Ford Falcon. Manual — part 28

204-02a-3

Rear Suspension — IRS

204-02a-3

DESCRIPTION AND OPERATION

Rear Suspension — IRS

The Independent Rear Suspension (IRS) design is

press-fitted rubber bush in the lower control arm. At

based on three control arms attached to the subframe the other end the droplink also has a press fitted

and knuckle. The Rear Lower Control Arms (RLCA)

rubber bush for the attachment to the stabiliser bar.

seat the base of the spring and also allow for

The stabiliser bar and droplink can be replaced

adjusting wheel alignment. Torque is transmitted to

individually or altogether as an assembly if necessary.

the wheels via a centrally located differential and two

independent halfshafts. The design allows for

servicing on either side of the module. Alternatively,

the entire module may be removed from the vehicle.

Components

Wheel Knuckle Assembly

carries the wheel hub.
carries the brake caliper assembly.
carries the parkbrake assembly.
carries the ABS sensor.
carries the shock absorber.
is supported by three arms and a knuckle support

blade each side.

Item

Description

Stabiliser Bar Assembly

1

Droplink

2

Stabiliser Bar

The stabiliser bar assembly consists of the stabiliser

bar and two droplinks. The assembly is attached to

3

Attachment Bolt

the subframe with two brackets with rubber d-blocks.

4

Attachment Nut

The droplink serves as a linkage between the lower

control arm and the stabiliser bar. The droplink has a

spigot at one end, which is bolted inside the

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204-02a-4

Rear Suspension — IRS

204-02a-4

DESCRIPTION AND OPERATION (Continued)

Upper Control Arm Assembly (UCA)

Front Lower Control Arm Assembly (FLCA)

Assembly consists of a forged arm with a rubber bush Assembly consists of a stamped arm with rubber

on the subframe end and a cross axis ball joint

bushes on the subframe end and a CABJ on the

(CABJ) on the Wheel Assembly end.

Wheel Assembly end.

Item

Description

Item

Description

1

Bushing

1

Nut FLCA to Subframe

2

Nut-UCA to Subframe

2

FLCA without Bushing

3

UCA without Bushing

3

Bolt-FLCA to Knuckle

4

Bolt-UCA to Knuckle

4

Cross Axis Ball Joint (CABJ)

5

Nut-UCA to Knuckle

5

Nut-FLCA to Knuckle

6

Cross Axis Ball Joint (CABJ)

6

Bolt-FLCA to Subframe

7

Bolt-UCA to Subframe

7

Bushing - Upper Inner

Rear Lower Control Arm Assembly (RLCA)

Assembly consists of a stamped arm with rubber

bushes on the subframe end and a CABJ on the

wheel assembly end. A cam bolt fixes the RLCA to

the subframe.

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204-02a-5

Rear Suspension — IRS

204-02a-5

DESCRIPTION AND OPERATION (Continued)

Item

Description

1

Cam Washer

2

Nut RLCA to Subframe

3

Bolt RLCA to Knuckle

4

Cross Axis Ball Joint (CABJ)

5

Nut RLCA to Knuckle

6

Rear Lower Control Arm RLCA

7

Bolt RLCA to Subframe

8

Cam Washer

9

Bush - Lower Inner

Control Blade Assembly

Assembly consists of a stamped blade with a rubber

bush on the end connecting to the body and is

retained by 3 bolts at the knuckle end.

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204-02a-6

Rear Suspension — IRS

204-02a-6

DIAGNOSIS AND TESTING

4. Inspect rubber bush for damage.

Inspection and Verification

Stabiliser Bar

1. Inspect the stabiliser bar for signs of corrosion,

deep scoring or cracks, which can dramatically

reduce the fatigue life of the stabiliser bar.

Replace if necessary.

2. Check the stabiliser bar for permanent

deformation. This can be checked by laying the

stabiliser bar on a flat bench as shown in figure

below. Measure the height of the eyes from the

bench and they should be within 4mm from each

other. Do not attempt to heat the stabiliser bar

and bend the eyes into position, as doing so will

affect the fatigue properties of the material.

Replace if necessary.

Diagnosis

NOTE: The droplink and its rubber bush must be

replaced as a unit.

1. Inspect the droplink for signs of corrosion or deep

scoring which can dramatically reduce the life of

the product. Replace if necessary.

2. Check the integrity of the press-fit for the rubber

bushes in the droplinks. Measure the distances

shown in the figure below. If the measurements

are outside the tolerances shown the press-fit has

probably worked itself loose under excessive

loads. If the facilities are available, the integrity of

the press-fit can also be checked by applying a

3kN (300kg) load to the bush. The bush should be

capable of taking the load without slipping. Do not

attempt to refit the rubber bushes into the

droplinks. Replace if necessary.

3. Inspect the rubber bush for any signs of tearing or

the failure of the bond from the steel sleeves in

the region shown in the figure above. Replace if

3. Inspection of press fit.

necessary.

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