remove the two of the three nuts securing the

7. Fit the shock absorber lower mounting bolt and

shock absorber/sprlng assembly to the

loosely fit the nut.

suspension tower and loosen the third nut.

NOTE: Bolt thread must point towards the front of

3. Raise the vehicle - supporting it under the body

the vehicle.

rails.

8. Fit the upper ball joint stud to the spindle; fit the

4. Remove the wheel and separate the upper ball

clamp bolt and nut. torque the nut.

joint stud from the spindle.

9. Fit the two remaining nuts securing the upper

5. Remove the shock absorber lower mounting bolt.

spring seat cap to the tower.

6. Remove the third nut supporting the shock

10. Fit the wheel.

absorber/spring assembly to the suspension

11. With the vehicle weight on it’s wheels, torque the

tower, gently ease down the lower arm and

shock absorber lower mounting hardware and the

remove the assembly, taking care to ensure that

three nuts on the suspension tower, to

the shock absorber lower brackets do not damage

specification.

the dust boot of the lower ball joint. Also take care

not to damage the ABS wire (where fitted).

7. Install the shock absorber/spring assembly onto

the spring compressor and compress the spring to

relieve the tension from the shock absorber piston

rod.

WARNING: Do not attempt to separate the

spring from the shock absorber until the

spring is restrained by the use of a spring

compressor.

8. Remove the nut, dual path shear mount and

spring seat insulator from the shock absorber

piston rod and withdraw the shock absorber.

9. Release the tension from the spring if the spring

is to be changed.

G48703 en

204-01-16 Front

Suspension 204-01-16

REMOVAL AND INSTALLATION (Continued)

Item

Description

1

Nut

2

Washer

3

Insulator

4

Bracket Assy

5

Insulator

6

Spring Frt Susp Coil

7

Shock Absorber Assy Frt

8

Nut

Item

Description

1

2A Crossmember

2

2B Crossmember

3

Nut Nyloc M12

G48703 en

204-02a-1

Rear Suspension — IRS

204-02a-1

SECTION : 204-02a Rear Suspension — IRS

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-02a-2

DESCRIPTION AND OPERATION

Rear Suspension — IRS . . . . . . . . . . . . . . . . . . . . . . . . . ..204-02a-3

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-02a-3

DIAGNOSIS AND TESTING

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...204-02a-6

Stabiliser

Bar

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-02a-6

Diagnosis

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-02a-6

GENERAL PROCEDURES

FPV Cam bolt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 204-02a-7

RLCA to subframe cam adjustment . . . . . . . . . . . . . . . . . . . . . .204-02a-7

REMOVAL AND INSTALLATION

Upper Control Arm Assembly (UCA) . . . . . . . . . . . . . . . . . . . . ...204-02a-8

Front Lower Control Arm Assembly (FLCA) . . . . . . . . . . . . . . . . . . 204-02a-9

Rear Lower Control Arm Assembly (RLCA) . . . . . . . . . . . . . . . . . ..204-02a-10

Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-02a-13

Rear Lower Control Arm (RLCA) park brake cable bracket . . . . . . . . . . . ..204-02a-15

Abutment bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-02a-15

Control Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-02a-16

Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-02a-17

Spring and Upper Spring Insulator . . . . . . . . . . . . . . . . . . . . . 204-02a-18

Stabiliser bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-02a-20

Upper Stabiliser Bar Insulator . . . . . . . . . . . . . . . . . . . . . . . 204-02a-21

Jounce Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-02a-22

Body Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-02a-22

IRS Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-02a-23

204-02a-2

Rear Suspension — IRS

204-02a-2

SPECIFICATIONS

Stabiliser Bar Specifications

Description

Specification

Stabiliser bar diameter:

18

± 0.2mm

Stabiliser bar diameter:

19

± 0.2mm

Stabiliser bar/droplink

M10 X 1.25 flanged head

attachment nut:

nut / Zinc plated

Stabiliser bar/droplink

M10 X 1.25 flanged head

attachment bolt:

bolt / Zinc plated

Torque Specifications

Description

Nm

Nut - M12 - RLCA to Subframe

105

± 15

Bolt - M12 - Diff Blade to Diff

88

± 17

Bolt - M16 - Front Diff Bush (subframe)

140

± 28

to Diff
Nut - M14 - RLCA to Knuckle

140

± 28 *

Nut - M14 - FLCA to Subframe

140

± 28 *

Nut - M14 - UCA to Subframe

140

± 28 *

Nut - M12 - FLCA to Knuckle

126

± 24

Nut - M12 - UCA to Knuckle

126

± 24

Bolt - M14 - Diff Rear Cover to

200

± 40

Subframe
Bolt - M14 - Diff Rear Cover to

200

± 40

Subframe with Mass Damper
Nut - M24 - Wheel End Pacnut

325

± 25

Bolt - M12 - Caliper to Knuckle

103

± 16

Screw - M8 - Stabiliser Bar Bracket to

25

± 5

Subframe
Nut - M10 - Stabiliser Bar Droplink to

25

± 5

RLCA
Nut - M10 - Stabiliser Bar Lower

52.5

± 2.5

Attachment
Screw - M8 - Abutment Bracket to

25

± 5

Knuckle
Screw - M6 - ABS Sensor to Knuckle

10.4

± 2

Nut - M10 - Body Brace to Subframe

50

± 9.5

Screw - M12 - Control Blade to

88

± 17

Knuckle
Bolt - M14 - Shock Absorber to

121

± 18

Knuckle
Shock Absorber to Upper Mount

70

(upper bolt)
Nut - M12 - Subframe to Body (rear

108

± 17

spring area)
Nut - M12 - Subframe to Body (front

108

± 17

area of subframe)
Nut - M12 - Control Blade to Body

100

Bolt - M10 - Body Brace to Body

50

± 9.5

Bolt - M10- Vee Brace to Subframe

108

± 17

(rear diff bush mount frame)

* Torque at ride height.

G765430 en