Ford Falcon. Manual - part 25

204-01-7 Front 

Suspension 204-01-7

REMOVAL AND INSTALLATION (Continued)

3.  Attach the ball joint to the spindle, tighten the

2.  Using a hydraulic press with two tonne approx.

clamp joint. Remove the spindle tie.

force push out ball joint using tool 204-229-2,

small diameter down.

4.  Install the wheel and lower the vehicle.
5.  With the vehicle at curb attitude tighten the

spindle pivot bolts to specification.

Item

Description

1

Arm Assy Frt Susp Upper

2

Receiver  Bolt

3

Spindle Assy

4

Nut

Upper Control Arm Ball Joint

Special Tools

204-229

Item

Description

1

204-229-Item 2

2

Ball Joint

3

204-229-Item 1 Receiver

4

Upper Control Arm

Removal
NOTE: Eye protection must be worn during the

Installation

following procedures.

1.  Remove rubber boot from the new ball joint,

ensuring not to damage the boot or retainer ring

1.  Place receiver 204-229-Item 1 large diameter

clip.

facing up, under upper arm casting.

2.  Position ball joint over control arm.
3.  Place receiver 204-229-Item 1, small end up,

under upper arm casting.

4.  Using a hydraulic press push ball joint home with

tool 204-229-Item 2 large end facing down.

G48695 en

204-01-8 Front 

Suspension 204-01-8

REMOVAL AND INSTALLATION (Continued)

5.  Reinstall protective rubber boot and retainer ring

3.  Fit the bolt and nut securing the shock absorber

clip.

to the lower arm.

4.  Fit the upper ball joint stud to the spindle and fit

the clamp bolt and nut.

5.  Fit the insulators and brackets supporting the

stabilizer bar to the siderails ensuring that the bar

is cenrally located.

6.  Attach the ends of the bar links, ensuring that the

insulators are correctly positioned.

7.  Fit the wheel and lower the vehicle.

Item

Description

1

204-229-Item 2

2

Upper Control Arm

3

204-229-Item 1 Receiver

4

Ball Joint with Boot Removed

Stabilizer Bar

Stabilizer Bar Centre Bushing (Front

Removal

or Rear Bar)

1.  Raise the vehicle supporting the body by the

side-rails.

Removal

2.  Disconnect the stabilizer bar from each link.

NOTE: Damage to suspension and/or steering

Remove the retaining brackets.

components may occur if care is not exercised when

positioning hoist adaptors or jacks when lifting the

3.  Remove the wheel and disconnect the upper ball

vehicle. Do not allow contact with the steering linkage.

joint stud from the spindle.

4.  Remove the shock absorber lower bolt.

1.  Raise the vehicle on a hoist positioning the

suspension in the curb load position.

5.  Move the shock absorber to allow the end of the

stabilizer bar to be brought rearwards past it.

2.  Remove the hardware and brackets attaching the

centre section of the stabilizer bar.

6.  Remove the stabilizer bar.

3.  Remove the insulators from the bar.

Installation

Installation

1.  Place one end of the bar into position.

1.  Position the insulators on the front bar. Position

2.  Move the other side shock absorber to allow that

the insulator on the rear bar.

end of the bar to be brought into position in front

of the shock absorber.

G48695 en

204-01-9 Front 

Suspension 204-01-9

REMOVAL AND INSTALLATION (Continued)

2.  Ensure that the links on each end of the bar are

Scenario 1-Replacement of small bush only

located at approximately the same angle relative

1.  Clamp lower control arm in vice using soft jaws

to the centre line of the vehicle and install the

with both bushes at top.

attaching brackets.

2.  Apply a graphite grease to forcing screw thread

3.  Lower the vehicle.

before usage.

Stabilizer Bar Link Bushing

3.  Screw the holding nut fully onto the forcing screw

204- 230-Item 5.

Removal
1.  Raise the vehicle on a hoist positioning the

suspension in the curb load position.

2.  Remove the nut, washers, spacer, insulators and

link bolt attaching the ends of the stabilizer bar.

Item

Description

1

Locating collar 204-230-Item 8

2

204-230-Item 9

3

Forcing screw 204-230-Item 5

Installation

4

Holding Nut

1.  Install the bolt, washers, insulators, spacer and

5

204-230-Item 10 Orient anvil so stamping

nut as illustrated. Ensure that the insulators are

is to top (this positions eccentric hole)

correctly located in the respective mounting holes.

4.  Slide large bush anvil 204-230-Item 10 onto the

2.  Lower the vehicle.

threaded end of forcing screw.

5.  Orient large bush anvil so part no stamping is on

Lower Arm Bushing

top.

Special Tools

6.  Position assembly over the inside end of large

bush.

204-230

7.  Place locating collar 204-230-Item 8 over

assembly.

8.  Place small hole in small bush tool 204-230-Item

9 over forcing screw spigot.

9.  Slide locating collar over small bush tool

204-230-Item 9 to prevent assembly slipping

during use.

Removal

10. Screw out holding nut to remove slack.

NOTE: Three scenarios exist for the replacement of

11. With suitable spanners, clamp holding nut and

lower control arm bushes. They are:

turn forcing screw using its hexagonal section

scenario 1 - replacement of the small bush only,

until small bush is removed.

scenario 2 - replacement of the large bush only,

NOTE: Beware, the unit will collapse as the bush

is removed.

scenario 3 - replacement of both bushes.

Refer to the applicable scenario numbers.

Removal
Scenario 2-Replacement of large bush only

Scenario 1 - Replacement of small bush only

NOTE: If both bushes are to be removed then remove 1.  Apply a graphite grease to Forcing Screw thread

small bush first.

before usage.

G48699 en

204-01-10 Front 

Suspension 204-01-10

REMOVAL AND INSTALLATION (Continued)

2.  Screw the Holding Nut fully on to the Forcing

Scenario 3-Replacement of both large and small

Screw (204-230-Item 5).

bushes

1.  First follow procedure to remove small bush.
2.  Slide Small Bush Anvil (204-230-Item 3) on the

threaded end of Forcing Screw (204-230-Item 5).

3.  Slide Small Bush Anvil (204-230-Item 3) on the

threaded end of Forcing Screw.

4.  Orient eccentric hole in Small Bush Anvil so part

stamping ‘UP’ is on Top.

3.  Place narrow end of Small Bush Anvil Locator

5.  Position assembly over the inside end of Small

(204-230-Item 4) in to empty small bush socket.

Bush.

4.  Orient Small Bush Anvil so stamping ‘UP’ is on

6.  Place Locating Collar (204-230-Item 1) over

Top.

assembly.

5.  Position assembly over the exposed end of Small

7.  Place small hole in Large Bush Tool

Bush Anvil Locator.

(204-230-Item 2) over Forcing Screw spigot.

6.  Place Locating Collar (204-230-Item 1) over

assembly.

7.  Place small hole in Large Bush Tool

(204-230-Item 2) over Forcing Screw spigot.

Item

Description

1

Locating collar 204-230-Item 1

2

204-230-Item 2

3

Forcing screw 204-230-Item 5

Item

Description

4

Holding Nut

1

Locating collar 204-230-Item 1

5

204-230-Item 3 Orient anvil so stamping is

2

204-230-Item 2

to top (this positions eccentric hole)

3

Forcing screw 204-230-Item 5

8.  Slide Locating Collar over Large Bush Tool to

4

Holding Nut

prevent assembly slipping during use.

5

204-230-Item 3 Orient anvil so stamping is

9.  With suitable spanners, clamp Holding Nut and

to top (this positions eccentric hole)

turn Forcing Screw using its hexagonal section

8.  Slide Locating Collar over Large Bush Tool to

until large bush is removed.

prevent assembly slipping during use.

Removal

9.  With suitable spanners, clamp Holding Nut and

NOTE: If both bushes are to be removed then remove

turn Forcing Screw using its hexagonal section

small bush first.

until large bush is removed.

G48699 en