Ford Falcon. Manual — part 35

204-02b-1

Rear Suspension — Beam Axle

204-02b-1

SECTION : 204-02b Rear Suspension — Beam Axle

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...204-02b-2

DESCRIPTION AND OPERATION

Rear Suspension — Beam Axle . . . . . . . . . . . . . . . . . . . . . . ..204-02b-3

Ute & Wagon Rear Suspension . . . . . . . . . . . . . . . . . . . . . . .204-02b-3

Shock

Absorbers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-02b-4

DIAGNOSIS AND TESTING

Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-02b-5

GENERAL PROCEDURES

Ride Height Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .204-02b-6

Wheel Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-02b-6

Hoisting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .204-02b-6

REMOVAL AND INSTALLATION

Shock Absorber — Ute/Wagon . . . . . . . . . . . . . . . . . . . . . . . 204-02b-7

Leaf Spring — Ute/Wagon . . . . . . . . . . . . . . . . . . . . . . . . ...204-02b-7

Leaf Spring Front Eye Bushing — Ute . . . . . . . . . . . . . . . . . . . . 204-02b-7

Leaf Spring Front Eye Bushing — Wagon . . . . . . . . . . . . . . . . . . ...204-02b-7

204-02b-2

Rear Suspension — Beam Axle

204-02b-2

SPECIFICATIONS

Torque Specifications

Description

Nm

Rear Hanger Bracket to Body

50

Spring Shackle to Rear hanger and

120

Spring
Rear Shock Absorber to Upper

70

Mounting Bracket
Rear Shock Absorber Upper Mounting

35

Bracket to Body
Rear Shock Absorber to Rear Spring

40

Plate
Rear Spring to Rear Axle U-bolt, Nut

60

Wheel Nut

125

Rear Spring to Rear Spring Front

105

Hanger

G478919 en

204-02b-3

Rear Suspension — Beam Axle

204-02b-3

DESCRIPTION AND OPERATION

spring is suspended from the underbody side rail by a

Rear Suspension — Beam Axle

hanger at the front and shackle at the rear. The upper

end of each shock absorber is mounted to a bracket

Ute & Wagon Rear Suspension

in the underbody. The lower end is mounted to the

3/4 tonne & 1/2 tonne (Sports suspension)

spring clip plate.

Ute and Wagon

The springs and shock absorbers control the up and

down movement of the rear axle and wheels as

Two spring pads integral with the axle housing rest on

required by changes in the road surface. They also

a spring plate and rubber insulator. These are located

cushion road shocks.

on two leaf-type springs. The axle housing is fastened

to the springs by U-bolts, spring plates and nuts. Each

Item

Description

Item

Description

15

Shock absorber

1

Nut (Wagon only)

16

Shock absorber bracket

2

Nut

17

Plate assy. RR Spring

3

Bump stop

18

Nut

4

Bolt

19

Nut

5

U bolt

20

Insulator

6

Nut

21

Nut

7

Bushing

22

Leaf spring

8

Bushing

23

Bolt Hex HD Washer ½ 13x6

9

Rear spring bracket hanger

24

Insulator

10

Nut

25

Retaining bracket

11

Shackle

26

Bolt (Wagon only)

12

Bolt

27

Pinion nose bump stop (Wagon only)

13

Bolt

14

Bolt

G478920 en

204-02b-4

Rear Suspension — Beam Axle

204-02b-4

DESCRIPTION AND OPERATION (Continued)

1 Tonne Ute

The rear suspension layout differs from, 3/4 tonne &

1/2 tonne (Sports suspension) ute only by the deletion

of the rubber insulator between the spring pads and

the spring plate.

Item

Description

Item

Description

18

Bolt

1

Nut

19

Bolt

2

Bump stop

20

Bush

3

Bolt

21

Leaf Spring eye

4

U bolt

22

Leaf spring bushing

5

Nut

23

Nut

6

Bushing

24

Bush

7

Bushing

25

Nut

8

Rear spring bracket hanger

9

Nut

Shock Absorbers

10

Shackle

All vehicles are equipped with hydraulic gas

11

Bolt

pressurised shock absorbers of the direct-acting type

12

Bolt

and are non-adjustable and non-refillable, and cannot

be repaired.

13

Bolt

14

Shock absorber

WARNING: Under no circumstances should

15

Shock absorber bracket

the shock absorbers be pierced or heated.

16

Plate assy. RR Spring

Before replacing a shock absorber, check the action

17

Nut

of the shock absorbers.

G478920 en