Ford Falcon. Manual — part 30
204-02a-11
Rear Suspension — IRS
204-02a-11
REMOVAL AND INSTALLATION (Continued)
7. Loosen bolts connecting Stabiliser Bar brackets to 11. Lower jack slowly and rotate RLCA downwards.
Subframe.
12. Remove spring and Spring Insulators when spring
8. Rotate stabiliser bar away from RLCA, and
becomes fully extended.
towards Control Blade.
CAUTION: Springs have high spring rate
9. Unclip park brake cable from RLCA park brake
and extreme care should be taken when
cable bracket.
releasing jack.
NOTE: Wheel-ends must be supported at the
knuckle in the two indicated positions so that
halfshafts are not over-articulated.
13. Remove RLCA Cam bolt assembly.
10. Loosen RLCA Cam bolt assembly at subframe
attachment.
14. Slide RLCA downward from vehicle.
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204-02a-12
Rear Suspension — IRS
204-02a-12
REMOVAL AND INSTALLATION (Continued)
6. Locate and loosely fit RLCA-knuckle bolt. Ensure
Installation
bolt head faces the front of the module, and that
1. Ensure that park brake cable and stabiliser bar
the nut is fully closed over the bolt shank.
links are positioned away from the RLCA position
within module.
2. Locate RLCA and locate RLCA cam bolt
assembly through RLCA bush and subframe.
7. Attach Control Blade to knuckle using new Control
Blade-knuckle bolts.
NOTE: Replace Control Blade-Knuckle bolts as
they are a 1 use only item.
3. Position upper spring insulator and spring into
position on subframe. Position lower spring
insulator onto RLCA.
4. While holding spring and insulators in position,
rotate RLCA upward into position.
8. Torque RLCA-knuckle bolt to 140
±28Nm.
9. Torque Control Blade-Knuckle bolts to 88
±17Nm.
10. Adjust RLCA Cam bolt as necessary (see below)
and torque to 105
± 15 Nm.
5. Insert jack underneath RLCAs. Extend jack so
11. Clip park brake cable into RLCA cable bracket.
that spring is compressed and return the
halfshafts to a horizontal position.
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204-02a-13
Rear Suspension — IRS
204-02a-13
REMOVAL AND INSTALLATION (Continued)
12. Rotate stabiliser bar and insert stabiliser bar links
into RLCA. Complete stabiliser bar assembly as
detailed later in this section.
6. Lower transmission jack from ride height so that
springs are fully extended. Support wheel-ends at
the knuckle in the two indicated positions so that
13. Attach wheels and lowere vehicle.
halfshafts are not over-articulated.
Knuckle
Removal
1. Secure wheel/hub to prevent halfshaft rotation
loosen axle pac nuts from halfshafts.
NOTE: Pac nuts are substantially torqued.
2. Hoist vehicle with wheels fully supported. Refer to
Section 100-02.
3. Set vehicle to ride height (Refer to Section
204-00) and remove rear wheels.
4. Unbolt
ABS
sensor.
5. Disconnect Control Blade and remove from
Knuckle.
7. Release park brake. Disconnect park brake cable
from knuckle mount.
Item
Description
1
Hand Brake Cable
2
Retaining Spring Clip
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204-02a-14
Rear Suspension — IRS
204-02a-14
REMOVAL AND INSTALLATION (Continued)
8. Detach abutment brackets from knuckle. Refer
However, halfshafts and control arms must be
later in this section.
adequately supported so that they remain
horizontal.
9. Detach caliper and rotor. Refer to Section 206-00.
10. Disconnect shock absorbers from knuckle.
Installation
11. Loosen and remove UCA-knuckle nut,
1. Set the suspension to ride height. Refer to
FLCA-knuckle nut, and RLCA-knuckle nut.
Section 204-00.
1.
FPV Vehicles
2. Position knuckle assembly over halfshaft (with
Loosen nut from UCA to knuckle and remove
halfshaft supported horizontally). Replace axle
Cam bolt and washer. FLCA-knuckle and
pac nut and torque to 50Nm.
RLCA-knuckle connections are as for the
3. Locate FLCA to knuckle using FLCA-knuckle bolt
standard IRS module.
and nut.
12. Remove axle pac nut, UCA-knuckle bolt,
4. a) Locate UCA to knuckle using UCA-knuckle bolt
FLCA-knuckle bolt and RLCA-knuckle bolt.
and nut.
b) Insert Cam bolt into Cam slot on FPV knuckle.
5. Locate RLCA to knuckle using RLCA-knuckle bolt
and nut.
NOTE: This may require the adjustment of the
spring height, via the jack attached to the RLCA,
in order to position the RLCA groove over the
knuckle.
6. Torque RLCA-knuckle nut to 140
± 28 Nm.
7. Torque FLCA-knuckle bolt to 126
± 24 Nm.
8. Torque UCA-knuckle bolt to 126
± 24 Nm.
NOTE: Torquing of bolts should be done with the
vehicle at ride height.
1.
FPV Vehicles
Adjust Camber on UCA-knuckle as required
Item
Description
connection prior to the torque of the Cam bolt.
1
Upper Control Arm Nut and Bolt
For more information, see Section 204-00.
2
Axle Pac Nut
9. Secure wheel/hub to prevent halfshaft rotation
3
Rear Lower Control Arm Nut and Bolt
when torquing axle nut.
4
Lower Shock Absorber Bolt
10. Torque axle nuts to 325
± 25 Nm.
5
Front Lower Control Arm Nut and Bolt
11. Fit ABS sensor. See Section 206-09.
13. Remove knuckle from halfshaft in a horizontal
12. Fit abutment brackets.
direction.
13. Attach park brake cable to Banksia lever on
NOTE: Knuckles must be removed in a direction
knuckle.
parallel to the halfshafts to avoid damage to the
teeth on the halfshaft and knuckle splines.
NOTE: After removal of knuckle(s), the
suspension may be extended from ride height, to
allow springs to extend to uncompressed height.
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