Ford Falcon. Manual — part 21

100-04-56

Noise, Vibration and Harshness

100-04-56

GENERAL PROCEDURES (Continued)

6. Tighten all the exhaust hanger clamps and

3. Grip each front tyre at the top and bottom and

flanges (tighten the exhaust manifold flange joint

move the wheel inward and outward while lifting

last).

the weight of the tyre off the front wheel bearing.

Verify there is adequate clearance to prevent

grounding at any point in the system. Make

sure that the catalytic converter and heat

shield do not contact the frame rails.
After neutralization, the rubber in the exhaust

hangers should show some flexibility when

movement is applied to the exhaust system.
With the exhaust system installed securely

and cooled, the rear hanger should be angled

forward.

7. Lower the vehicle.
8. Test the exhaust system for normal operation.

Wheel Bearing Check

4. If the tyre and wheel (hub) is loose on the spindle,

1. Raise the vehicle until the front tyres are off the

does not rotate freely, or has a rough feeling

floor.

when spun, install a new wheel hub.

Make sure the wheels are in a straight

forward position.

2. Spin the tyre by hand to check the wheel bearings

for roughness.
NOTE: Make sure the wheel rotates freely and

that the brake pads are retraced sufficiently to

allow free movement of the tyre and wheel

assembly.

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204-00-1

Suspension System — General Information

204-00-1

SECTION : 204-00 Suspension System — General

Information

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

DESCRIPTION AND OPERATION

Suspension System — General Information . . . . . . . . . . . . . . . . . . ..204-00-2

Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 204-00-2

Rear Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . .204-00-4

DIAGNOSIS AND TESTING

Suspension System — General Information . . . . . . . . . . . . . . . . . . ..204-00-5

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...204-00-5

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-00-5

Shock

Absorbers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-00-8

GENERAL PROCEDURES

Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-00-9

Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . ..204-00-9

Toe & Steering Wheel Spoke Adjustments . . . . . . . . . . . . . . . . . . . 204-00-9

Front Wheel Lock Angle Adjustment . . . . . . . . . . . . . . . . . . . . . .204-00-9

Upper & Lower Ball Joint Inspection . . . . . . . . . . . . . . . . . . . . . ..204-00-9

XR Rear Camber Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 204-00-9

RLCA (Rear Lower Control Arm) to Subframe Cambolt Adjustment . . . . . . . . . .204-00-9

204-00-2

Suspension System — General Information

204-00-2

DESCRIPTION AND OPERATION

where necessary at kerb height.

Suspension System — General

Information

NOTE: When checking ute and wagon front caster it

is important that the rear ride height is correct. This

Front Wheel Alignment

can be achieved by ensuring the vehicle unladen.

Suggested method and sequence for checking

The following charts show wheel alignment data for

steering wander or drift

the various models.

1. Check and adjust tyre pressures to specification.

Toe settings are provided in degrees.

Make sure the vehicle is loaded evenly so ride

heights are relatively even side to side.

2. Check all wheel bearings, steering mechanisms

and suspension joints are to specification. Adjust,

repair or replace as required.

3. Check tyres for uneven wear patterns especially

the inner edges compared to the outer edges.

Rotate tyres front to rear if required.

4. Road test vehicle on a level road surface and

note direction and extent of steering pull or drift.

Ensure prevailing crosswinds are not a factor.

5. If pull of drift is confirmed check the wheel

alignment and confirm that the vehicle is within

specification.

Wheel Alignment Equipment/Maintenance
It is extremely important the wheel alignment

equipment used is periodically checked and

recalibrated to ensure vehicle readings are both

accurate and repeatable. Please consult your

equipment supplier for advice as to how and when the

periodic checking and recalibration should occur.

Regular checking and calibration of wheel alignment

equipment is essential with the current generation of

wheel alignment machines.

NOTE: See text for XR camber adjustment.

NOTE: Ute and Wagon rear alignment can not be

adjusted.

NOTE: Camber and castor figures will vary depending

on the vehicle ride height. The ride height will alter

depending on the how heavily the vehicle is loaded,

the way the load is distributed, the amount of fuel in

the tank and accessories fitted eg: bulbar. The lower

the vehicle the more negative the camber value

becomes and the more positive the castor value

becomes.

NOTE: Toe in is shown as a + (positive) value while

toe out is shown as a - (negative) value. It is

preferable to measure vehicles in degrees. Data is for

reference only.

NOTE: With correct tyre pressures the ride height is

measured vertically from the exact centre of the wheel

to the underside of the guard lip (refer figure).

Measure all four corners of the vehicle and locate the

appropriate ride height in the left hand column in both

table: 1 for front the suspension and table: 2 for the

rear suspension. Then select the appropriate

alignment values for each corner of the vehicle and

confirm if vehicle is within specification. Adjust toe

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204-00-3

Suspension System — General Information

204-00-3

DESCRIPTION AND OPERATION (Continued)

Front Wheel Alignment

Sedan / Wagon

Ride

Camber

Castor

Total Toe at kerb height

Height Min. ° Opt. ° Max. °

Max.

Min.

° Opt. ° Max. °

Max.

Min.

°

Opt.

° Max. °

Variation

°

Variation

350

-1.91

-1.41

-0.91

0.7

7

7.50

8

0.7

360

-1.66

-1.16

-0.66

0.7

6.9

7.40

7.9

0.7

370

-1.44

-0.94

-0.44

0.7

6.8

7.30

7.8

0.7

380

-1.23

-0.73

-0.23

0.7

6.69

7.19

7.69

0.7

-0.02

0.08

0.18

390

-1.07

-0.57

-0.07

0.7

6.59

7.09

7.59

0.7

400

-0.92

-0.42

-0.08

0.7

6.48

6.99

7.48

0.7

410

-0.81

-0.31

-0.19

0.7

6.38

6.88

7.38

0.7

420

-0.72

-0.22

-0.28

0.7

6.27

6.77

7.27

0.7

XR Sedan

Ride

Camber

Castor

Total Toe at kerb height

Height Min. ° Opt. ° Max. °

Max.

Min.

° Opt. ° Max. °

Max.

Min.

°

Opt.

° Max. °

Variation

°

Variation

340

-1.52

-1.02

-0.52

0.7

7.32

7.82

8.32

0.7

350

-1.22

-0.72

-0.22

0.7

7.21

7.71

8.21

0.7

360

-0.95

-0.45

0.05

0.7

7.10

7.60

8.10

0.7

370

-0.71

-0.21

0.29

0.7

6.99

7.49

7.99

0.7

0.06

0.16

0.26

380

-0.50

0.00

0.50

0.7

6.88

7.38

7.88

0.7

390

-0.33

0.17

0.67

0.7

6.77

7.27

7.77

0.7

400

-0.17

0.33

0.83

0.7

6.65

7.15

7.65

0.7

Ute

Ride

Camber

Castor

Total Toe at kerb height

Height Min. ° Opt. ° Max. °

Max.

Min.

° Opt. ° Max. °

Max.

Min.

°

Opt.

° Max. °

Variation

°

Variation

370

-1.24

-0.74

-0.24

0.7

6.81

7.31

7.81

0.7

380

-1.05

-0.55

-0.05

0.7

6.7

7.20

7.7

0.7

390

-0.88

-0.38

-0.12

0.7

6.59

7.09

7.59

0.7

-0.02

0.08

0.18

400

-0.73

-0.23

-0.27

0.7

6.48

7.99

7.48

0.7

410

-0.62

-0.12

-0.38

0.7

6.38

7.88

7.38

0.7

420

-0.54

-0.04

-0.46

0.7

6.27

6.77

7.27

0.7

XR Ute, XLS Ute with standard sports suspension

Ride

Camber

Castor

Total Toe at kerb height

Height Min. ° Opt. ° Max. °

Max.

Min.

° Opt. ° Max. °

Max.

Min.

°

Opt.

° Max. °

Variation

°

Variation

340

-1.92

-1.42

-0.92

0.7

5.70

6.20

6.70

0.7

350

-1.63

-1.13

-0.63

0.7

5.56

6.06

6.56

0.7

360

-1.37

-0.87

-0.37

0.7

5.43

5.93

6.43

0.7

370

-1.13

-0.63

-0.13

0.7

5.30

5.80

6.30

0.7

0.06

0.16

0.26

380

-0.93

-0.43

0.07

0.7

5.18

5.68

6.18

0.7

390

-0.76

-0.26

0.24

0.7

5.06

5.56

6.06

0.7

400

-0.61

-0.11

0.39

0.7

4.93

5.43

5.93

0.7

G22340 en