Ford Falcon. Manual — part 31

204-02a-15

Rear Suspension — IRS

204-02a-15

REMOVAL AND INSTALLATION (Continued)

14. Fit Control Blade to knuckle.

3. Remove park brake cable bracket by squeezing

the wire ends together using wide-grip pliers or

equivalent.

15. Replace wheels. Release jack supporting the

suspension and slowly lower vehicle weight onto

the wheels.

Installation
1. Attach park brake cable bracket to RLCA by

Rear Lower Control Arm (RLCA) park

squeezing ends together and inserting into two

brake cable bracket

holes on the RLCA.

Removal
1. Hoist vehicle (Refer to section 100-02) to obtain

access to IRS module.

2. Unhook park brake cable from RLCA cable

bracket.

2. Clip park brake cable onto RLCA bracket.

3. Ensure that park brake cable is fitted correctly to

all attachment points as given in park brake cable

procedure.

Abutment bracket

Removal
1. Release park brake.

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204-02a-16

Rear Suspension — IRS

204-02a-16

REMOVAL AND INSTALLATION (Continued)

2. Hoist vehicle and remove rear wheels. See

Installation

Section 100-02.

1. Locate abutment brackets with two abutment

3. Disconnect abutment bracket v-clip.

bracket-knuckle bolts per side.

4. Disconnect park brake cable from attachment

point on knuckle and feed cable through abutment

bracket.

2. Torque bolts to 25

± 5 Nm.

3. Locate park brake cable through abutment

bracket and attach to Banksia lever on inside of

knuckle assembly.

Item

Description

1

Hand Brake Cable

2

Retaining Spring Clip

5. Loosen abutment bracket-knuckle bolts - 2 per

side.

6. Remove bolts and release abutment brackets.

Item

Description

1

Hand Brake Cable

2

Retaining Spring Clip

4. Attach park brake cable to abutment bracket

using v-clips.

5. Ensure park brake cable routing and adjust park

brake cable as required. See Section 206-05.

Control Blade

Removal
1. Hoist vehicle so that the wheels are fully

supported. See Section 100-02.

2. Set vehicle to design height. For more

information, see Section 204-00.

3. Remove rear wheels.

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204-02a-17

Rear Suspension — IRS

204-02a-17

REMOVAL AND INSTALLATION (Continued)

4. a) Detach ABS cable from attachment point

Installation

beneath the rear seat.

1. Set vehicle to ride height. See Section 204-00.

b) Remove both ferntree clips from the control

2. Locate knuckle support arm to knuckle with 3

blade.

bolts each side.

c) Feed the ABS cable through the hole in the

NOTE: The flanges of the knuckle support arms

control blade.

face inwards on the vehicle.

3. Fit knuckle support arm-chassis mounting bolts.

NOTE: The transmission jack used to set design

height may require adjustment to correctly align

the knuckle support arm with the chassis

mounting points.

4. Torque knuckle support arm-knuckle bolts to

between 85-100Nm and torque knuckle support

arm-chassis mounting bolts.

5. Feed ABS cable through hole in knuckle support

arm. Attach ferntree clip to ABS cable and clip to

knuckle support arm. Connect ABS cable to

attachment point at front of knuckle support arm.

Refer to Section 206-09.

5. Disconnect Control Blade from chassis mounts.

Shock Absorber

6. Hoist vehicle and remove rear wheels. Allow

spring to extend to uncompressed length and

Removal

support wheel ends at this length.

1. Disconnect brake hose from support bracket.

7. Disconnect control blade from chassis mounting

2. With the vehicle on the ground, remove the upper

points.

shock absorber bolt by gaining access through

the wheel arch gap directly above the rear tyre.

3. Hoist vehicle slowly. Refer to Section 100-02.

Shock absorber will drop with the lower control

arm. Watch for spring dislodgment.

4. Remove lower shock absorber attachment bolt.
5. Maneuver the shock absorber from the vehicle.

WARNING: Never attempt to remove the

shock absorber from the fully installed

position by removing the upper or lower bolts

when the vehicle is raised on a hoist. This

may cause the wheel to drop suddenly

resulting injury.

Installation

8. Disconnect Control Blade from knuckle by

loosening and removing knuckle support

1. Install the shock absorber to the vehicle and

arm-knuckle bolts - 3 per side.

loosely install the lower mounting bolt.

2. Begin to lower the vehicle from hoist, stopping the

hoist and guiding the upper shock absorber into

the upper bracket where necessary. Do not guide

the shock absorber whilst the hoist is in operation.

Ensure rear spring is not dislodged. Lower the

hoist until the shock absorber upper mount is

aligned with the bracket hole.

3. Install the upper shock absorber bolt. Lower the

vehicle completely (if not already) and tighten

both the upper and lower bolts to the specified

torque.

4. Reconnect the brake hose to bracket.

NOTE: Shock absorber hand tests are detailed in

section Section 204-00.

9. Remove knuckle support arm.

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204-02a-18

Rear Suspension — IRS

204-02a-18

REMOVAL AND INSTALLATION (Continued)

5. Remove links from RLCA and rotate stabiliser bar

Spring and Upper Spring Insulator

towards the front of the vehicle.

Removal
1. Hoist vehicle, remove rear wheels and set

suspension to ride height. For further information,

see Section 204-00.

2. Disconnect park brake cable from knuckle.

Item

Description

1

Hand Brake Cable

2

Retaining Spring Clip

3. Unclip cable from RLCA cable clips.

6. Loosen RLCA-knuckle nuts and remove

RLCA-knuckle bolts.

4. Loosen and remove stabiliser bar link nuts and

washers.

7. Loosen RLCA-subframe nut.

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