Ford Falcon. Manual — part 32

204-02a-19

Rear Suspension — IRS

204-02a-19

REMOVAL AND INSTALLATION (Continued)

8. By slowly extending the transmission jack, lower

3. Connect RLCA to knuckle by loosely fitting bolt

the RLCA to extend the spring.

and nut.
NOTE: Ensure bolt head faces front of vehicle.

9. Remove spring and insulators as necessary.
Installation

4. Torque RLCA to knuckle to 140Nm.

1. With vehicle hoisted and RLCA-subframe

5. Rotate stabiliser bar links through RLCAs and

connection loose, insert spring insulators and

attach nut and washer. Torque nut to 15-20Nm.

spring.
NOTE: The flat end of spring faces the subframe

and the curved end of the spring faces the RLCA.

2. Insert transmission jack underneath RLCAs.

Extend jack to slowly compress spring and return

suspension to design height.

6. Adjust RLCA-subframe cam bolt as required. See

Section 204-00.

7. Attach wheels to knuckles. Lower jack under

RLCAs while returning the vehicle weight to its

own wheels.

CAUTION: Ensure that the vehicle is well

supported on its own wheels before

completely removing the jack.

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204-02a-20

Rear Suspension — IRS

204-02a-20

REMOVAL AND INSTALLATION (Continued)

5. Undo stabiliser bar link-RLCA nuts and

Stabiliser bar

disconnect stab bar.

6. Unclip stabiliser bar bushes from the stabiliser

Item

Description

bar.

1

Stabiliser Bar Link Insulator

7. Undo bolt/nut from stabiliser bar link to stabiliser

bar.

2

Drop Link

8. Remove

link.

3

Stabiliser Bar Lower Bolt

Installation

4

Stabiliser Bar

1. Locate stabiliser bar link to stabiliser bar.

5

Stabiliser Bar Insulator

Stabiliser bar links should be positioned on the

6

Stabiliser Bar Mounting Bracket

outside of the stabiliser bar.

7

M8 Screw - Stabiliser Bar Bracket to

2. Connect bolt/nut from stabiliser bar link to

Subframe

stabiliser bar loosely.

8

M10 - Stabiliser Bar Lower Attachment

3. Locate stabiliser bar bushes to stabiliser bar.

9

Stabiliser Bar Bush

4. Locate stabiliser bar links through insulators on

Removal

RLCAs. Affix stabiliser bar to RLCAs by loosely

fitting stabiliser bar link-RLCA nut/washer.

1. Hoist vehicle and remove rear wheels.

NOTE: Support knuckles to ensure halfshafts are

not over-articulated.

2. Loosen stabiliser bar link-RLCA nuts.
3. Loosen stabiliser bar bracket bolts and remove

from the subframe.

4. Remove stabiliser bar bush brackets.

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204-02a-21

Rear Suspension — IRS

204-02a-21

REMOVAL AND INSTALLATION (Continued)

5. Locate stabiliser bar bush brackets to stabiliser

3. Loosen bolts connecting stabiliser bar brackets to

bar bushes. Locate the stabiliser bar brackets to

subframe.

the subframe using bracket-subframe bolts.

4. Rotate stabiliser bar and links away from RLCA

6. Torque stabiliser bar bush brackets to subframe

towards knuckle support arms.

to between 20Nm and 30Nm.

5. Reach into rear of module over the top of RLCA.

7. Torque stabiliser bar link to RLCA to between

Remove stabiliser bar insulator.

20Nm and 30Nm.

8. Torque stabiliser bar link bolt to stabiliser bar.

NOTE: Module should be supported on its own

wheels with halfshafts horizontal before torquing

stabiliser bar links.

Upper Stabiliser Bar Insulator

Removal
1. Hoist vehicle and set to ride height. For more

information, see Section 204-00.

2. Disconnect stabiliser bar links by removing

nut/washer connecting link to RLCA.

Installation
1. Locate and fit upper stabiliser bar insulator by

compressing the insulator with a screwdriver and

using a twisting motion.
NOTE: Two grooved steps of the stabiliser bar

insulator should be inserted into the RLCA.

2. Rotate stabiliser bar and insert stabiliser bar links

into RLCA. Complete stabiliser bar assembly as

detailed in stabiliser bar installation procedure.

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204-02a-22

Rear Suspension — IRS

204-02a-22

REMOVAL AND INSTALLATION (Continued)

2. Torque subframe-body brace nut to 50

± 9.5 Nm.

Jounce Bumper

3. Torque chassis-body brace bolt to 50

± 9.5 Nm.

Removal
1. Hoist vehicle so that access is available to the

suspension module.
NOTE: The vehicle should be supported on its

wheels so that the halfshafts remain horizontal

(i.e. design height). Unclip jounce bumper from

upper subframe.

Installation
1. With vehicle hoisted, locate jounce bumper and

plug on subframe above RLCA.

Body Brace

Removal
1. Loosen subframe-body brace bolt.
2. Loosen chassis-body brace connection.
3. Remove subframe-body brace and chassis-body

brace bolts. Disconnect body brace.

Installation
1. Locate body brace to subframe and chassis using

respective bolts. Body brace should be fixed so

that standard hole is fitted to the module subframe

and the slotted hole is fitted to vehicle chassis.
NOTE: Body brace should be oriented with

flanged ends higher than the middle section of the

body brace.

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