Ford Falcon. Manual — part 33

204-02a-23

Rear Suspension — IRS

204-02a-23

REMOVAL AND INSTALLATION (Continued)

Special Tool(s)

IRS Module

IRS alignment pins

Special Tool(s)

204-478

IRS module remover and

installer cradle

502-006

General

Removal

3. Replace 1 wheel nut to retain rear rotors.

1. Using a 2 post hoist (note position).

4. Remove rear seat bottom cushion.

2. Remove rear wheels.

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204-02a-24

Rear Suspension — IRS

204-02a-24

REMOVAL AND INSTALLATION (Continued)

5. Unplug both ABS connector and push out

11. Remove loctite from bolts.

grommet and connect through the floor sheet

metal.

6. Remove both brake calipers and secure up out off

the way. Beware not to kink brake hose.

Item

Description

1

Constant Velocity Joint

2

Differential Flange

7. Raise vehicle on hoist.

3

Bolt

8. Remove the rear intermediate exhaust mounting

12. Disconnect the rear hand brake cables.

rubber from the LH side of vehicle.

13. Disconnect the differential breather hose.

9. Mark rear drive shaft CV and diff flange. If the

vehicle is fitted with drive shaft balance weight,

number them and their corresponding location

before removing them.

10. Unbolt and drive shaft from diff flange.

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204-02a-25

Rear Suspension — IRS

204-02a-25

REMOVAL AND INSTALLATION (Continued)

18. Remove the 2 nuts forward of the springs on the

14. Remove IRS braces (note orientation).

subframe.

15. Remove the 4 nuts retaining the front bush off the

19. Loosen (crack) the 2 nuts reward of the springs

Trailing Arms to the body.

on the subframe.

16. Remove the bolt at the rear of the differential.

20. Loosen (crack) both lower shock absorber bolts.
21. Fit the IRS module removal and installation cradle

502-006.

17. Remove the 2 bolts on the front off the IRS

module (in front of the springs).

Item

Description

1

Front Location Bosses

2

Front Tabs

3

Rear Pins

1. Locate the 2 front bosses of the SST 502-006

into the IRS subframe

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204-02a-26

Rear Suspension — IRS

204-02a-26

REMOVAL AND INSTALLATION (Continued)

2. Tighten the rear pins

25. Move the trolley jack under the IRS module SST

and take up the weight of the IRS. Do not lift the

3. Engage the 2 front tabs and tighten with a

vehicle off of the hoist.

spanner

26. Remove the remaining 2 nuts (rearward of the

springs) on the subframe.

22. Lower the vehicle until the knuckle is approx 1

foot above the ground.

27. Lower the IRS using the trolley jack. The front

23. Using a trolley jack take up the load of the

bush off the trailing arms may need some help

spring/shocker and remove the shocker lower bolt

coming away from the studs using a breaker bar.

lower jack slowly.

28. Raise the vehicle on the hoist.

NOTE: It is important that the knuckle be

Installation

supported by the jack to avoid having the spring &

half shaft fall-out.

1. Unbolt and remove the IRS sensors.

24. Repeat step 23 for the other side.

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