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Ford Falcon. Manual - part 99

211-04-8 Steering

Column 211-04-8

REMOVAL AND INSTALLATION (Continued)

6. Disconnect the 2 wire harnesses from the

9. Remove the four bolts retaining the alloy steering

clockspring.

column mounting bracket onto the instrument

panel, and completely remove the column from

the vehicle.
NOTE: The four bolts are retained in the alloy

mounting bracket using special fibre retaining

washers. Make sure all these washers are in

place before re-installing the steering column. If

one or more of the washers are missing, the alloy

mounting bracket may become distorted,

adversely affecting the column adjustment

mechanism and column break-away mechanism .

Delete all the washers from the installation if one

or more of the fibre washers are missing.

Installation
1. Before re-installing the steering column, check

that the front wheels are in the straight ahead

position.

2. Check that the clockspring has been centralized

on the steering column. See Section 211-04-13.

3. Fit the lower steering column shaft into the

connector tube on the floor plate. Loosely fit the

M8 flanged head bolt.

4. To align the alloy mounting bracket to the steering

column, close the adjustment lever so that the

clamping mechanism is just nipped up. The alloy

bracket should still be able to rotate by hand so

that it can align to the instrument panel. Secure

the four M8 mounting bracket bolts to the

instrument panel and torque to 18Nm.
NOTE: The four bolts are retained in the alloy

mounting bracket using special fibre retaining

Item

Description

washers. Make sure all these washers are in

Four mounting bolts. Torque to 18 Nm.

place before re-installing the steering column. If

Two clockspring connectors

one or more of the washers are missing, the alloy

mounting bracket may become distorted,

One release tab for lever lock connector

adversely affecting the column adjustment

Pull back safety clip before removing the

mechanism and column break-away mechanism .

aluminum shaft

Delete all the washers from the installation if one

Torque bolt to 25 Nm

or more of the fibre washers are missing.

Two release tabs for ignition wiring lever

5. Torque the M8 flanged head bolt in the lower

lock connector

steering column shaft to 25Nm.

7. Disconnect the ignition wire harness lever-lock

6. Connect the lever lock connectors for the multi

connector. The lever has two retaining tabs that

function switch, and ignition wiring.

keep the lever locked in place. These must be

7. Connect the two clockspring connectors.

disengaged before the lever can be rotated.

8. Refit the shrouds. See Section 211-04-5.

8. Disconnect the multi-function switch wire harness

9. Refit the steering wheel and Driver Air Bag. See

lever-lock connector. The lever has a single

Section 211-04-09 & Section 211-04-10.

retaining tab that keeps the lever locked in place.

This must be disengaged before the lever can be

10. Adjust the steering column through its full range to

rotated.

ensure the movement is smooth.

11. Re-connect the battery.

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211-04-9 Steering

Column 211-04-9

REMOVAL AND INSTALLATION (Continued)

2. In the driver’s foot well, remove the M8 flanged

Fixed Steering Column (Column Shift

head bolt that joins the steering column shaft to

automatic)

the floor plate connector tube. Carefully lift the

plastic safety clip and pull the steering shaft

Removal and Installation

rearwards out of the connector tube.

1. The removal and installation of the Column Shift

3. In the engine bay remove the three nuts securing

Automatic steering column is identical to the

the floor plate to the dash panel.

adjustable steering, but requires one additional

operation.

2. Put the gear shift lever into "Park". Underneath

the instrument panel on the LHS of the steering

column, is the cable that operates the automatic

transmission. Remove the cable end (ball socket)

from the steering column by levering it off with a

screwdriver.

Item

Description

Floor plate securing nut

Intermediate nut to steering rack nut

4. Remove the bolt that secures the lower end of the

intermediate shaft to the steering rack. Slide the

intermediate shaft rearwards to collapse it,

3. To assemble the cable end ball socket, pull it

removing the universal joint from the steering rack

rearwards onto the ball stud, which is fitted to the

input shaft.

steering column shift mechanism.

5. The intermediate shaft and floor plate assembly

can now be removed from the vehicle.

Floor Plate & Intermediate Shaft

CAUTION: Be carefull collapsing steering

NOTE: The apperance of the intermediate shaft in

shaft .

XR6 Turbo and XR8 will vary from that shown in that

Installation

the shaft will be fitted with a reflective sheath and in

that no ’bell’ will be fitted over the lower universal

1. Ensure that the front wheels and steering wheel

joint. Removal of this type of intermediate shaft is as

are in the straight ahead position.

described below with the exception that the body

2. Before installation of the floor plate assembly,

mounted intermediate shaft heat shield may need to

check that the rubber gasket face on the floor

be removed to obtain adequate access to the

plate, and the mating sealing surface on the dash

intermediate shaft.

panel are clean and dry. Ensure that the threads

of the three studs on the dash panel are clean,

Removal

and that the nuts are free running.

1. Ensure that the front wheels and steering wheel

3. Position the floor plate over the three studs of the

are in the straight ahead position. Tape the

dash panel, and loosely attach the three nuts.

steering wheel to the upper and lower shrouds so

that the steering wheel cannot be inadvertently

4. From the driver’s foot well, extend the steering

rotated during this procedure. This protects the

shaft by hand and guide it into the floor plate

clockspring from being over-wound at full left

connector tube. Install the M8 flanged head bolt

hand or right hand steering wheel lock.

shaft and torque to 25Nm.

A12348 en

211-04-10 Steering

Column 211-04-10

REMOVAL AND INSTALLATION (Continued)

5. Torque the three M6 nuts on the floor plate to

deformation. Install and correctly position the new

7Nm.

sensor or any other damaged supplemental

restraint system (SRS) components whether or

WARNING: Over torquing could result in

not the air bag is deployed.

the stud snapping off.

WARNING: To avoid accidental deployment

and possible personal injury, the backup power

supply must be depleted before repairing or

installing a new front or side supplemental

restraint system (SRS) components and before

repairing, installing new, adjusting or striking

components near the front or side air bag

sensors, such as doors, instrument panel,

console, door latches, strikers, seats and

hoodlatches.

Please refer to the appropriate workshop manual

to determine the location of the front air bag

sensors.

To deplete the backup power supply energy,

disconnect the battery ground cable and wait at

least one minute. Be sure to disconnect auxiliary

Item

Description

batteries and power supplies (if equipped).

Floor plate securing nut

Intermediate nut to steering rack nut

WARNING: The restraint system diagnostic

tool is for restraint system repair only. Remove

6. Slide the intermediate shaft lower universal joint

from vehicle prior to road use. Failure to remove

yoke onto the steering rack input shaft. Note that

could result in injury and possible violation of

the spline is keyed so that it can only be

vehicle safety standards.

assembled in one orientation.

1. Disconnect the battery. Wait at least one minute

7. Insert the M8 bolt into the yoke and torque to

to deplete the backup power supply energy.

22Nm.

2. Rotate the steering wheel 90

° from straight

Driver Air Bag

ahead, to access one of the Driver Air Bag

retaining screws on the front face of the steering

NOTE: Also refer to Section 501-20B.

wheel.

Removal

WARNING: Always wear safety glasses when

repairing an air bag supplemental restraint system

(SRS) vehicle and when handling an air bag

module. This will reduce the risk of injury in the

event of an accidental deployment.

WARNING: Never probe the connectors on

the air bag module. Doing so can result in air bag

deployment, which can result in personal injury.

WARNING: Vehicle sensor orientation is

critical for correct system operation. If a vehicle

equipped with an air bag supplemental restraint

3. Rotate the steering wheel 180

° to access the

system (SRS) is involved in a collision, inspect

other screw.

the sensor mounting bracket and wiring pigtail for

A12348 en

211-04-11 Steering

Column 211-04-11

REMOVAL AND INSTALLATION (Continued)

4. Gently pull the Driver Air Bag away from the

2. Unscrew the retaining bolt using a Torx T50

steering wheel.

driver. To stop the steering wheel rotating,

remove the key from ignition barrel, and rotate the

steering wheel to the left until the steering column

lock engages.

Item

Description

Horn/Cruise/Audio Connector

Inflator Connectors

3. Install the steering wheel puller, Ford service tool

No. J-1859-A (09561-11002).

5. Disconnect the wiring to the Driver Air Bag inflator

Ensure that the pusher block is used so that the

by depressing the retaining clips on either side of

thread in the end of the steering column is not

the connector.

damaged. Loosen the wheel from the column.

6. Remove the horn/audio wiring connector.

4. Carefully feed the clockspring wire harnesses

7. Remove the Driver Air Bag from the vehicle.

through the hub of the steering wheel, and

remove the steering wheel from the vehicle.

Installation

5. Installation of the steering wheel is a reverse of

1. Disconnect the battery. Wait at least one minute

the above procedure. Torque the M10 steering

to deplete the backup power supply energy.

wheel attachment bolt to 38Nm.

2. Connect the wiring to the Driver Air Bag inflators.

The connectors are mechanically keyed to fit in

only one orientation.

3. Ensure the inflator wire harness is clipped into

position.

4. Connect the horn/audio wiring. Ensure the wire

harness is clipped into position.

5. Gently push the Driver Air Bag into the steering

wheel. Ensure all wiring is clear of the Driver Air

Bag attachment screws.

6. Rotate the steering wheel 90

° from straight

ahead, to access the one of the Driver Air Bag

retaining screws on the front face of the steering

wheel. Torque the screw with a Torx T30 bit, to

5Nm.

7. Rotate the steering wheel 180

° to access the

other screw.

8. Reconnect the battery.

Steering Wheel

Removal and Installation
1. Remove the Driver Air Bag. See Section

211-04-09.

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