Ford Falcon. Manual - part 30

204-02a-11 

Rear Suspension — IRS 

204-02a-11

REMOVAL AND INSTALLATION (Continued)

7.  Loosen bolts connecting Stabiliser Bar brackets to 11. Lower jack slowly and rotate RLCA downwards.

Subframe.

12. Remove spring and Spring Insulators when spring

8.  Rotate stabiliser bar away from RLCA, and

becomes fully extended.

towards Control Blade.

 CAUTION: Springs have high spring rate

9.  Unclip park brake cable from RLCA park brake

and extreme care should be taken when

cable bracket.

releasing jack.
NOTE: Wheel-ends must be supported at the

knuckle in the two indicated positions so that

halfshafts are not over-articulated.

13.  Remove RLCA Cam bolt assembly.

10. Loosen RLCA Cam bolt assembly at subframe

attachment.

14. Slide RLCA downward from vehicle.

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204-02a-12 

Rear Suspension — IRS 

204-02a-12

REMOVAL AND INSTALLATION (Continued)

6.  Locate and loosely fit RLCA-knuckle bolt. Ensure

Installation

bolt head faces the front of the module, and that

1.  Ensure that park brake cable and stabiliser bar

the nut is fully closed over the bolt shank.

links are positioned away from the RLCA position

within module.

2.  Locate RLCA and locate RLCA cam bolt

assembly through RLCA bush and subframe.

7.  Attach Control Blade to knuckle using new Control

Blade-knuckle bolts.
NOTE: Replace Control Blade-Knuckle bolts as

they are a 1 use only item.

3.  Position upper spring insulator and spring into

position on subframe. Position lower spring

insulator onto RLCA.

4.  While holding spring and insulators in position,

rotate RLCA upward into position.

8.  Torque RLCA-knuckle bolt to 140

±28Nm.

9.  Torque Control Blade-Knuckle bolts to 88

±17Nm.

10. Adjust RLCA Cam bolt as necessary (see below)

and torque to 105 

± 15 Nm.

5.  Insert jack underneath RLCAs. Extend jack so

11. Clip park brake cable into RLCA cable bracket.

that spring is compressed and return the

halfshafts to a horizontal position.

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204-02a-13 

Rear Suspension — IRS 

204-02a-13

REMOVAL AND INSTALLATION (Continued)

12. Rotate stabiliser bar and insert stabiliser bar links

into RLCA. Complete stabiliser bar assembly as

detailed later in this section.

6.  Lower transmission jack from ride height so that

springs are fully extended. Support wheel-ends at

the knuckle in the two indicated positions so that

13. Attach wheels and lowere vehicle.

halfshafts are not over-articulated.

Knuckle

Removal
1.  Secure wheel/hub to prevent halfshaft rotation

loosen axle pac nuts from halfshafts.
NOTE: Pac nuts are substantially torqued.

2.  Hoist vehicle with wheels fully supported. Refer to

Section 100-02.

3.  Set vehicle to ride height (Refer to Section

204-00) and remove rear wheels.

4. Unbolt 

ABS 

sensor.

5.  Disconnect Control Blade and remove from

Knuckle.

7.  Release park brake. Disconnect park brake cable

from knuckle mount.

Item

Description

1

Hand Brake Cable

2

Retaining Spring Clip

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204-02a-14 

Rear Suspension — IRS 

204-02a-14

REMOVAL AND INSTALLATION (Continued)

8.  Detach abutment brackets from knuckle. Refer

However, halfshafts and control arms must be

later in this section.

adequately supported so that they remain

horizontal.

9.  Detach caliper and rotor. Refer to Section 206-00.
10. Disconnect shock absorbers from knuckle.

Installation

11. Loosen and remove UCA-knuckle nut,

1.  Set the suspension to ride height. Refer to

FLCA-knuckle nut, and RLCA-knuckle nut.

Section 204-00.

 1. 

FPV Vehicles

2.  Position knuckle assembly over halfshaft (with

Loosen nut from UCA to knuckle and remove

halfshaft supported horizontally). Replace axle

Cam bolt and washer. FLCA-knuckle and

pac nut and torque to 50Nm.

RLCA-knuckle connections are as for the

3.  Locate FLCA to knuckle using FLCA-knuckle bolt

standard IRS module.

and nut.

12. Remove axle pac nut, UCA-knuckle bolt,

4.  a) Locate UCA to knuckle using UCA-knuckle bolt

FLCA-knuckle bolt and RLCA-knuckle bolt.

and nut.

b) Insert Cam bolt into Cam slot on FPV knuckle.

5.  Locate RLCA to knuckle using RLCA-knuckle bolt

and nut.
NOTE: This may require the adjustment of the

spring height, via the jack attached to the RLCA,

in order to position the RLCA groove over the

knuckle.

6.  Torque RLCA-knuckle nut to 140 

± 28 Nm.

7.  Torque FLCA-knuckle bolt to 126 

± 24 Nm.

8.  Torque UCA-knuckle bolt to 126 

± 24 Nm.

NOTE: Torquing of bolts should be done with the

vehicle at ride height.

 1. 

FPV Vehicles

Adjust Camber on UCA-knuckle as required

Item

Description

connection prior to the torque of the Cam bolt.

1

Upper Control Arm Nut and Bolt

For more information, see Section 204-00.

2

Axle Pac Nut

9.  Secure wheel/hub to prevent halfshaft rotation

3

Rear Lower Control Arm Nut and Bolt

when torquing axle nut.

4

Lower Shock Absorber Bolt

10. Torque axle nuts to 325 

± 25 Nm.

5

Front Lower Control Arm Nut and Bolt

11. Fit ABS sensor. See Section 206-09.

13. Remove knuckle from halfshaft in a horizontal

12. Fit abutment brackets.

direction.

13. Attach park brake cable to Banksia lever on

NOTE: Knuckles must be removed in a direction

knuckle.

parallel to the halfshafts to avoid damage to the

teeth on the halfshaft and knuckle splines.
NOTE: After removal of knuckle(s), the

suspension may be extended from ride height, to

allow springs to extend to uncompressed height.

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