Ford Falcon. Manual - part 36

204-02b-5 

Rear Suspension — Beam Axle 

204-02b-5

DIAGNOSIS AND TESTING

Rear Suspension

Refer to, Section 204-00.

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204-02b-6 

Rear Suspension — Beam Axle 

204-02b-6

GENERAL PROCEDURES

Ride Height Procedure

Loading Reqirements

1.  Full tank of fuel.
2.  Cooling system filled.
3.  Crankcase oil at full.
4.  Spare wheel and tyre stowed in design position.
5.  Front seat one notch forward from rearmost

position.

Measuring Procedure

1.  Position vehicle on level surface as loaded above.
2.  Bounce the front and rear of the vehicle up and

down approximately 50 mm in each direction.

3.  With the parking brake disengaged, push the

vehicle rear end at the centre of the rear bumper

evenly down, approximately 25 mm, and release

slowly.

4.  With appropriate instruments measure from the

fender opening eyebrow to the wheel centreline

on both sides and record these measurements.

5.  Raise the vehicle rear end at the centre of the

rear bumper evenly, approximately 25 mm, and

release slowly.

6.  Repeat item 4.
7.  Average the above measurements for each side

and record as rear ride heights left and right.

NOTE: Ride height specifications for coil springs are

base on springs that have settled in operation. When

are fitted a further 6 mm for coil springs and 15 mm

for leaf springs may be added to the maximum

allowable height. Ride height is also dependent on the

options fitted to a base vehicle and the quantity of fuel

carried.

Wheel Balancing

NOTE: Refer to the instructions provided with the

Wheel Balancer.

Hoisting Instructions

NOTE: Damage to suspension and/or steering

components may occur if care is not exercised when

positioning hoist adaptors or jacks when lifting the

vehicle. Do not allow contact with the steering linkage.

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204-02b-7 

Rear Suspension — Beam Axle 

204-02b-7

REMOVAL AND INSTALLATION

2.  Position the upper insulator pad and the bracket

Shock Absorber — Ute/Wagon

to the spring. Lift the rear end of the spring, locate

the insulator bracket to the rear axle and install

Removal

the bushings and the shackle plate and pin

1.  Raise the vehicle on a hoist supporting it under

assemblies. Install the nuts finger tight.

the body side-rails. Position a jack under the axle

3.  Position the lower insulator pad to the spring and

to ensure that the axle breather hose and the

the upper insulator bracket.

brake hose are not stretched.

4.  Install the U-bolts, spring plate and the attaching

2.  Remove the nut securing the shock absorber

nuts.

lower mounting to the U-bolt plate and disconnect

this lower mounting.

5.  Place stands beneath the rear axle and lower the

vehicle to the curb load position.

3.  Remove the bolt from the shock absorber upper

mounting, and rotate the shock absorber and

6.  Install the lower shock absorber mounting.

remove.

7.  Tighten the front hanger and the rear shackle lock

Installation

nuts.

1.  With the vehicle raised and supported under the

8.  Where the RH spring has been removed attach

body rails, fit the shock absorber and upper

the exhaust system.

mounting bolt.

9.  Remove the stand and lower the vehicle.

2.  Fit the shock absorber lower mounting stud to the

U-bolt plate.

Leaf Spring Front Eye Bushing — Ute

3.  Lower the vehicle to the ground and torque the

Removal

hardware to specification.

1.  Remove the spring as previously described.

Leaf Spring — Ute/Wagon

2.  Using suitable adaptors press the old bush from

the spring eye.

Removal

3.  Press the new bush into the spring eye.

1.  Raise the vehicle on an underbody support hoist.

4.  Install the spring as previously described.

2.  Place a stand beneath the rear axle and lower the

hoist sufficient to remove the weight of the rear

axle from the shock absorber. Disconnect the

lower end of the shock absorber from the spring

plate, and push the shock absorber clear of the

work area.

3.  Raise the hoist and support the rear axle on the

stand.

4.  Remove the nuts from the U-bolts: then, remove

the plate and insulator (where fitted).

5.  Remove the nut from the front hanger bolt.
6.  Remove the nuts, the rear shackle plate and pin

assemblies and the shackle bushings. Lower the

rear end of the spring.

7.  Remove the upper insulator and spring plate from Installation

the spring.

1.  Install by reverse procedure.

8.  When removing the RH side spring detach the 2

NOTE: Torque nuts to specification with the

rear exhaust system supports and lower the

suspension in curb load position.

muffler to enable the front hanger bolt to be

2.  Where necessary attach exhaust system.

removed.

3. Lower 

vehicle.

9.  Remove the front hanger bolt and remove the rear

spring.

Leaf Spring Front Eye Bushing —

Installation

Wagon

1.  Position the spring front eye in the front hanger

and (from the inboard side) insert the bolt through Removal

the hanger and the bushing. Install the lock nut on 1.  Remove the spring as previously described.

the bolt and tighten finger tight.

2.  Using suitable adaptors press the old bush from

the spring eye.

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204-02b-8 

Rear Suspension — Beam Axle 

204-02b-8

REMOVAL AND INSTALLATION (Continued)

3.  Press the new bush into the spring eye.

NOTE: The bush must be installed with the void

toward the front of the spring and flange at the

inboard side of the spring.

4.  Install the spring as previously described.

Installation
1.  Install by reverse procedure.

NOTE: Torque nuts to specification with the

suspension in curb load position.

2.  Where necessary attach exhaust system.
3. Lower 

vehicle.

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