Page 1

100-00-1

General Information

100-00-1

SECTION : 100-00 General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

DESCRIPTION AND OPERATION About this Manual .................................................................................................................100-00-3 Introduction ..........................................................................................................................100-00-3 Replacement Parts ...............................................................................................................100-00-3 Special Tools ........................................................................................................................100-00-3 Important Safety Instructions ...............................................................................................100-00-3 Warnings, Cautions and Notes in This Manual ....................................................................100-00-3 How to Use This Manual ......................................................................................................100-00-3 Samples ...............................................................................................................................100-00-4 Health and Safety Precautions .............................................................................................100-00-4 Introduction ..........................................................................................................................100-00-4 Acids and Alkalis ..................................................................................................................100-00-4 Air Bags ................................................................................................................................100-00-4 Air Conditioning Refrigerant .................................................................................................100-00-5 Adhesives and Sealers ........................................................................................................100-00-5 Antifreeze .............................................................................................................................100-00-6 Asbestos ..............................................................................................................................100-00-6 Battery Acids ........................................................................................................................100-00-6 Brake and Clutch Linings and Pads .....................................................................................100-00-6 Brakes Fluids (Polyalkylene Glycols) ...................................................................................100-00-6 Brazing .................................................................................................................................100-00-6 Chemical Materials ...............................................................................................................100-00-6 Chlorofluorocarbons (CFC) ..................................................................................................100-00-7 Clutch Fluids ........................................................................................................................100-00-7 Clutch Linings and Pads ......................................................................................................100-00-7 Corrosion Protection Materials .............................................................................................100-00-7 Cutting ..................................................................................................................................100-00-7 Dewaxing .............................................................................................................................100-00-7 Dusts ....................................................................................................................................100-00-7 Electric Shock ......................................................................................................................100-00-7 Engine Oils ...........................................................................................................................100-00-7 Exhaust Fumes ....................................................................................................................100-00-8 Fibre Insulation .....................................................................................................................100-00-8 Fire .......................................................................................................................................100-00-8 First Aid ................................................................................................................................100-00-8 Fluoroelastomer ...................................................................................................................100-00-8 Foams - Polyurethane ..........................................................................................................100-00-8 Freon ....................................................................................................................................100-00-8 Fuels ....................................................................................................................................100-00-8 Gas Cylinders .......................................................................................................................100-00-9 Gases ...................................................................................................................................100-00-9 Gaskets (Fluoroelastomer) ...................................................................................................100-00-9 General Workshop Tools and Equipment ............................................................................100-00-9 High Pressure Air, Lubrication and Oil Test Equipment ....................................................100-00-10 Halon ..................................................................................................................................100-00-10 Legal Aspects .....................................................................................................................100-00-10 Lubricants and Greases .....................................................................................................100-00-10 Noise ..................................................................................................................................100-00-10 Noise Insulation Materials ..................................................................................................100-00-10 01/2003 2003.0 BA Falcon


100-00-2

General Information

100-00-2

(Continued) O-Rings (Fluoroelastomer) .................................................................................................100-00-10 Paints .................................................................................................................................100-00-10 Pressurized Equipment ......................................................................................................100-00-11 Solder .................................................................................................................................100-00-11 Solvents .............................................................................................................................100-00-11 Sound Insulation ................................................................................................................100-00-11 Suspended Loads ..............................................................................................................100-00-11 Transmission Brake Bands ................................................................................................100-00-11 Underseal ...........................................................................................................................100-00-11 Viton ...................................................................................................................................100-00-11 Welding ..............................................................................................................................100-00-12 Warning Symbols on Vehicles ...........................................................................................100-00-12 White Spirit .........................................................................................................................100-00-13 Standard Workshop Practices ............................................................................................100-00-13 Vehicle in Workshop ..........................................................................................................100-00-13 Alternative Fuel ..................................................................................................................100-00-14 Alternative Fuel — Do’s .....................................................................................................100-00-14 Alternative Fuel — Do Nots ...............................................................................................100-00-14 Towing the Vehicle .............................................................................................................100-00-14 Connecting a Slave Battery Using Jumper Cables ............................................................100-00-14 Component Cleaning .........................................................................................................100-00-15 Calibration of Essential Measuring Equipment ..................................................................100-00-15 Solvents, Sealers and Adhesives .......................................................................................100-00-15 Introduction ........................................................................................................................100-00-15 General Specifications .......................................................................................................100-00-16 Road/Roller Testing ............................................................................................................100-00-16 Pre-Test Checks ................................................................................................................100-00-16 Starting the Engine ............................................................................................................100-00-16 On Road or Roller Test Check: ..........................................................................................100-00-17 Brake Testing .....................................................................................................................100-00-17

01/2003 2003.0 BA Falcon


100-00-3

General Information

100-00-3

DESCRIPTION AND OPERATION

About this Manual Introduction This manual has been written in a format that is designed to meet the needs of Ford technicians worldwide. The objective is to use common formats and include similar content in each manual worldwide. This manual provides general descriptions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.

NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number).

How to Use This Manual

Replacement Parts

This manual covers service and repair procedures. This manual is structured into groups and sections, with specific system sections collected together under their relevant group. A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body Special Tools and Paint. The number of the group is the first The Special Tool(s) Table provided at the beginning number of a section number. of each procedure shows all special tools required to Pages at the start of the manual list all sections carry out a repair. Where possible, illustrations are available. Each section has a contents list detailing provided to assist in identifying the special tool General Specifications, Description and Operation required. and Service Adjustment and Checks. Special tools may be ordered from: If components need to be removed or disassembled in sequence, the sequence will be identified Australia numerically in a graphic and the corresponding text SPX AUSTRALIA will be numbered accordingly (refer to ‘Samples’). Tel: +61 (03) 9544 6222 All left and right-hand references to the vehicle are Fax: +61 (03) 9544 5222 taken from a position sitting in the driver seat looking forward. Important Safety Instructions All left and right-hand references to the engine are taken from a position at the flywheel looking towards Appropriate service methods and correct repair the front camshaft pulley. procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal Where appropriate, instructions will be given for the use of WDS, diagnostic equipment. safety of the individual carrying out the work. Inspection and Verification This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Visual Inspection Charts, Symptom Charts and other Anyone who departs from the instructions provided in information charts (such as diagnostic routines), this manual must first establish that he compromises supplement test procedures with technical neither his personal safety nor the vehicle integrity by specifications, or navigate the user to a specific test his choice of methods, tools or parts. procedure. Sympton Chart Warnings, Cautions and Notes in This The symptom chart indicates symptoms, sources and Manual actions to address a condition. Pinpoint Tests WARNING: Warnings are used to indicate that failure to follow a procedure correctly may For electrical systems, pinpoint test steps are used to result in personal injury. identify the source of a concern in a logical, step-by-step manner. Pinpoint tests have two CAUTION: Cautions are used to indicate that columns: CONDITIONS and DETAILS/RESULTS/ACTIONS. failure to follow a procedure correctly may result in damage to the vehicle or equipment being The CONDITIONS column is used exclusively for used. graphics and icons (with or without captions) and the DETAILS/RESULTS/ACTIONS column provides Ford and Motorcraft parts are made to the same exacting standards as the original factory fitted components. For this reason, it is recommended that only genuine Ford or Motorcraft parts are installed during service or repair.

G17365 en

01/2003 2003.0 BA Falcon


100-00-4

General Information

100-00-4

DESCRIPTION AND OPERATION (Continued) direction to another test step or specific corrective actions. The boxed numbers indicate the order in which the described action is to be performed. Component Tests A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted within a single page of the pinpoint test. Graphics Test graphics show the measurement or test to be performed in a test step. A representative tester graphic is used for voltmeters and ohmmeters. If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements, at which point dashed lines are used. Breakout box-type testers are represented by a double circle test pin. Test pins are labelled with the pin number.

Samples Special Tools and Torque Figures Any requirement for special tools will picture the tool, showing it in use and with its tool number shown. Torque settings will be given at the relevant point in the procedure.

Health and Safety Precautions Introduction Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This subsection lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. Precautions necessary to avoid these hazards are identified. The list is not exhaustive and all operations and procedures, and the handling of materials, should be carried out with health and safety in mind.

G17365 en

Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted.

Acids and Alkalis See also Battery Acids. For example caustic soda, sulphuric acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing. Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists. Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents. Display Eye Hazard sign.

Air Bags See also Fire, Chemical Materials Highly flammable, explosive – observe No Smoking policy. Used as a safety restraint system mounted in the steering wheel and passenger side of the instrument panel and side impact Airbags. The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT GAS (2500°C). The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage. After normal deployment, gloves and safety goggles should be worn during the handling process. Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site. Following any direct contact with gas generant. wash affected areas thoroughly with water. seek medical assistance if necessary. Air Bags - Do’s do store modules in an upright position. do keep modules dry. do carry modules with the cover side pointing away from the body. do place modules with their cover side upwards. do carefully inspect modules for damage. do stand to one side when connecting modules. do make sure all test equipment is properly calibrated and maintained. do wash hands after handling deployed air bags. 01/2003 2003.0 BA Falcon


100-00-5

General Information

100-00-5

DESCRIPTION AND OPERATION (Continued) Air Bags - Do Nots do not store highly flammable material together with modules or gas generators. do not store gas generators at temperatures exceeding 80°C. do not store modules upside down. do not attempt to open a gas generator housing. do not expose gas generators to open flame or sources of heat. do not place anything on top of a module cover. do not use damaged modules. do not touch a fired module or gas generator for at least 10 minutes. do not use any electrical probes on the wiring circuit.

Air Conditioning Refrigerant See also Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking policy. Skin contact may result in frostbite. Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles. If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.

Air Conditioning Refrigerant - Do Nots do not expose refrigerant bottles to sunlight or heat. do not stand refrigerant bottles upright; when filling, hold them with the valve downwards. do not expose refrigerant bottles to frost. do not drop refrigerant bottles. do not vent refrigerant to atmosphere under any circumstance. do not mix refrigerants, for example R12 (Freon) and R134a.

Adhesives and Sealers See also Fire, Chemical Materials Highly flammable, flammable, combustible – observe No Smoking policy. Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be observed, for example disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately.

G17372 en

Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions.

Water-based Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction.

Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact.

Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants. Skin and eye contact should be avoided and the manufacturers instructions followed. Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation to the nose and eyes. For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Isocyanate (Polyurethane) Adhesives/Sealers See also Resin-based Adhesives Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur. Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapour concentrations may result in adverse health effects. 01/2003 2003.0 BA Falcon


100-00-6

General Information

100-00-6

DESCRIPTION AND OPERATION (Continued) Prolonged contact with the skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis. Splashes entering the eye will cause discomfort and possible damage. Any spraying should preferably be carried out in exhaust ventilated booths, removing vapours and spray droplets from the breathing zone. Wear appropriate gloves, eye and respiratory protection.

Antifreeze See also Fire, Solvents. For example isopropanol, ethylene glycol, methanol. Highly flammable, flammable, combustible. Used in vehicle coolant systems, brake air pressure systems, screenwash solutions. Vapours may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these vapours. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY. These products must not be used in any cooling or industrial water system which is connected or linked to general, food preparation or drinking water supplies.

Asbestos See also Warning Symbols on Vehicles at the end of this subsection. Breathing asbestos dust may cause lung damage or, in some cases, cancer. Used in brake and clutch linings, transmission brake bands and gaskets. Ford original production and genuine replacement items for this model are asbestos free. The use of drum cleaning units, vacuum cleaning or damp wiping is preferred. Asbestos dust waste should be dampened, placed in a sealed container and marked for safe disposal. If any cutting or drilling is attempted on materials containing asbestos the item should be dampened and only hand tools or low speed power tools used.

Battery Acids See also Acids and Alkalis. Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries. Make sure there is adequate ventilation.

Brake and Clutch Linings and Pads See Asbestos.

G17372 en

Brakes Fluids (Polyalkylene Glycols) See also Fire. Splashes to the skin and eyes are extremely irritating. Avoid skin and eye contact as far as possible. Inhalation vapour hazards do not arise at ambient temperatures because of the very low vapour pressure.

Brazing See Welding.

Chemical Materials See also Legal Aspects. Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts. The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life expectancy.

Chemical Materials - Do’s Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be obtained from manufacturers. Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned. Do organise work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapours, aerosols, dusts or fumes; inadequate container labelling; fire and explosion hazards. Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials. Do keep work areas clean, uncluttered and free of spills. Do store chemical materials according to national and local regulations. Do keep chemical materials out of the reach of children.

Chemical Materials - Do Nots Do not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together. Do not spray chemical materials, particularly 01/2003 2003.0 BA Falcon


100-00-7

General Information

100-00-7

DESCRIPTION AND OPERATION (Continued) those based on solvents, in confined spaces, for example when people are inside a vehicle. Do not apply heat or flame to chemical materials except under the manufacturers instructions. Some are highly flammable and some may release toxic or harmful fumes. Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas such as pits. Do not transfer chemical materials to unlabelled containers. Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities. Do not use emptied containers for other materials except when they have been cleaned under supervised conditions. Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.

Cutting See Welding.

Dewaxing See Solvents and Fuels (Kerosene).

Dusts Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate. Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.

Electric Shock

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition. Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labelled and preferably removed from the work station. Chlorofluorocarbons (CFC) Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise There is concern in the scientific community that damaged. CFCs and Halons are depleting the upper ozone layer Make sure that electrical equipment and flexes do not which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet radiation may result come into contact with water. in increases in skin cancer, cataracts and immune Make sure that electrical equipment is protected by system suppression in humans, as well as decreased the correct rated fuse. productivity of crops and aquatic systems. Never misuse electrical equipment and never use CFCs are used primarily as refrigerants in vehicle air equipment which is in any way faulty. The results conditioning systems and as aerosol propellants. could be fatal. Halons are used as fire extinguishants. Make sure that the cables of mobile electrical Ford supports worldwide elimination of CFC usage equipment cannot get trapped and damaged, such as and it is recommended that Company subsidiaries in a vehicle hoist. and affiliates should phase out CFC usage as soon as Make sure that the designated electrical workers are acceptable substitutes are commercially available. trained in basic First Aid. In cases of electrocution: Clutch Fluids switch off the power supply before approaching See Brake fluids. the victim. Clutch Linings and Pads if this is not possible push or drag the victim from the source of electricity using dry non-conductive See Asbestos. material. Corrosion Protection Materials commence resuscitation if trained to do so. SUMMON MEDICAL ASSISTANCE. See also Solvents, Fire. Highly flammable, flammable – observe No Smoking Engine Oils policy. See Lubricants and Grease. These materials are varied and the manufacturers instructions should be followed. They may contain Exhaust Fumes solvents, resins or petroleum products. Skin and eye These contain asphyxiating, harmful and toxic contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic in confined spaces. G17372 en

01/2003 2003.0 BA Falcon


100-00-8

General Information

100-00-8

DESCRIPTION AND OPERATION (Continued) hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.

Foams - Polyurethane

First Aid

Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

See also Fire. Used in sound and noise insulation. Cured foams Gasolene (petrol) engine used in seat and trim cushioning. There may not be adequate warning of odour or of Follow manufacturers instructions. irritation before toxic or harmful effects arise. These Unreacted components are irritating and may be may be immediate or delayed. harmful to the skin and eyes. Wear gloves and goggles. Diesel engine Individuals with chronic respiratory diseases, asthma, Soot, discomfort and irritation usually give adequate bronchial medical problems, or histories of allergic warning of hazardous fume concentrations. diseases should not work in or near uncured materials. Fibre Insulation The components, vapours or spray mists can cause See also Dusts. direct irritation, sensitivity reactions and may be toxic Used in noise and sound insulation. or harmful. The fibrous nature of surfaces and cut edges can Vapours and spray mists must not be inhaled. These cause skin irritation. This is usually a physical and not materials must be applied with adequate ventilation a chemical effect. and respiratory protection. Do not remove the respirator immediately after spraying, wait until the Precautions should be taken to avoid excessive skin contact through careful organization of work practices vapour/mists have cleared. and the use of gloves. Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Fire Smoking, naked flames or the use of electrical equipment during foaming operations and until See also Welding, Foams, Legal Aspects. Many of the materials found on or associated with the vapours/mists have cleared should not be allowed. repair of vehicles are highly flammable. Some give off Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation. toxic or harmful fumes if burnt. See also the vehicle Body Repair Manual. Observe strict fire safety when storing and handling flammable materials or solvents, particularly near Freon electrical equipment or welding processes. See Air Conditioning Refrigerant. Make sure, before using electrical or welding equipment, that there is no fire hazard present. Fuels Have a suitable fire extinguisher available when using See also, Fire, Legal Aspects, Chemicals and welding or heating equipment. Solvents. Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures. Splashes in the eye should be flushed carefully with clean water for at least ten minutes. Soiled skin should be washed with soap and water. In case of cold burns, from alternative fuels, place affected area in cool to cold water. Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist, consult a doctor. If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not induce vomiting unless this action is indicated on the label.

Fluoroelastomer See Viton.

G17372 en

Gasoline (Petrol) Highly flammable - observe No Smoking policy. Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, through vomiting, is a very serious hazard. Gasolene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor gasolene may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasolene vapours must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness. 01/2003 2003.0 BA Falcon


100-00-9

General Information

100-00-9

DESCRIPTION AND OPERATION (Continued) Make sure there is adequate ventilation when handling and using gasolene. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces. Special precautions apply to cleaning and maintenance operations on gasolene storage tanks. Gasolene should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.

checked for integrity following the specified procedures. If the fuel tank is to be removed for service or repair the fuel must be evacuated using dedicated equipment and following the specified procedures.

Gas Cylinders

See also Fire. Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to Gas-oil (Diesel Fuel) 138 bar (2000 psi) and great care should be taken in Combustible. handling these cylinders to avoid mechanical damage Gross or prolonged skin contact with high boiling point to them or to the valve gear attached. The contents of each cylinder should be clearly identified by gas oils may also cause serious skin disorders appropriate markings. including skin cancer. Cylinders should be stored in well ventilated Kerosene (Paraffin) enclosures, and protected from ice and snow, or Used also as heating fuel, solvent and cleaning agent. direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in close proximity to Flammable - observe No Smoking policy. oxygen cylinders. Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. liquid aspiration into the lungs occurs. Only trained personnel should undertake work Liquid contact dries the skin and can cause irritation involving gas cylinders. or dermatitis. Splashes in the eye may be slightly irritating. Gases In normal circumstances the low volatility does not See Gas Cylinders. give rise to harmful vapours. Exposure to mists and vapours from kerosene at elevated temperature Gaskets (Fluoroelastomer) should be avoided (mists may arise in dewaxing). See Viton. Avoid skin and eye contact and make sure there is adequate ventilation.

Alternative Fuel Highly flammable. Observe “NO SMOKING� signs. Make sure there is adequate ventilation when working on alternative fuelled vehicles. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up in confined spaces. Inhalation in high concentrations may cause dizziness, headache, nausea and loss of co-ordination. Very high concentrations may result in loss of consciousness. Contact with liquidified petroleum gas (LPG) or compressed natural gas (CNG) to skin may cause cold burns and may cause frost bite. Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves should be worn during removal and installation of LPG/CNG fuel system components. LPG/CNG fuel leaks could cause a fire and be a hazard to health that can lead to personal injury, illness or even death. If a leak is detected, under no circumstances attempt to seal the leak by tightening the union/connection until the fuel in the system or component is depressurised. Once tightened the system should be G17372 en

General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required. Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used. Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury. Wear suitable eye protection when using grinding, chiselling or sand blasting equipment. Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment. Make sure there is adequate ventilation to control dusts, mists and fumes.

01/2003 2003.0 BA Falcon


100-00-10

General Information

100-00-10

DESCRIPTION AND OPERATION (Continued) High Pressure Air, Lubrication and Oil Test Equipment See also Lubricants and Greases. Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions. Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the underlying tissue, and cause serious injury.

Halon See CFCs.

Legal Aspects There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment in a workshop. For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the many health and safety laws and regulations within their country, published by both national and local authorities.

Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanoline replace the natural skin oils which have been removed. Do not use gasolene (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practicable, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face shields; in addition an eye wash facility should be provided.

Environmental Precautions

Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt check with the appropriate local authority and manufacturer of approved appliances. Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed Lubricants and Greases waste disposal sites, or to the waste oil reclamation Avoid all prolonged and repeated contact with mineral trade. If in doubt, contact the relevant local authority oils. All lubricants and greases may be irritating to the for advice on disposal facilities. eyes and skin. It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses. Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided. Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.

Health Protection Precautions Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags into pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First Aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. G17372 en

Noise Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection must be worn.

Noise Insulation Materials See Foams, Fibre Insulation.

O-Rings (Fluoroelastomer) See Viton.

Paints See also Solvents, Chemical Materials. Highly flammable, flammable - observe No Smoking policy

One Pack Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should be carried out only with adequate ventilation.

Two Pack Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and Sealers under Adhesives and Sealers. 01/2003 2003.0 BA Falcon


100-00-11

General Information

100-00-11

DESCRIPTION AND OPERATION (Continued) Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals working in booths should wear appropriate respiratory protection. Those doing small scale repair work in the open workshop should wear air-fed respirators.

Pressurized Equipment See High Pressure Air, Lubrication and Oil Test Equipment.

Solder Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced. Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these should be avoided. Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary. Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead. High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary. Make sure there is good ventilation when in use, avoid breathing fumes, vapours and spray mists and keep containers tightly sealed. Do not use in confined spaces. When spraying materials containing solvents, for example paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation. Do not apply heat or flame except under specific and detailed manufacturers instructions.

Sound Insulation See Fibre Insulation, Foams.

Suspended Loads CAUTION: Never improvise lifting tackle. There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load, for example a suspended engine. Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the job, in good condition and regularly maintained.

Transmission Brake Bands See Asbestos.

Underseal

Solvents

See Corrosion Protection.

See also Chemical Materials, Fuels (Kerosene), Fire. For example acetone, white spirit, toluene, xylene, trichloroethane. Used in cleaning and dewaxing materials, paints, plastics, resins and thinners. Some may be highly flammable or flammable. Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe irritation and could lead to loss of vision. Brief exposure of high concentrations of vapours or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness. Repeated or prolonged exposure to excessive but lower concentrations of vapours or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects. Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.

Viton

G17372 en

In common with many other manufacturers vehicles, some components fitted to the Ford range have O-rings, seals or gaskets which contain a material known as ‘Viton’. Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon. When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid. This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system. O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance. DO NOT, under any circumstances touch them or the attached components. 01/2003 2003.0 BA Falcon


100-00-12

General Information

100-00-12

DESCRIPTION AND OPERATION (Continued) Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material may be Viton or any fluoroelastomer. If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work. Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Gas Welding (and Cutting)

This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion. The process will produce metal spatter and eye and skin protection is necessary. The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc welding, and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided. In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required. Special precautions must be taken before any welding or cutting takes place on vessels which have contained combustible materials, for example boiling or steaming out of fuel tanks .

Arc Welding

Warning Symbols on Vehicles

This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people. CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye. Metal spatter will also occur, and appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.

Decals showing warning symbols will be found on various vehicle components. These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair operations on the vehicle. The most commonly found decals are reproduced below together with an explanation of the warnings.

Welding See also Fire, Electric Shock, Gas Cylinders. Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Resistance Welding

G17372 en

1. Components or assemblies displaying the caution triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind.

01/2003 2003.0 BA Falcon


100-00-13

General Information

100-00-13

DESCRIPTION AND OPERATION (Continued)

2. Components or assemblies displaying the warning 5. Displaying this symbol (normally in conjunction triangle with the ‘electrified’ arrow and open book with 5 above) warn of the presence of potentially symbol give warning of inherent high voltages. explosive matter within the immediate vicinity. Never touch these with the engine running or the ignition switched on. See Electric Shock in this subsection.

6. Displaying this symbol warn that children should not be allowed in the immediate vicinity unsupervised.

3. Components or assemblies displaying this symbol White Spirit give warning that the component contains a corrosive substance. See Acids and Alkalis in this See Solvents. subsection.

Standard Workshop Practices Vehicle in Workshop

When working on a vehicle in the workshop always make sure that: the parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards. the key is removed from key operated hood locks before any work is carried out around the front of the vehicle. if the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes. 4. Displaying the caution circle with a deleted lighted there is adequate room to raise the vehicle and match symbol, caution against the use of naked remove the wheels, if necessary. lights or flames within the immediate vicinity due fender covers are always fitted if any work is to be to the presence of highly flammable or explosive carried out in the engine compartment. liquids or vapours. See Fire in this subsection.

G17373 en

01/2003 2003.0 BA Falcon


100-00-14

General Information

100-00-14

DESCRIPTION AND OPERATION (Continued) the battery is disconnected if working on the engine.

do not work on the fuel lines or system components unless the alternative fuel has been evacuated and the pressure in the system is reduced to atmospheric, or less CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to do not use anything other than the specified leak prevent the possibility of a surge of current detector fluid to trace fuel leaks causing damage to the internal components of the Be aware of situations that may cause the LPG or generator. CNG fuel system to vent off fuel, such as: If using welding equipment on the vehicle, a extremely hot days suitable fire extinguisher is readily available. parking by a space heater Alternative Fuel hoisting a vehicle up near a ceiling heater Only personnel fully trained to Ford and local WARNING: When servicing the fuel system standards are to work on alternative fuel vehicles. always follow the recommended procedures. Towing the Vehicle Failure to follow these instructions may result in personal injury. If the odour of liquified petroleum gas (LPG) or WARNING: When the vehicle is being towed compressed natural gas (CNG) is present in the air in the ignition switch must be in position II (steering the workshop, warn all persons in the area to: lock released and warning lights illuminated). Only then will the steering, turn signal lamps, extinguish all flames and lighted tobacco. horn and stop lamps be operational. Failure to shut off electrical and air powered equipment. follow these instructions may result in personal evacuate the area. injury. ventilate the area. When a vehicle with automatic transmission is towed, the gear selector must be in position N (Neutral). contact fire control authorities. Never tow a vehicle with automatic transmission remove the vehicle to a dedicated, ventilated faster than 30 mph (50 km/h) or further than 30 miles area. (50 km). If it is necessary to tow the vehicle a greater distance, the drive wheels must be lifted clear off the Alternative Fuel — Do’s ground. do work on the vehicle in a designated area that Alternatively the vehicle can be transported on a low is well ventilated and its access restricted to loader or a trailer. qualified personnel only install new warning labels to their original Connecting a Slave Battery Using Jumper locations Cables if possible always isolate the alternative fuel tank, run the vehicle on the alternative fuel until it WARNING: If the slave battery has recently automatically switches to its normal fuel prior to been charged and is gassing, cover the vent plugs taking the vehicle into the workshop/service area or covers with a damp cloth to reduce the risk of only use tested and approved components and explosion should arcing occur when connecting pipes when repairing or servicing LPG and CNG the jumper cables. Failure to follow these systems instructions may result in personal injury.

Alternative Fuel — Do Nots do not vent off LPG fuel do not use shop air pressure to force LPG fuel from the fuel tank do not use paint drying ovens above 40°C for any alternative fuel vehicles. LPG and CNG fuel tanks should be removed from the vehicles prior to being put into paint drying ovens above 40°C do not modify the system or install new components with parts not designed for gas vehicles do not evacuate fuel tanks unless there is repair that requires removed of the fuel tank

G17373 en

CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper cables are connected. CAUTION: While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only practical way to mobilize a vehicle. In such an instance the discharged battery must be recharged immediately after jump starting to avoid permanent damage.

01/2003 2003.0 BA Falcon


100-00-15

General Information

100-00-15

DESCRIPTION AND OPERATION (Continued) Always make sure that the jumper cables are adequate for the task. Heavy duty cables must be used. Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel. Always make sure that switchable electric circuits are switched off before connecting jumper cables. This reduces the risk of arcing occurring when the final connection is made.

Component Cleaning To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or dismantling components or assemblies. Components should be thoroughly cleaned before inspection prior to reassembly.

Cleaning Methods: dry cleaning removal of loose dirt with soft or cable brushes scraping dirt off with a piece of metal or wood wiping off with a rag CAUTION: Compressed air is sometimes ‘wet’ so use with caution, especially on hydraulic systems. blowing dirt off with compressed air. (Eye protection must be worn when using this method) removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material dust (asbestos particles) steam cleaning

WARNING: Make sure that the ends of the jumper cables do not touch each other or ground against the vehicle body at any time while the cables are attached to the battery. A fully charged battery, if shorted through jumper cables, can discharge at a rate well above 1000 amps causing violent arcing and very rapid heating of the jumper cables and terminals, and can even cause the battery to explode. Failure to follow these instructions may result in personal injury. Always connect the jumper cables in the following sequence: slave battery positive first then vehicle battery positive slave battery negative next and then vehicle ground at least 12 inches (300 mm) from the battery terminal, for example engine lifting eye Always reduce the engine speed to idle before disconnecting the jumper cables. Before removing the jumper cables from the vehicle that had the discharged battery, switch on the heater blower (high) or the heated rear window, to reduce the voltage peak when the cables are removed. Always disconnect the jumper cables in the reverse order to the connecting sequence and do not short the ends of the cables. Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight hours continuous driving with no additional loads placed on the battery.

G17374 en

WARNING: Most solvents require careful handling and some are harmful. Refer to Health and Safety Precautions and to the manufacturers literature for safety precautions. Failure to follow these instructions may result in personal injury. Various solvents are available which are suitable for component cleaning. Some components such as brake hydraulic parts and electrical assemblies should be cleaned only with recommended solvents — refer to Solvents, Sealers and Adhesives or to the section of the manual relevant to the component.

Calibration of Essential Measuring Equipment WARNING: Failure to follow these instructions may result in personal injury or damage to components. It is of fundamental importance that certain essential equipment, for example torque wrenches, multimeters, exhaust gas analysers or rolling roads, are regularly calibrated in accordance with the manufacturers instructions.

Solvents, Sealers and Adhesives Introduction WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals or give off fumes which can be dangerous to health. Always follow the manufacturers instructions. If in doubt about any 01/2003 2003.0 BA Falcon


100-00-16

General Information

100-00-16

DESCRIPTION AND OPERATION (Continued) substance, particularly a solvent, DO NOT use it. CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the manufacturer of the product for information regarding storage, handling and application. The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated with their use, and safety measures to be taken. Some of these chemicals may be included in the following list either in their own right or as an ingredient in a sealer or adhesive.

General Specifications Anti-Seize Compound Ford Spec. SAM-1C-9107A SAM-1C-9107A ESE-M1244-A

General Spark plug threads Sealers Application For camshaft bearing caps For cylinder block For fitting rear lamp assembly For transmission housing (80 gram can)

Ford Spec. ESK-M4G260-A WSK-M4G320-A WSK-M4G329-ABC Finis Code 6 160 443

Manufacturer and Identification Loctite 518 Hylosil 502

Adhesives Application PU for windscreen, side and rear glass

Road/Roller Testing Road or roller testing may be carried out for various reasons and a procedure detailing pre-test checks, through engine starting and stopping, pre-driving checks, on-test checks to final checks on completion of the test is given overleaf. Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those items particularly relevant to the system/s being checked can be extracted.

Pre-Test Checks WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and rectified. It is suggested that pre-test checks, and functional tests of those systems/circuits which affect the safe and legal operations of the vehicle, such as brakes, lights and steering, should always be carried out before the road or roller test. G17374 en

Ford Spec. Finis Code 6 997 259 Engine oil level Engine coolant level Tires, for correct pressure, compatible types and tread patterns, and wear within limits. There is sufficient fuel in the tank to complete the test. All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of the test.

Starting the Engine NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator pedal at full travel whilst the engine is cold. With the ignition switched off, check: The handbrake is applied. The gear lever is in neutral.

01/2003 2003.0 BA Falcon


100-00-17

General Information

100-00-17

DESCRIPTION AND OPERATION (Continued) All instrument gauges (except fuel gauge) read zero. With the ignition switched on, check: Ignition controlled warning lights come on. Engine temperature gauge registers a reading compatible with the engine temperature. Fuel gauge registers a reading appropriate to the fuel level in the tank. The operation of the handbrake warning light and fluid level warning indicator light.

On Road or Roller Test Check: CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found and rectified. Clutch pedal operation is not stiff or heavy. Initial gear engagement is smooth and there is no evidence of clutch drag. Handbrake control operates smoothly and the handbrake releases quickly and completely. Clutch takes up the drive smoothly, without slip or judder. Gear changing is smooth, and there are no abnormal noises or vibrations from the transmission. The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or heavy, and engine speed returns to idle correctly. There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun conditions. Steering operation, including power steering where fitted, is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does not pull to one side and self centres smoothly after cornering. Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer (where fitted) register the correct readings or operate correctly. Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the direction indicator control self cancels when the steering is returned to the straight ahead position. Heating and ventilation systems work correctly and effectively. Brake operation and efficiency.

G17375 en

Brake Testing WARNING: When brake testing, avoid breathing the smoke or fumes from hot brakes, this may contain asbestos dust which is hazardous to health, see Health and Safety Precautions. Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users. CAUTION: Brake testing which includes heavy brake applications should not be carried out with new brake pads/discs or linings/drums until the components have bedded-in. New brake friction components will not reach full efficiency until the bedding-in process is complete. Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in application or release. Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding. After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake temperature. A disc which feels hot, or appreciably hotter than the others, indicates that the brake is binding. After completion of the test, check for: Oil, coolant, hydraulic, air and fuel leaks. Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission, axle etc., which might indicate overtightness or lack of lubrication.

01/2003 2003.0 BA Falcon


100-01-1

Identification Codes

100-01-1

SECTION : 100-01 Identification Codes VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

DESCRIPTION AND OPERATION Identification Codes ..............................................................................................................100-01-2 Vehicle Identification Number ..............................................................................................100-01-2 Vehicle Compliance (VC) Label .............................................................................................100-01-5 Emission Decal ....................................................................................................................100-01-6

01/2003 2003.0 BA Falcon


100-01-2

Identification Codes

100-01-2

DESCRIPTION AND OPERATION

Identification Codes Vehicle Identification Number The vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is printed on a label located in the engine compartment or on the driver’s side A-pillar as shown. The VIN number is also found on the vehicle compliance (VC) label located in the same area. Typical Identification Plate Locations

Identification Label (engine bay)

G86656 en

01/2003 2003.0 BA Falcon


100-01-3

Identification Codes

100-01-3

DESCRIPTION AND OPERATION (Continued) Identification Label (A-pillar)

G86656 en

01/2003 2003.0 BA Falcon


100-01-4

Identification Codes

100-01-4

DESCRIPTION AND OPERATION (Continued) Body Style Code BODY TYPE XT Sedan XT Wagon Futura Sedan Futura Wagon XR Sedan XR Ute GT Sedan Fairmont Sedan Fairmont Wagon Fairmont Ghia Sedan Fairlane Ghia LTD XL Ute XLS Ute Model Code Body Type Sedan Wagon Sedan Wagon Sedan Sedan Wagon Sedan Sedan Sedan Ute Ute Ute Ute Ute

G86656 en

Body Style XT XT Futura Futura XR FMT FMT FMT Ghia Fairlane Ghia LTD XL Tray XL SSB XR Tray XLS Tray XLS SSB

CODE SW WA SW WA SW CM SW SW WA SW LW LW CM CM Model Code 18333 18363 18334 18364 18335 18332 18332 18338 18349 18346 45313 45373 45375 45314 45374

01/2003 2003.0 BA Falcon


100-01-5

Identification Codes

100-01-5

DESCRIPTION AND OPERATION (Continued)

Paint Colour and Code Colour Winter White Venom Ice Mint Silver Barossa Reb Congo Green Silhouette Blue Print Narooma Blue Phantom Mercury Silver Blue Pearl Acid Rush Citric Acid Blood Orange Victorian Taxi Yellow Taxi Orange Trim Colour and Code Colour Stone Warm Charcoal

Code A1 VF EI B7 DG ST UU NR P3 M7 CP RH JA HO 44 22

with the Design Rules referred to on the compliance label of the vehicle. Such Laws must be complied with at all times. Failure to do so may result in Substantial Financial Penalties. Where State/Territory Laws differ from the repair manual procedures, the Laws MUST take precedence. To ensure continuing compliance it is imperative that the engine/emission system is serviced according to the specified procedure. A typical compliance plate is shown below. Compliance Plate (engine bay)

Code S1 B1

Vehicle Compliance (VC) Label Australian Design Rules (A.D.R.) reuire vehicle manufacturere to comply with specific requirements regarding consumer, environment protection, and safety devices. A compliance plate is fitted to the vehicle and this contains codes which relate to specific design rules in effect at the time of vehicle manufacture. Legiclation requires that no alteration be made to a vehicle that would result in the vehicle not complying G86657 en

01/2003 2003.0 BA Falcon


100-01-6

Identification Codes

100-01-6

DESCRIPTION AND OPERATION (Continued) Compliance Plate (A-pillar)

Emission Decal Emission Control Information Decal is affixed to the underside of the bonnet. Should this decal become mutilated or unreadable, a new decal must be obtained and affixed to the vehicla. To ensure contained compliance it is imperative that the engine and emission system is serviced according to the service procedures outlined in this manual. Should it become necessary to replace a component which affects vehicle emissions, it is mandatory that the replacement part be of the same calibration as the original part. No circumstances would permit the disconnection, alteration or modification of any emission related component on vehicles marketed by Ford Sales Company of Australia Limited, except in accordance with the diagnostic, maintenance and repair procedures specified in the Company’s service materials. Any person who removes, modifies or otherwise renders ineffective any emission control components fitted to a vehicle could be contravening the relevant regulations and be guilty of an offence under the regulations. Any person who owns and/or operates such a vehicle could also be guilty of an offence under the regulations.

G86657 en

01/2003 2003.0 BA Falcon


100-02-1

Jacking and Lifting

100-02-1

SECTION : 100-02 Jacking and Lifting VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

DESCRIPTION AND OPERATION Jacking ..................................................................................................................................100-02-2 Jacking/Lifting Points - Sedan/Wagon .................................................................................100-02-2 Jacking/Lifting Points - Ute ..................................................................................................100-02-2

01/2003 2003.0 BA Falcon


100-02-2

Jacking and Lifting

100-02-2

DESCRIPTION AND OPERATION

Jacking

Jacking/Lifting Points - Ute

WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. WARNING: Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury.

1. The front jacking\lifting point for the ute is on the sill at the point where the rocker moulding has been cut away to expose the sill. CAUTION: The service jack provided with the 2. The rear jacking\lifting point for the ute is on the vehicle is only intended to be used in an leaf spring hanger bracket. emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle.

Jacking/Lifting Points - Sedan/Wagon

1. The front jacking\lifting point for sedan and wagon is on the sill at the point where the rocker moulding has been cut away to expose the sill. 2. The rear jacking\lifting point for the sedan and wagon is on the sill at the point where the rocker moulding has been cut away to expose the sill.

G72676 en

01/2003 2003.0 BA Falcon


100-04-1

Noise, Vibration and Harshness

100-04-1

SECTION : 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) ................................................................................100-04-2 Acceptable Noise, Vibration and Harshness .......................................................................100-04-2 Diagnostic Theory ................................................................................................................100-04-2 Glossary of Terms ................................................................................................................100-04-2 DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) ................................................................................100-04-7 1: Customer Interview ........................................................................................................100-04-10 2: Pre-Drive Check .............................................................................................................100-04-10 3: Preparing for the Road Test ..........................................................................................100-04-10 4: Verify the Customer Concern ........................................................................................100-04-10 5: Road Test ......................................................................................................................100-04-10 6: Check OASIS/TSBs/Repair History ...............................................................................100-04-12 7: Diagnostic Procedure .....................................................................................................100-04-12 NVH Condition and Symptom Categories .........................................................................100-04-13 Symptom Charts ................................................................................................................100-04-14 Pinpoint Tests ....................................................................................................................100-04-35 Component Tests ...............................................................................................................100-04-49 GENERAL PROCEDURES Brake Disc Machining .........................................................................................................100-04-55 Powertrain/Drivetrain Mount Neutralizing ...........................................................................100-04-55 Exhaust System Neutralizing ..............................................................................................100-04-55 Wheel Bearing Check .........................................................................................................100-04-56

01/2003 2003.0 BA Falcon


100-04-2

Noise, Vibration and Harshness

100-04-2

DESCRIPTION AND OPERATION

Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle’s response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns.

within an acceptable range.

Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds.

Acceptable Noise, Vibration and Harshness

Ambient Temperature The surrounding or prevailing temperature.

All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok® differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode.

Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude.

Diagnostic Theory The shortest route to an accurate diagnosis results from: system knowledge, including comparison with a known good system. system history, including repair history and usage patterns. condition history, especially any relationship to repairs or sudden change. knowledge of possible sources. using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: a road or system test to determine the exact nature of the concern. an analysis of the possible causes. testing to verify the cause. repairing any concerns found. a road test or system test to make sure the concern has been corrected or brought back to G72678 en

Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations (less than 1000 Hz) caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound (200-5000 Hz) like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200–800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle.

01/2003 2003.0 BA Falcon


100-04-3

Noise, Vibration and Harshness

100-04-3

DESCRIPTION AND OPERATION (Continued) Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle.

Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section.

Item 1 2 3

Description True vertical Positive caster Steering axis

Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.

G72678 en

CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes 01/2003 2003.0 BA Falcon


100-04-4

Noise, Vibration and Harshness

100-04-4

DESCRIPTION AND OPERATION (Continued) applied and the transmission engaged. This test is used for noise and vibration checks.

from side-to-side (wobble). Dynamically unbalanced wheel and tyre assemblies can cause wheel shimmy.

Driveline Angles The differences of alignment between the transmission output shaft, the driveshaft, and the rear axle pinion centerline.

Engine Imbalance A condition in which an engine’s center mass is not concentric to the rotation center, causing excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint.

Item 1 2 3

Description Engine Driveshaft Differential

Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.

Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.

Drivetrain Damper A weight attached to the engine, the transmission, the Hiss transfer case, or the axle. It is tuned by weight and Steady high frequency (200–800 Hz) noise. Vacuum placement to absorb vibration. leak sound. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan.

Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.

Drumming A cycling, low-frequency (20–100 Hz), rhythmic noise often accompanied by a sensation of pressure on the ear drums. Also described as a low rumble, boom, or rolling thunder.

Howl A mid-range frequency (200-800 Hz) noise between drumming and whine. Also described as a hum.

Dynamic Balance The equal distribution of weight on each side of the centerline, so that when the wheel and tyre assembly spins, there is no tendency for the assembly to move G72678 en

Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. 01/2003 2003.0 BA Falcon


100-04-5

Noise, Vibration and Harshness

100-04-5

DESCRIPTION AND OPERATION (Continued) Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound’s amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100–200 Hz) tone. Also described as a hum.

Item 1 2

Description Lateral runout Radial runout

Rattle A random and momentary or short duration noise.

Neutral Engine Run-Up (NERU) Test The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations.

Rotary Blade Coupling (RBC) This part is attached to the rear axle on 4WD vehicles. It includes an internal hydraulic pump and clutch pack to control the torque supplied to the rear axle/wheels. It also has an internal electromagnetic clutch to lock to the RCB for the 4WD ON mode. This unit is not to be disassembled and if necessary a new unit must be installed.

Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up.

Ring Gear The large, circular, driven gear in a ring and pinion gearset.

Outboard Away from the centerline of the vehicle.

Road Test The operation of the vehicle under conditions intended to produce the concern under investigation.

Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. G72678 en

Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Lateral runout means measuring the movement or “wobble” of a wheel or tyre at the sidewall. Radial runout means measuring the out-of-round of the tyre tread surface. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5–20 Hz), usually with visible component movement. Usually relates to tyres, wheels, brake drums or brake discs if it is vehicle 01/2003 2003.0 BA Falcon


100-04-6

Noise, Vibration and Harshness

100-04-6

DESCRIPTION AND OPERATION (Continued) speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble.

warm. Also, irregular tyre wear patterns in the tyre tread resulting from wheel-locked skids.

Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application.

Tyre Force Vibration A tyre vibration caused by variations in the construction of the tyre that is noticeable when the tyre rotates against the pavement. This condition can be present on perfectly round tyres because of variations in the inner tyre construction. This condition can occur at wheel rotation frequency or twice rotation frequency.

Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.

Transient A noise or vibration that is momentary, a short duration.

Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates.

Two-Plane Balance Radial and lateral balance.

Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tyre assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tyre wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together.

Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500 Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT The acronym wide-open throttle is WOT.

Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR The acronym for the total indicated runout is TIR. Tyre Deflection The change in tyre diameter in the area where the tyre contacts the ground. Tyre Flat Spots A condition commonly caused by letting the vehicle stand while the tyres cool off. This condition can be corrected by driving the vehicle until the tyres are G72678 en

01/2003 2003.0 BA Falcon


100-04-7

Noise, Vibration and Harshness

100-04-7

DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH) To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. NHV Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis.

G72679 en

01/2003 2003.0 BA Falcon


100-04-8

Noise, Vibration and Harshness

100-04-8

DIAGNOSIS AND TESTING (Continued)

G72679 en

01/2003 2003.0 BA Falcon


100-04-9

Noise, Vibration and Harshness

100-04-9

DIAGNOSIS AND TESTING (Continued)

G72679 en

01/2003 2003.0 BA Falcon


100-04-10

Noise, Vibration and Harshness

100-04-10

DIAGNOSIS AND TESTING (Continued) 1: Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the concern and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: When was the concern first noticed? Did the concern appear suddenly or gradually? Did any abnormal occurrence coincide with or proceed its appearance? Use the information gained from the customer to accurately begin the diagnostic process.

2: Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs or adjustments before taking the vehicle on the road.

The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.

4: Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly.

5: Road Test NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test, take into consideration the customer’s driving habits and the driving conditions. The customer’s concern just may be an acceptable operating condition for that vehicle.

The following is a brief overview of each test in the order in which it appears. A review of this information 3: Preparing for the Road Test helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After Observe the following when preparing for the road reviewing this information, select and carry out the test: appropriate test(s), proceeding to the next step of this Review the information recorded on the NVH process. Diagnostic Guide. It is important to know the The Slow Acceleration Test is normally the first specific concern the customer has with the test to carry out when identifying an NVH concern, vehicle. especially when a road test with the customer is Do not be misled by the reported location of the not possible. noise or vibration. The cause can actually be The Heavy Acceleration Test helps to determine if some distance away, transferred from another the concern is torque-related. part of the vehicle. The Neutral Coast Down Speed Test helps to Remember that the vibrating source component determine if the concern is vehicle speed-related. (originator) may only generate a small vibration. This small vibration can in turn cause a larger The Downshift Speed Test helps to determine if vibration or noise to emanate from another the concern is engine speed-related. receiving component (reactor), due to contact with The Steering Input Test helps to determine how other components (transfer path). the wheel bearings and other suspension Conduct the road test on a quiet street where it is components contribute to a vehicle speed-related safe to duplicate the vibration or noise. The ideal concern. testing route is an open, low-traffic area where it The Brake Test helps to identify vibrations or is possible to operate the vehicle at the speed in noise that are brake-related. which the condition occurs. The Road Test Over Bumps helps isolate a noise If possible, lower the radio antenna in order to that occurs when driving over a rough or bumpy minimize turbulence. Identify anything that could surface. potentially make noise or be a source of wind The Engine Run-Up Tests consist of the Neutral noise. Inspect the vehicle for add-on items that Run-up Test and the Engine Load Test. These create vibration/noise. Turn off the radio and the heating and cooling system blower. G72679 en

01/2003 2003.0 BA Falcon


100-04-11

Noise, Vibration and Harshness

100-04-11

DIAGNOSIS AND TESTING (Continued) tests help to determine if the concern is engine speed-related. The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage.

Downshift Speed Test To carry out this test, proceed as follows: Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. Drive at the engine rpm where the concern occurs. The concern is engine speed related if duplicated while carrying out this test. This eliminates the tyres, wheels, brakes and the suspension components as sources. If necessary, repeat this test using other gears and NEUTRAL to verify the results. Proceed as necessary.

Steering Input Test

To carry out this test, proceed as follows: Drive at the speed where the concern occurs, while making sweeping turns in both directions. Slow Acceleration Test If the concern goes away or gets worse, the To carry out this test, proceed as follows: wheel bearings, hubs, U-joints (contained in the Slowly accelerate to the speed where the reported axles of 4WD applications), and tyre tread wear concern occurs. Note the vehicle speed, the are all possible sources. engine rpm and, if possible, determine the Proceed as necessary. vibration frequency. Brake Test Attempt to identify from what part of the vehicle the concern is coming. To carry out this test, proceed as follows: Attempt to identify the source of the concern. Warm the brakes by slowing the vehicle a few Proceed as necessary. times from 80–32 km/h (50–20 mph) using light braking applications. At highway speeds of 89–97 Heavy Acceleration Test km/h (50–60 mph), apply the brake using a light pedal force. To carry out this test, proceed as follows: Accelerate to 89–97 km/h (55–60 mph). Accelerate hard from 0-64 km/h (0-40 mph). Lightly apply the brakes and slow the vehicle to Decelerate in a lower gear. 30 km/h (20 mph). The concern is torque-related if duplicated while A brake vibration noise can be felt in the steering carrying out this test. wheel, seat or brake pedal. A brake noise can be Proceed as necessary. heard upon brake application and diminish when Neutral Coast Down Speed Test the brake is release. To carry out this test, proceed as follows: Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed-related. Proceed as necessary.

G72679 en

Road Test Over Bumps To carry out this test, proceed as follows: Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. Proceed as necessary.

Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: Install a tachometer. Increase the engine rpm up from an idle to approximately 3,500 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the

01/2003 2003.0 BA Falcon


100-04-12

Noise, Vibration and Harshness

100-04-12

DIAGNOSIS AND TESTING (Continued) engine rpm and, if possible, determine the vibration frequency. Attempt to identify what part of the vehicle the concern is coming from. Attempt to identify the source of the concern. Proceed as necessary.

Drive Engine Run-Up (DERU) Load Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. Apply the parking brake and the service brake. Install a tachometer. Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2,000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. Repeat the test in REVERSE. If the vibration or noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. Proceed as necessary.

Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. NOTE: A serpentine drive belt decreases the usefulness of this test. In these cases, use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device, such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. Increase the engine rpm to where the concern occurs.

G72679 en

If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not sources. If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source.

Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-8 hours. Before starting the engine, conduct a visual inspection under the hood. Turn the key on, but do not start the engine. Listen for the fuel pump, anti-lock brake system (ABS) and air suspension system noises. Start the engine. CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.

6: Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults.

7: Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the “symptom” to “system” to “component” to “cause” diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Verify the “symptom”. Determine which “system(s)” can cause the “symptom”. If a vibration concern is vehicle speed related, the tyre and wheel rpm/frequency or driveshaft frequency should be calculated.

01/2003 2003.0 BA Falcon


100-04-13

Noise, Vibration and Harshness

100-04-13

DIAGNOSIS AND TESTING (Continued) If a vibration concern is engine speed related, the engine, engine accessory or engine firing frequencies should be calculated. After determining the “system”, use the diagnostic tools to identify the worn or damaged “components”. After identifying the “components”, try to find the “cause” of the failure. Once the concern is narrowed down to a symptom/condition, proceed to NVH Condition and Symptom Categories.

2.

NVH Condition and Symptom Categories Operating Condition—Vehicle is Not Moving 1. Static operation Noise occurs during part/system functioning. Goto Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. Goto Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. Goto Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle Idle noise. Goto Idle Noise/Vibration. Idle vibration or shake. Goto Idle Noise/Vibration. 4. During gear selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. Goto Driveline Noise/Vibration. 3. Vehicle with a manual transmission. Goto Transmission (Manual) and Transfer Case Noise/Vibration.

3. 4.

5.

Operating Condition—Vehicle is Moving 1. Depends more on how the vehicle is operated 1. Speed-related Related to vehicle speed Pitch increases with vehicle speed. Goto Tire Noise/Vibration. Noise occurs at specific vehicle speed. A high-pitch noise (whine). Goto Drivline Noise/Vibration. Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. Goto Driveline Noise/Vibration. A low-pitched noise (drumming). Goto Engine Noise/Vibration. Vibration occurs at a particular speed (mph) regardless of acceleration or G72679 en

6.

7. 8.

deceleration. Goto Tire Noise/Vibration. Noise varies with wind/vehicle speed and direction. Goto Air Leak and Wind Noise. Related to engine speed. Noise varies with engine rpm. Goto Engine Noise/Vibration. Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). Acceleration Wide open throttle (WOT) Engine induced contact between components. Inspect and repair as necessary. Noise is continuous throughout WOT. Exhaust system or engine ground out. Goto Engine Noise/Vibration. Light/moderate acceleration Tip-in moan. Engine/exhaust noise. Goto Engine Noise/Vibration. Knock-type noise. Goto Engine Noise/Vibration. Driveline shudder. Goto Driveline Noise/Vibration. Engine vibration. Goto Engine Noise/Vibration. Turning noise. Goto Steering Noise/Vibration. Braking. Clicking sound is signaling ABS is active. Acceptable ABS sound. A continuous grinding/squeal. Goto Brake Noise/Vibration. Brake vibration/shudder. Goto Brake Noise/Vibration. Clutching. A noise occurring during clutch operation. Goto Transmission (Manual) and Transfer Case Noise/Vibration. Vibration. Goto Transmission (Manual) and Transfer Case Noise/Vibration. Shifting Noise or vibration condition related to the transmission (automatic). Goto Transmission (Automatic) Noise/Vibration. Noise or vibration related to the transmission (manual). Goto Transmission (Manual) and Transfer Case Noise/Vibration. Engaged in four-wheel drive. Goto Transmission (Manual) and Transfer Case Noise/Vibration. Cruising speeds Accelerator pedal vibration. Goto Engine Noise/Vibration. Driveline vibration. Goto Driveline Noise/Vibration.

01/2003 2003.0 BA Falcon


100-04-14

Noise, Vibration and Harshness

100-04-14

DIAGNOSIS AND TESTING (Continued) A shimmy or shake. Goto Tire Noise/Vibration. 9. Driving at low/medium speeds A wobble or shudder. Goto Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. Goto Suspension Noise/Vibration. Noise is random or intermittent occurring from road irregularities. Goto Squeak and Rattle. Noise or vibration changes from one road surface to another. Normal sound changes. Noise or vibration associated with a hard/firm ride. Goto Suspension Noise/Vibration.

Symptom Charts Symptom Chart — Air Leak and Wind Noise Condition Air leak around door perimeter

Air leak around glass run

Air leak at inner belt line

G72679 en

Source

Action

Loose fit seal.

PINCH the seal carrier to improve retention on the seal flange.

Seal installed incorrectly.

REINSTALL the seal.

Door misaligned.

REALIGN the door. CHECK door gaps and fit in the door opening and ADJUST as necessary.

Scuff plate installed incorrectly.

REINSTALL the scuff plate.

Seal or seal push pins damaged.

INSTALL a new seal.

Door glass misaligned.

ADJUST the door glass.

Glass run installed incorrectly.

ADJUST the glass run. INSERT foam in the glass run carrier.

Leak path behind glass run.

INSTALL foam rope behind the glass run.

Glass run channel spread wide.

PINCH the glass run channel to reduce the size of the opening.

Blow-out clip bent or contacting door glass.

ADJUST the blow-out clip or INSTALL a new glass run/blow-out clip molding assembly.

Glass run damaged.

INSTALL a new glass run.

Belt line seal installed incorrectly on flange.

ADJUST the seal. (Do not bend the flange.)

Belt line seal integrated with door trim installed incorrectly (no glass contact).

REINSTALL the door trim.

No contact with side glass.

ADJUST the door glass.

No contact with glass runs at both ends of belt line seal.

ADJUST the belt line seal or ADD foam at the seal ends.

Belt line seal damaged.

INSTALL a new seal.

01/2003 2003.0 BA Falcon


100-04-15

Noise, Vibration and Harshness

100-04-15

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Belt line seal installed incorrectly on flange (no glass contact).

ADJUST the seal.

Belt line seal does not contact the glass.

ADJUST the door glass.

No contact with glass runs at both ends of belt line seal.

ADJUST the belt line seal/ADD foam at the seal ends.

Belt line seal damaged.

INSTALL a new seal.

Hole in watershield.

SEAL the hole with a suitable tape.

Watershield misaligned.

REALIGN the watershield. INSTALL a new watershield if the pressure sensitive adhesive fails.

Exterior door handle seal misaligned/damaged.

REALIGN or INSTALL a new seal as necessary.

Exterior mirror housing misaligned.

REALIGN with the edges shingled correctly and no gaps.

Mirror sail gasket folded/misaligned.

REINSTALL with the gasket unfolded and aligned correctly.

Mirror housing trim cap installed incorrectly.

REINSTALL with the edges shingled to the air flow.

Air leak through mirror housing hinge.

Fully ENGAGE the mirror into its operating position/USE foam to block the air path through the hinge.

Inner sail trim installed incorrectly.

REINSTALL the sail trim/ADJUST the door trim.

Inner sail gasket/barrier installed incorrectly.

REINSTALL the trim cover with the gasket/barrier aligned correctly.

Air path through wiring bundle/fastener access holes.

BLOCK the air path(s) with foam/tape.

Exposed fastener access hole on mirror housing/sail.

INSTALL a new cap if it is missing.

Gaps in the sealant bead.

APPLY approved sealant.

Air traveling up windshield molding along A-pillar.

INSTALL foam rope the full length of the A-pillar.

Windshield/backlite misaligned or not installed correctly.

REINSTALL the windshield/backlite.

Rear hood seal at base of windshield misaligned/damaged.

REALIGN or INSTALL a new seal as necessary.

Air leak at cowl

Cowl gasket misaligned/damaged.

REALIGN or INSTALL a new seal as necessary.

Air leak around liftgate perimeter

Loose fit seal.

PINCH the seal carrier to improve retention on the seal flange or INSERT foam in the carrier.

Seal misaligned.

REINSTALL the seal.

Liftgate misaligned.

REALIGN the liftgate. CHECK the liftgate fit in the body opening and ADJUST as necessary.

Scuff plate misaligned.

REINSTALL the scuff plate.

Seal or seal push pins damaged.

INSTALL a new seal.

Air leak at outer belt line

Draft at inner door handle/speaker opening

Wind noise from exterior rear view mirror

Air leak around perimeter of fixed glass

G72679 en

01/2003 2003.0 BA Falcon


100-04-16

Noise, Vibration and Harshness

100-04-16

DIAGNOSIS AND TESTING (Continued) Condition Air leak around the liftgate flip window perimeter

Wind noise from antenna

Air leak from closed roof opening panel

Buffeting from an open roof opening panel

Wind noise created by airflow over or behind body panels

Wind noise created by grille opening panel

Wind noise from air extractor

Noise from roof rack

Wind noise from bug shield/exterior windshield sun visor

G72679 en

Source

Action

Loose fit seal.

PINCH the seal carrier to improve the retention to the seal flange.

Seal misaligned.

REINSTALL the seal.

Glass misaligned.

REALIGN the glass.

Seal damaged.

INSTALL a new seal.

Shape of antenna.

INSTALL an antenna boot or a spiral antenna.

Air leak around antenna cable access hole.

INSPECT the antenna access hole grommet. REPAIR as necessary.

Seal installed incorrectly.

REINSTALL the seal.

Roof opening panel glass/door misaligned.

REALIGN the roof opening panel glass/door.

Roof opening panel damaged.

INSTALL a new roof opening panel. REFER to Section 501-17 .

Wind deflector inoperative/damaged.

REPAIR or INSTALL a new wind deflector as necessary. REFER to Section 501-17 .

Wind deflector height incorrect.

ADJUST the wind deflector higher.

Fender splash shield misaligned.

REALIGN the fender splash shield.

Body panel misaligned (exposed edge).

REALIGN the appropriate body panel.

Hood misaligned (front margin).

CHECK hood gaps and fit. ADJUST the hood as necessary.

Front grille edge noise.

APPLY foam in the hollow areas behind the louvers.

Grille relationship to leading edge on hood.

ADJUST the grille opening panel forward to eliminate wind noise.

Sharp edges due to material imperfections.

REMOVE the sharp edges (no damage to visible surface).

Air extractor housing seated incorrectly.

REINSTALL the air extractor housing.

Air extractor housing or flaps damaged.

INSTALL a new air extractor.

Roof rack rails or crossbars loose.

TIGHTEN the fasteners.

Roof rack fasteners missing.

INSTALL the approved fasteners.

Roof rack crossbars installed backward.

REINSTALL the crossbars.

Roof rack rub strips partially lifting from roof.

REAPPLY adhesive or fasteners or INSTALL new rub strips as necessary.

Roof rack gaskets loose or misaligned.

REINSTALL the gasket.

Turbulence created by location and shape.

REMOVE per customer direction if it is a dealer installed option.

01/2003 2003.0 BA Falcon


100-04-17

Noise, Vibration and Harshness

100-04-17

DIAGNOSIS AND TESTING (Continued) Symptom Chart — Brake Noise/Vibration Condition

Source

Action

Caliper mounting bolts loose.

CHECK the caliper bolts. TIGHTEN to specifications. REFER to Section 206-03 .

Damaged or worn caliper pins or retainers.

CHECK the caliper pins and retainers for lubrication and correct fit. LUBRICATE or INSTALL new components as necessary.

Missing or damaged anti-rattle clips or springs.

CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary. REFER to Section 206-03 .

Loose brake disc shield.

TIGHTEN the brake disc shield bolts to specification. REFER to Section 206-03 .

Clicking noise—with brakes applied with ABS brakes

ABS hydraulic control unit.

Acceptable condition.

Squealing noise—occurs on first (morning) brake application

Disc brake pads.

Acceptable condition. Caused by humidity and low disc brake pad temperature.

Squealing noise—a continuous squeal

Disc brake pads worn below minimum thickness.

INSTALL new disc brake pads. REFER to Section 206-03 .

Squealing noise—an intermittent squeal brought on by cold, heat, water, mud or snow

Disc brake pads.

Acceptable condition.

Groaning noise—occurs at low speeds with brake lightly applied (creeping)

Disc brake pads.

Acceptable condition.

Grinding noise—continuous

Disc brake pads worn below minimum thickness.

INSPECT the brake pads, shoes, brake discs and attaching hardware for damage. REPAIR or INSTALL new components as necessary. REFER to Section 206-03 for front disc brakes or Section 206-02 for rear disks.

Moaning noise

Brake linings contaminated with grease or oil.

INSPECT the brake pads and shoes for contamination. REPAIR or INSTALL new components as necessary. REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disks.

Brake vibration/shudder—occurs when brakes are applied

Uneven disc or drum wear. Uneven disc brake pad or lining transfer. Suspension components.

Go to PinPoint Test A .

Brake vibration/shudder—occurs when the brake pedal is released

Brake drag.

INSPECT the brake pads and shoes for premature wear. REPAIR or INSTALL a new caliper or wheel cylinder as necessary. REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disk brakes.

Rattling noise

Symptom Chart—Driveline Noise/Vibration Condition Axle howling or whine—rear axle or transfer case

G72679 en

Source Axle lubricant low.

Action CHECK the lubricant level. FILL the axle to specification.

01/2003 2003.0 BA Falcon


100-04-18

Noise, Vibration and Harshness

100-04-18

DIAGNOSIS AND TESTING (Continued) Condition

Driveline clunk—loud clunk when shifting from reverse to drive

Driveline clunk—occurs as the vehicle starts to move forward following a stop

Clicking, popping or grinding—occurs while vehicle is turning

G72679 en

Source

Action

Axle housing damage.

INSPECT the axle housing for damage. REPAIR or INSTALL a new axle as necessary. REFER to Section 205-02 .

Damaged or worn wheel bearings or axle bearings.

CHECK for abnormal wheel bearing play or roughness. REFER to Wheel Bearing Check in this section. ADJUST or INSTALL new wheel bearings as necessary. REFER to Section 204-01 for front bearings or Section 204-02 for rear bearings.

Damaged or worn differential ring and pinion.

INSPECT the ring and pinion ring for abnormal wear patterns or broken teeth. INSTALL a new ring and pinion as necessary. REFER to Section 205-02 .

Damaged or worn differential side or pinion bearings.

CHECK for abnormal bearing play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02 .

Damaged or worn differential side gears and pinion gears.

DISASSEMBLE the differential carrier. INSPECT the side and pinion gears for abnormal wear patterns or broken teeth. INSTALL new gears as necessary. REFER to Section 205-02 .

Transfer case housing or internal gear damage or low lubricant.

INSPECT the transfer case for damage. CHECK the lubricant level and fill transfer case to specification. REFER to Section 308-07b .

Incorrect axle lubricant level.

CHECK the lubricant level. FILL the axle to specification.

Excessive backlash in the axle or transmission.

CARRY OUT a total backlash check.

Damaged or worn pinion bearings.

CHECK for abnormal bearing play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02 .

Damaged or worn universal joints (U-joints).

INSPECT the U-joints for wear or damage. INSTALL new U-joints as necessary. REFER to Section 205-01 .

Loose suspension components.

INSPECT the suspension for damage or wear. REPAIR or INSTALL new components as necessary. REFER to Section 204-00 .

Broken powertrain mounts.

INSPECT the powertrain mounts. INSTALL new mounts as necessary. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine.

Idle speed too high.

CHECK for the correct idle speed.

Worn driveshaft constant velocity (CV) joint or U-joints with excessive play.

INSPECT the CV joint and U-joints for a worn condition. INSTALL a new Driveshaft as necessary. REFER to Section 205-01 .

Loose rear axle mount.

CHECK the axle for loose bolts. TIGHTEN to specification.

Inadequate or contaminated lubrication in the CV joints.

CHECK the CV joint boots and joints for wear or damage. REPAIR or INSTALL new components as necessary. REFER to Section 205-04 .

01/2003 2003.0 BA Falcon


100-04-19

Noise, Vibration and Harshness

100-04-19

DIAGNOSIS AND TESTING (Continued) Condition

High pitched chattering—noise from the rear axle when the vehicle is turning

Buzz—buzzing noise is the same at cruise or coast/deceleration

Rumble or boom—noise occurs at coast/deceleration, usually driveshaft speed related and noticeable over a wide range of speeds

Grunting—normally associated with a shudder experienced during acceleration from a dead stop

G72679 en

Source

Action

Another component contacting the halfshaft.

CHECK the halfshafts and the area around the halfshafts. REPAIR as necessary.

Brake components.

INSPECT the front brakes for wear or damage. REPAIR as necessary. REFER to Section 206-03 .

Steering components.

INSPECT the drag link, inner and outer tie-rods or idler arm for wear or damage. REPAIR as necessary. REFER to Section 211-00 .

Suspension components.

INSPECT the upper and lower ball joints for wear or damage. REPAIR as necessary. REFER to Section 204-01 for front ball joints or Section 204-02 for rear ball joints.

Damaged or worn wheel bearings.

CHECK for abnormal wheel bearing play or roughness. REFER to Wheel Bearing Check in this section. ADJUST or INSTALL new wheel bearings as necessary. REFER to Section 204-01 for front wheel bearings or Section 204-02 for rear wheel bearings.

Incorrect or contaminated lubricant.

CHECK the vehicle by driving in tight circles (5 clockwise, 5 counterclockwise). FLUSH and REFILL with the specified rear axle lubricant and friction modifier as necessary.

Damaged or worn differential (differential side gears and pinion gears).

DISASSEMBLE the differential assembly. INSPECT the differential case, pin and gears for wear or damage. REPAIR or INSTALL a new differential as necessary. REFER to Section 205-02 .

Damaged or worn tyres.

CHECK for abnormal tyre wear or damage. INSTALL a new tyre as necessary. REFER to Section 204-04 .

Incorrect driveline angles.

CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .

Driveshaft is out-of-balance.

CHECK the driveshaft for damage, missing balance weights or undercoating. Using the Driveline balancer, CHECK the driveshaft balance. CARRY OUT a driveline vibration test. REFER to Section 205-00 . REPAIR as necessary.

U-joints binding or seized.

ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL new U-joints as necessary. REFER to Section 205-01 .

Excessive pinion flange runout.

CARRY OUT a runout check. REPAIR as necessary.

Driveshaft CV joint binding.

CLEAN the CV joint and INSTALL a new driveshaft as necessary. REFER to Section 205-01 .

Loose rear axle mount bolts or suspension fasteners

INSPECT the rear suspension and axle. TIGHTEN the fasteners to specification.

01/2003 2003.0 BA Falcon


100-04-20

Noise, Vibration and Harshness

100-04-20

DIAGNOSIS AND TESTING (Continued) Condition

Source

Howl—can occur at various speeds and driving conditions—affected by acceleration and deceleration

Incorrect ring and pinion contact, incorrect bearing preload or gear damage.

CHECK the ring and pinion and bearings for damage. INSPECT the ring and pinion wear pattern. REFER to Checking Tooth Contact Pattern and Condition of the Ring and Pinion component test in this section. ADJUST or INSTALL new components as necessary. REFER to Section 205-02 .

Chuckle—heard at coast/deceleration—also described as a knock

Incorrect ring and pinion contact or by damaged teeth on the coast side of the ring and pinion.

CHECK the ring and pinion for damage. INSPECT the ring and pinion wear pattern. REFER to Checking Tooth Contact Pattern and Condition of the Ring and Pinion component test in this section. ADJUST or INSTALL new components as necessary. REFER to Section 205-02 .

Knock—noise occurs at various speeds—not affected by acceleration or deceleration

Gear tooth damage to the ring and pinion.

CHECK the differential case and ring and pinion for damage. INSTALL new components as necessary. REFER to Section 205-02 .

Excessive axle shaft end play (vehicles with integral axles).

CHECK the axle end play using a dial indicator. INSTALL a new axle shaft or side gears as necessary. REFER to Section 205-02 .

Scraping noise—a continuous low pitched noise starting at low speeds

Worn or damaged pinion bearings.

CHECK the pinion bearings. INSTALL new pinion bearings as necessary. REFER to Section 205-02 .

Driveline shudder—occurs during acceleration from a slow speed or stop

Rear drive axle assembly mispositioned.

CHECK the axle mounts and the rear suspension for damage or wear. REPAIR as necessary.

Loose rear axle bolts.

INSPECT the bolts. TIGHTEN the bolt nuts to specification.

Incorrect or high CV joint operating angle.

CHECK vehicle ride height is within limits. REPAIR as necessary.

Damaged or worn front suspension components.

CHECK for a loose stabilizer bar, damaged or loose strut/strut bushings or loose or worn ball joints. INSPECT the steering linkage for wear or damage. REPAIR or INSTALL new components as necessary. REFER to Section 204-00 .

Driveline angles out of specification.

CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .

U-joints binding or seized.

ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL new U-joints as necessary. REFER to Section 205-01 .

Binding the driveshaft CV joint.

INSPECT the driveshaft shaft CV joint and coupling shaft for a worn, or damaged condition. INSTALL a new or driveshaft assembly as necessary. REPAIR as necessary. REFER to Section 205-01 . REPAIR as necessary.

Loose rear axle bolts.

INSPECT the bolts. TIGHTEN the bolts to specification.

G72679 en

Action

01/2003 2003.0 BA Falcon


100-04-21

Noise, Vibration and Harshness

100-04-21

DIAGNOSIS AND TESTING (Continued) Condition Driveline vibration—occurs at cruising speeds

Source

Action

U-joints are worn.

CHECK for wear or incorrect seating. INSTALL new driveshaft as necessary. REFER to Section 205-01 .

Worn or damaged driveshaft center bearing support.

CHECK the insulator for damage or wear. ROTATE the driveshaft and CHECK for rough operation. INSTALL a new center bearing support as necessary. REFER to Section 205-01 .

Loose axle pinion flange bolts.

INSPECT the axle pinion flange. TIGHTEN the pinion flange bolts to specification. REFER to Section 205-01 .

Excessive axle pinion flange runout.

CARRY OUT a Runout Check. REFER to Section 205-01 . REPAIR as necessary.

Driveshaft is out-of-balance.

CHECK the driveshaft for damage, missing balance weights or undercoating. CHECK driveshaft balance. CARRY OUT a driveline vibration test. REFER to Section 205-01 . REPAIR as necessary.

Binding or damaged driveshaft CV joint.

INSPECT the driveshaft CV joint for wear or damage. INSTALL a new driveshaft assembly as necessary. REFER to Section 205-01 . REPAIR as necessary.

Driveshaft runout.

CARRY OUT a runout check. REFER to Section 205-01 . REPAIR as necessary.

Incorrect lateral and radial tyre/wheel runout.

INSPECT the tyre and wheels. MEASURE tyre runouts. REPAIR or INSTALL new components as necessary. REFER to Section 204-04 .

Driveline angles out of specification.

CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .

Incorrectly seated CV joint in the front wheel hub.

CHECK the outer CV joint for correct seating into the hub. REPAIR as necessary. REFER to Section 205-04 for front CV joints or Section 205-05 for rear CV joints.

Symptom Chart — Engine Noise/Vibration Condition Grinding noise—occurs during engine cranking

G72679 en

Source

Action

Incorrect starter motor mounting.

INSPECT the starter motor for correct mounting. REPAIR as necessary. REFER to Section 303-06 .

Starter motor.

CHECK the starter motor. REPAIR or INSTALL a new starter motor as necessary. REFER to Section 303-06 .

Incorrect starter motor drive engagement.

INSPECT the starter motor drive and flexplate/flywheel for wear or damage. If necessary, INSTALL a new starter motor drive. REFER to Section 303-06 . If necessary, INSTALL a new flexplate/flywheel. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine.

01/2003 2003.0 BA Falcon


100-04-22

Noise, Vibration and Harshness

100-04-22

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Engine ticking noise

Fuel injector. Fuel line. Oil pump. Valve lifter. Belt tensioner. Water pump. Obstruction of cooling fan.

Go to PinPoint Test B .

Engine drumming noise—normally accompanied by vibration

Powertrain mount.

CARRY OUT Powertrain/Drivetrain Mount Neutralizing in this section.

Damaged or misaligned exhaust system.

INSPECT the exhaust system for loose or broken clamps and brackets, flex coupling or damper (2.0L Zetec). CARRY OUT Exhaust System Neutralizing in this section.

Whistling noise—normally accompanied with poor idle condition

Air intake system.

CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit. REPAIR or ADJUST as necessary. REFER to Section 303-12 .

Clunking noise

Water pump has excessive end play or imbalance.

CHECK the water pump for excessive end play. INSPECT the water pump with the drive belt off for imbalance. INSTALL a new water pump as necessary. REFER to Section 303-03 .

Alternator has excessive end play.

CHECK the generator for excessive end play. REPAIR or INSTALL a new alternator. REFER to Section 414-02 .

Exhaust system leak.

INSPECT the exhaust system for leaks. REPAIR as necessary.

Gasoline octane too low.

VERIFY with customer the type of gasoline used. CORRECT as necessary.

Knock sensor operation.

CHECK the knock sensor. INSTALL a new knock sensor as necessary. REFER to Section 303-14 .

Incorrect spark timing.

CHECK the spark timing. REPAIR as necessary.

High operating temperature.

INSPECT cooling system for leaks. CHECK the coolant level. REFILL as necessary. CHECK the coolant for the correct mix ratio. DRAIN and REFILL as needed. CHECK engine operating temperature is within specifications. REPAIR as necessary.

Foul-out spark plug.

CHECK the spark plugs. REPAIR or INSTALL new spark plugs as necessary.

Catalytic converter.

Acceptable noise.

Excessive clearance between the piston and the cylinder wall.

Engine cold and at high idle. Using an EngineEAR, pull a spark plug or fuel injector connector until the noise goes away. CARRY OUT a cylinder bore clearance to piston check. INSTALL a new piston.

Pinging noise

Knocking noise—light knocking noise, also described as piston slap—noise is most noticeable when engine is cold with light to medium acceleration—noise disappears as engine warms

G72679 en

01/2003 2003.0 BA Falcon


100-04-23

Noise, Vibration and Harshness

100-04-23

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Knocking noise—light double knock or sharp rap sound—occurs mostly with warm engine at idle or low speeds in DRIVE—increases in relation to engine load—associated with poor lubrication history

Excessive clearance between the piston and the piston pin.

INSTALL a new piston or piston pin.

Knocking noise—light knocking noise is most noticeable when engine is warm—noise tends to decrease when vehicle is coasting or in neutral

Excessive clearance between the connecting rod bearings and the crankshaft.

Engine warm and at idle. PULL a spark plug or fuel injector connector until the noise goes away. INSTALL new bearings.

Knocking—deep knocking noise—noise is most noticeable when engine is warm, at lower rpm and under a light load and then at float

Worn or damaged crankshaft main bearings.

CARRY OUT DERU test. CHECK for noise with vehicle at operating temperature, during medium to heavy acceleration. CHECK at idle with injector disconnected, noise does not change. INSTALL new main bearings.

Knocking noise—occurs mostly with warm engine at light/medium acceleration

Spark plugs.

CHECK the spark plug for damage or wear. INSTALL new spark plugs as necessary.

Carbon accumulation in combustion chamber.

REMOVE carbon from combustion chamber.

Air intake system.

CHECK the air cleaner and ducts for correct fit. INSPECT the air intake system for leaks or damage. REPAIR as necessary. REFER to Section 303-12 .

Alternator electrical field or bearings.

CARRY OUT alternator load test. REPAIR or INSTALL a new alternator as necessary. REFER to Section 412-02 .

Exhaust system.

CARRY OUT the Exhaust System Neutralizing in this section. REPAIR as necessary.

A/C compressor.

CHECK for noise with vehicle at constant speeds. CYCLE the compressor on and off and listen for a change in pitch. REPAIR as necessary. REFER to Section 412-03 .

Powertrain mounts.

CARRY OUT the Exhaust System Neutralizing in this section.

Sputter type noise—noise worse when cold, lessens or disappears when vehicle is at operating temperature

Damaged or worn exhaust system components.

INSPECT the exhaust system for leaks or damage. REPAIR as necessary. REFER to Section 309-00 .

Rattling noise—noise from the upper engine (valve train)—worse when engine is cold

Low oil level.

CHECK oil level. FILL as necessary.

Thin or diluted oil.

INSPECT the oil for contamination. If oil is contaminated, CHECK for the source. REPAIR as necessary. CHANGE the oil and filter.

Low oil pressure.

CARRY OUT an oil pressure test. If not within specifications, REPAIR as necessary. REFER to Section 303-00 .

Worn rocker arms/fulcrums or followers.

CARRY OUT a valve train analysis. INSTALL new valve train components as necessary. REFER to Section 303.

Worn valve guides.

CARRY OUT a valve train analysis. INSTALL new valve guides as necessary. REFER to Section 303.

Whine or moaning noise

Drone type noise

G72679 en

01/2003 2003.0 BA Falcon


100-04-24

Noise, Vibration and Harshness

100-04-24

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Excessive runout of valve seats on the valve face.

CARRY OUT a valve seat runout test. INSPECT the valve face and seat. INSTALL new valves as necessary. REFER to Section 303.

Rattling noise—from the bottom of the vehicle

Loose muffler shields or catalytic converter shields.

CHECK the exhaust system for loose shields. REPAIR as necessary.

Thumping noise—from the bottom of the vehicle, worse at acceleration

Exhaust pipe/muffler grounded to chassis.

CHECK the exhaust system to chassis clearance. CHECK the exhaust system hangers for damage. REPAIR as necessary.

Engine vibration—increases intensity as engine rpm is increased

Engine out-of-balance.

CARRY OUT Neutral Engine Run-up (NERU) Test. ROTATE the torque converter, 120° for 3 bolt and 180° for 4 bolt. INSPECT the torque converter pilot outer diameter to crankshaft pilot inner diameter.

Engine vibration—is felt with increases and decreases in engine rpm

Strain on exhaust mounts.

CARRY OUT the Exhaust System Neutralizing procedure in this section. REPAIR as necessary.

Damaged or worn powertrain/drivetrain mounts.

CHECK the powertrain/drivetrain mounts for damage. REPAIR as necessary.

Engine or transmission grounded to chassis.

INSPECT the powertrain/drivetrain for correct clearances. REPAIR as necessary.

Excessive engine pulley runout.

CARRY OUT Engine Accessory Test. INSTALL a new engine pulley as necessary. REFER to Section 303.

Damaged or worn accessory component.

CARRY OUT Engine Accessory Test. REPAIR or INSTALL a new component as necessary. REFER to Section 303-05.

Engine vibration—mostly at coast/neutral coast—condition improves with vehicle accelerating

Combustion instability.

CHECK the ignition system. INSTALL new components as necessary.

Engine vibration or shudder—occurs with light to medium acceleration above 56 km/h (35 mph)

Worn or damaged spark plugs.

INSPECT the spark plugs for cracks, high resistance or broken insulator. INSTALL a new spark plug(s) as necessary.

Plugged fuel injector.

REPAIR or INSTALL a new injector as necessary.

Damaged spark plug wire.

INSPECT the spark plug wires for damage. INSTALL a new spark plug wire(s) as necessary.

Contaminated fuel.

INSPECT the fuel for contamination. DRAIN the fuel system and refill.

Worn or damaged torque converter.

CHECK the torque converter. INSTALL a new torque converter as necessary. REFER to Section 307-01 .

Engine vibration—vibration felt at all times

Symptom Chart—Idle Noise/Vibration Condition

Source

Idle air control (IAC) valve moan — occurs on throttle tip-out

IAC valve is contaminated with oil.

G72679 en

Action GO to Component Tests in this section.

01/2003 2003.0 BA Falcon


100-04-25

Noise, Vibration and Harshness

100-04-25

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Accessory drive belt chirp — occurs at idle or high idle, cold or hot—most common occurrence is during humid weather

Accessory drive belt worn, or pulley is misaligned or loose.

INSPECT for loose or misaligned pulleys. CHECK the drive belt for wear or damage. INSTALL new pulley(s) or accessory drive belt, as necessary. REFER to Section 303-05 .

Accessory drive bearing hoot — occurs at idle or high idle in cold temperatures of approximately +4°C (+40°F) or colder at first start of the day

Accessory drive idler or tensioner pulley bearing is experiencing stick/slip between ball bearings and bearing race.

Go to PinPoint Test C .

Power steering moan — occurs at high idle and possibly at idle during the first cold start of the day in temperatures of approximately -18°C (0°F) or colder—noise can even be a severe screech for less than one minute in very cold temperatures of approximately -29°C (-20°F) or colder

High fluid viscosity, or plugged reservoir screen in power steering reservoir starves pump causing cavitation.

Go to PinPoint Test D .

Alternator whine — during high electrical loads at idle or high idle, a high pitch whine or moan is emitted from the alternator

Alternator electrical field noise.

CHECK for changes in the noise level while changing electrical loads (such as rear defrost, headlamps etc.). CARRY OUT a alternator load test. REFER to Section 414-00 . If the system passes the load test, the noise is from the alternator bearings, INSTALL new bearings. If the system fails the load test, INSTALL a new alternator. REFER to Section 414-02 .

Drumming noise — occurs inside the vehicle during idle or high idle, hot or cold—very low-frequency drumming is very rpm dependent

Exhaust system vibration excites the body resonances inducing interior noise. Engine vibration excites the body resonances inducing interior noise.

Go to PinPoint Test E .

Hissing noise — occurs during idle or high idle that is apparent with the hood open

Vacuum leak or idle air control (IAC) valve flow noise.

CHECK the air intake system from the inlet to each cylinder intake port. DISCARD the leaking parts, and INSTALL a new component.

Automatic transmission buzz or hiss

Incorrect driveline angles.

CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .

Worn or damaged main control solenoids or valves.

Using a transmission tester, ACTIVATE the solenoids to duplicate sound. INSTALL new components as necessary. REFER to Section 307-01 .

Manual Transmission Clutch throw-out bearing whine—a change in noise pitch or loudness while depressing the clutch pedal

Worn throw-out bearing.

INSTALL a new throw-out bearing. REFER to Section 308-01 .

Heating, vacuum and air conditioning (HVAC) system chirp — most audible inside the vehicle—listen for a change in noise pitch or loudness while changing the HVAC system blower speed

Damaged or worn HVAC blower bearing.

INSTALL a new blower motor. REFER to Section 412-02 .

Air conditioning (A/C) clutch ticking — occurs when the compressor clutch engages

Acceptable noise. Incorrect air gap.

LISTEN to the clutch to determine if the noise occurs with clutch engagement. A small amount of noise is acceptable. If the noise is excessive, CHECK the A/C clutch air gap. INSPECT the A/C clutch for wear or damage. INSTALL a new clutch as necessary. REFER to Section 412-03 .

G72679 en

01/2003 2003.0 BA Falcon


100-04-26

Noise, Vibration and Harshness

100-04-26

DIAGNOSIS AND TESTING (Continued) Condition Intermittent rattle, or scraping/rubbing noise

Source

Action

Loose exhaust heat shield(s).

INSPECT the exhaust system for loose parts using a glove or clamps to verify cause. REPAIR as necessary. REFER to Section 309-00 .

Wiring, hose or other part interfering with the accessory drive belt or pulley.

INSPECT the accessory drive system closely verifying there is adequate clearance to all rotating components. REPAIR as necessary.

Engine ticking or knocking noise — occurs during idle or high idle during the first cold start of the day

Piston noise or valvetrain noise (bled down lifter/lash adjuster).

Go to PinPoint Test F .

A continuous, speed-dependent rattle from the engine — occurs during idle or high idle during the first cold start of the day and disappears as the engine warms up

Piston noise or valvetrain noise (bled down lifter/lash adjuster).

Go to PinPoint Test F .

Idle vibration—a low-frequency vibration (5-20 Hz) or mild shake that is felt through the seat/floorpan

Cylinder misfire.

Using the diagnostic tool, CHECK the ignition system. CARRY OUT a cylinder power test. REFER to Section 303-00 .

Engine or torque converter out of balance.

VERIFY the torque converter to crankshaft pilot clearance is correct, REPAIR as necessary. RE-INDEX the torque converter on the flex plate by 120° on a 3-bolt converter or 180° for a 4-bolt converter. REFER to Section 307-01 . RETEST the vehicle.

Exhaust system mounts bound up.

VERIFY concern occurs at engine firing frequency. CHECK that the exhaust system vibrates at the same frequency as the engine. ADD 9–14 km (20–30 lb.) to the tail pipe to test, CARRY OUT Exhaust System Neutralizing in this section.

Power steering lines grounded out.

INSPECT that the power steering lines are not contacting the chassis or each other. REPAIR as necessary.

Engine mounts binding.

NEUTRALIZE the powertrain/drivetrain mounts. CARRY OUT Powertrain/Drivetrain Mount Neutralizing in this section.

Idle vibration—a high-frequency vibration (20–80 Hz) or buzz, that is felt through the steering wheel or seat

Symptom Chart—Squeak and Rattle Condition

Source

Squeak—heard inside the vehicle when closing/opening the door

Insufficient lubrication on the door hinge or check strap.

LUBRICATE the hinge or check strap.

Internal door components loose, rubbing or misaligned.

CHECK the inside of the door. TIGHTEN or ALIGN as necessary. USE the Rotunda Squeak and Rattle Kit to ISOLATE any rubbing components.

Squeak—heard inside the vehicle when closing/opening the window

Worn or damaged glass run/channel.

REPAIR or INSTALL a new glass run/channel. REFER to Section 501-11 .

Squeak—heard outside of vehicle when closing/opening the door

Exhaust shield rubbing against the chassis or exhaust pipe.

CHECK the exhaust system. REPAIR as necessary. REFER to Section 309-00 .

G72679 en

Action

01/2003 2003.0 BA Falcon


100-04-27

Noise, Vibration and Harshness

100-04-27

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Squeak—occurs with initial brake pedal application

Disc brake pads.

Under certain conditions, asbestos free pads can generate a squeak noise. This noise is normal and does not indicate a concern.

Squeak—a constant noise that occurs with brake pedal applications

Damaged or worn disc brake pads.

INSPECT the pads for oil, grease or brake fluid contamination. CHECK for glazed linings. A brake disc with hard spots will also cause a squeak type noise. REPAIR or INSTALL new brake pads as necessary. REFER to Section 206-03 .

Squeak—noise occurs over bumps or when turning

Worn control arm bushings.

INSPECT the control arm bushings. Spray with lubricant and CARRY OUT a “bounce test” to determine which bushing. REPAIR as necessary. REFER to Section 204-01 for front bushings or Section 204-02 for rear bushings.

Worn or damaged shock absorber/strut.

INSPECT the shock absorber for damage. CARRY OUT a “bounce test” to isolate the noise. INSTALL a new shock absorber/strut as necessary. REFER to Section 204-01 for front shock absorber/strut or Section 204-02 for rear shock absorber/strut.

Rattle—heard when closing/opening the door or window

Loose internal door mechanism, bracket or attachment.

REPEAT the motion or CARRY OUT a “tap test” to duplicate the noise. INSPECT the door for loose components. TIGHTEN loose components.

Squeak or rattle—heard inside the vehicle over rough roads/bumps

Misaligned glove compartment door/hinge.

ALIGN the glove compartment door.

Instrument panel trim loose or misaligned.

INSPECT the instrument panel trim for missing or loose clips or screws. REPAIR as necessary.

Loose interior component or trim.

CARRY OUT a “touch test”. ELIMINATE the noise by pressing or pulling on interior trim and components.

Damaged or worn sub-frame mounts.

INSPECT the upper and lower absorbers for damage or wear. CHECK the sub-frame for damage. CHECK the nuts and bolts are tightened to specifications. TIGHTEN as necessary.

Squeak or rattle—noise with a vibration concern

Symptom Chart—Steering Noise/Vibration Condition

Source

Action

Steering grunt or shudder — occurs when turning into or out of a turn at low speeds (temperature sensitive)

Steering gear or power steering hoses.

GO to Steering Gear Grunt/Shudder Test component test in this section.

Steering System clonk—hydraulic knocking sound

Air in the steering hydraulic system.

CHECK for leaks in the system. PURGE the air from the system. REFER to Section 211-00 .

Power steering pump moan — loud humming noise occurs when the steering wheel is rotated to the stop position. Produces a 120-600 Hz frequency that changes with rpm

Power steering hose grounded out to chassis.

INSPECT the power steering hoses. REPAIR as necessary.

G72679 en

01/2003 2003.0 BA Falcon


100-04-28

Noise, Vibration and Harshness

100-04-28

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Aerated fluid.

CHECK for leaks in the system. PURGE the air from the system. REFER to Section 211-00 .

Steering gear isolators.

INSPECT the isolators for wear or damage. REPAIR as necessary.

Low fluid.

CHECK the fluid level. REFILL as necessary.

Power steering pump brackets loose or misaligned.

CHECK bolts, brackets and bracket alignment. TIGHTEN bolts to specification. REPAIR or INSTALL new brackets as necessary. REFER to Section 211-02.

Steering gear clunk — occurs only while cornering over a bump (can be temperature sensitive)

Steering gear.

INSPECT the steering gear for loose mounting bolts. TIGHTEN as necessary. REFER to Section 211-02 .

Feedback (rattle, chuckle or knocking noise in the steering gear) — a condition where roughness is felt in the steering wheel when the vehicle is driven over rough surfaces

Column intermediate/flexible shaft joints damaged or worn.

INSTALL a new intermediate/flexible shaft. REFER to Section 211-04 .

Loose, damaged or worn tie-rod ends.

TIGHTEN the nuts to specification or INSTALL new tie-rod ends as necessary. REFER to Section 211-03 .

Steering gear insulators or mounting bolts loose or damaged.

TIGHTEN the bolts or INSTALL new bolts as necessary. REFER to Section 211-02 .

Steering column intermediate shaft bolts are loose.

TIGHTEN the bolts to specification.

Steering column damaged or worn.

REPAIR or INSTALL a new steering column as necessary. REFER to Section 211-04 .

Loose suspension bushings, bolts or ball joints.

INSPECT the suspension system. TIGHTEN or INSTALL new components as necessary. REFER to Section 204-01 for front suspension or Section 204-02 for rear suspension.

Feedback (nibble at the steering wheel) — a condition where slight rotational movement is felt in the steering wheel when the vehicle is driven over rough or grooved surfaces

Lateral runout in the tyre or wheel.

GO to Pinpoint Test G.

Accessory drive belt squeal/chirp—when rotating the steering wheel from stop to stop

Loose or worn accessory drive belt.

ADJUST or INSTALL a new accessory belt as necessary. REFER to Section 303-05 .

Power steering gear hiss

Steering column intermediate/flexible shaft-to-steering gear is binding or misaligned.

REPAIR or INSTALL a new intermediate/flexible shaft as necessary. REFER to Section 211-04 .

Grounded or loose steering column boot at the dash panel.

REPAIR as necessary.

Damaged or worn steering gear input shaft and valve.

REPAIR or INSTALL a new steering gear as necessary. REFER to Section 211-02 .

Steering column rattle

G72679 en

Loose bolts or attaching brackets.

TIGHTEN the bolts to specifications.

Loose, worn or insufficiently lubricated column bearings.

LUBRICATE or INSTALL new steering column bearings as necessary. REFER to Section 211-04 .

01/2003 2003.0 BA Falcon


100-04-29

Noise, Vibration and Harshness

100-04-29

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Steering shaft insulators damaged or worn.

INSTALL new insulators. REFER to Section 211-04 .

Intermediate/flexible shaft compressed or extended.

INSTALL a new intermediate/flexible shaft. REFER to Section 211-04 .

Insufficiently lubricated steering shaft bushings.

LUBRICATE the steering shaft and shaft tube seals.

Loose or misaligned steering column shrouds.

TIGHTEN or ALIGN the steering column shrouds.

Steering wheel rubbing against steering column shrouds.

REPOSITION the steering column shrouds.

Insufficient lubricated speed control slip ring.

LUBRICATE the speed control slip ring.

Upper or lower bearing sleeve out of position.

REPOSITION the bearing sleeves.

Power steering pump noisy

Incorrect assembly of components. Imperfections on the outside diameter or end surface of the power steering pump rotor. Damaged or worn power steering pump rotor splines. A crack on the inner surface of the power steering pump cam. Interference between the power steering pump rotor and cam. Damaged or worn power steering pump rotor and pressure plates.

REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .

Power steering pump swish noise

Power steering fluid flow into the bypass valve of the pump valve housing with fluid temperature below 54°C (130°F).

Acceptable condition.

Power steering pump whine noise

Aerated fluid.

PURGE the air from the system. REFER to Section 211-00 . CHECK for a leak in the system.

Damaged power steering pump.

REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .

Damaged valve cover O-ring seal.

REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .

Power steering pump clicking (mechanical) noise

Power steering pump rotor slippers too long, excessive rotor slipper-to-slot clearance or damaged or worn rotor assembly.

REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .

Power steering pump clatter noise

Damaged corners on the outside diameter or the power steering rotor or distorted rotor slipper ring.

REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .

Steering column squeak or cracks

Symptom Chart—Suspension Noise/Vibration Condition

Source

Action

Squeak or grunt—noise from the front suspension, occurs more in cold ambient temperatures—more noticeable over rough roads or when turning

Front stabilizer bar insulators.

Under these conditions, the noise is acceptable. CHECK TSBs.

Clunk—noise from the front suspension, occurs in and out of turns

Loose front struts or shocks.

INSPECT for loose nuts or bolts. TIGHTEN to specifications. REFER to Section 204-01 .

G72679 en

01/2003 2003.0 BA Falcon


100-04-30

Noise, Vibration and Harshness

100-04-30

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Clunk—noise from the rear suspension, occurs when shifting from reverse to drive

Loose rear suspension components.

INSPECT for loose or damaged rear suspension components. REPAIR or INSTALL new components as necessary. REFER to Section 204-02 .

Click or pop—noise from the front suspension—more noticeable over rough roads or over bumps

Worn or damaged ball joints.

CARRY OUT a ball joint inspection. INSTALL new control arm as necessary. REFER to Section 204-01 .

Front suspension noise—a squeak, creak or rattle noise—occurs mostly over bumps or rough roads

Steering components. Loose or bent front struts or shock absorbers. Damaged spring or spring mounts. Damaged or worn control/radius arm bushings. Worn or damaged stabilizer bar bushings or links.

Go to PinPoint Test G .

Rear suspension noise—a squeak, creak or rattle noise—occurs mostly over bumps or rough roads

Loose or bent rear shock absorbers. Damaged spring or spring mounts. Damaged or worn control arm bushings.

Go to PinPoint Test H .

Shudder—occurs during acceleration from a slow speed or stop

Rear drive axle assembly mispositioned.

CHECK the axle mounts and the rear suspension for damage or wear. REPAIR as necessary.

Incorrect or high CV joint operating angle.

CHECK vehicle ride height is within limits. REPAIR as necessary.

Damaged or worn front suspension components.

CHECK for a loose stabilizer bar, damaged or loose strut/strut bushings or loose or worn ball joints. INSPECT the steering linkage for wear or damage. REPAIR or INSTALL new components as necessary.

Excessive positive caster.

CHECK the caster alignment angle. CORRECT as necessary. REFER to Section 204-00 .

Shimmy—most noticeable on coast/deceleration—also hard steering condition

Symptom Chart—Tyre Noise/Vibration Condition

Source

Action

Tyre noise—hum/moan at constant speeds

Abnormal wear patterns.

SPIN the tyre and CHECK for tyre wear. INSTALL a new tyre as necessary. INSPECT for damaged/worn suspension components. CARRY OUT wheel alignment.

Tyre noise—noise tone lowers as the vehicle speed is lowered

Out-of-balance tyre.

BALANCE the tyre and road test. INSTALL a new tyre as necessary. REFER to Section 204-04 .

Tyre noise — ticking noise, changes with speed

Nail puncture or stone in tyre tread.

INSPECT the tyre. REPAIR as necessary.

Wheel and tyre—vibration and noise concern is directly related to vehicle speed and is not affected by acceleration, coasting or decelerating

Damaged or worn tyre.

Go to PinPoint Test I .

Tyre wobble or shudder — occurs at lower speeds

Damaged wheel bearings.

SPIN the tyre and CHECK for abnormal wheel bearing play or roughness. ADJUST or INSTALL new wheel bearings as necessary. REFER to Section 204-01 for front bearings or Section 204-02 for rear bearings.

G72679 en

01/2003 2003.0 BA Falcon


100-04-31

Noise, Vibration and Harshness

100-04-31

DIAGNOSIS AND TESTING (Continued) Condition

Tyre shimmy or shake— occurs at lower speeds

High speed shake or shimmy—occurs at high speeds

Source

Action

Damaged wheel.

INSPECT the wheel for damage. INSTALL a new wheel as necessary. REFER to Section 204-04 .

Damaged or worn suspension components.

INSPECT the suspension components for wear or damage. REPAIR as necessary.

Loose wheel nuts.

CHECK the wheel nuts. TIGHTEN to specification. REFER to Section 204-04 .

Damaged or uneven tyre wear.

SPIN the tyre and CHECK for abnormal tyre wear or damage. INSTALL a new tyre as necessary. REFER to Section 204-04 .

Wheel/tyre out of balance.

BALANCE the wheel/tyre assembly.

Uneven tyre wear.

CHECK for abnormal tyre wear. INSTALL a new tyre as necessary. REFER to Section 204-04 .

Excessive radial runout of wheel or tyre.

CARRY OUT a radial runout test of the wheel and tyre. INSTALL a new tyre as necessary. REFER to Section 204-04 .

Worn or damaged wheel studs or elongated stud holes.

INSPECT the wheel studs and wheels. INSTALL new components as necessary.

Excessive lateral runout of the wheel or tyre.

CARRY OUT a lateral runout test of the wheel and tyre. CHECK the wheel, tyre and hub. REPAIR or INSTALL new components as necessary.

Foreign material between the brake disc and hub or in the brake disc fins.

CLEAN the mounting surfaces of the brake disc and hub. CHECK the brake disc fins for material.

Excessive wheel hub runout. Damaged or worn tyres. Damaged or worn wheel bearings. Worn or damaged suspension or steering linkage components. Brake disc or drum imbalance.

Go to PinPoint Test J .

Symptom Chart—Transmission (Manual) Vibration Condition

Source

Action

Clutch rattling noise—occurs with clutch engaged, noise changes/disappears with clutch pedal depressed

Flywheel bolts, clutch housing bolts or clutch pressure plate bolts loose.

TIGHTEN the bolts to specifications. CHECK the bolts for damage.

Clutch squeaking noise—noise is heard when the clutch is operated—vehicle moves slowly or creeps when the clutch is disengaged—can also be difficult to shift into first and reverse gear

Pilot bearing seized or damaged.

INSTALL a new pilot bearing. REFER to Section 308-01 .

Clutch squeaking noise—occurs with clutch pedal depressed/released

Worn clutch pedal shaft or bushings.

INSPECT the clutch pedal for wear or damage. REPAIR as necessary. REFER to Section 308-02 .

Clutch whirring/rattle noise—occurs when clutch pedal is depressed

Worn, damaged or misaligned clutch release bearing.

INSTALL a new clutch release bearing. REFER to Section 308-02 .

G72679 en

01/2003 2003.0 BA Falcon


100-04-32

Noise, Vibration and Harshness

100-04-32

DIAGNOSIS AND TESTING (Continued) Condition Clutch grating/grinding noise—occurs when clutch pedal is depressed

Source

Action

Clutch pressure plate fingers bent or worn.

INSPECT the clutch pressure plate release fingers. INSTALL a new pressure plate as necessary. REFER to Section 308-01 .

Contact surface of clutch release bearing worn or damaged.

INSTALL a new clutch release bearing. REFER to Section 308-01 .

Clutch chatter—a small amount of noise when clutch pedal is released at initial take-off

Clutch engagement.

Acceptable operating condition.

Clutch chatter/grabs—in some cases a shudder is felt—occurs with clutch pedal depressed/released

Damaged or worn powertrain/driveline mounts.

INSPECT the powertrain/drivetrain mounts. INSTALL new mounts as necessary. REFER to Section 308-03 .

Binding or dragging plunger of the clutch master cylinder or slave cylinder.

CHECK the master and slave cylinder operation. INSPECT the components for damage or wear. INSTALL a new master or slave cylinder as necessary. REFER to Section 308-02 .

Grease or oil on the clutch disc facing.

CHECK the input shaft seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch disc. REFER to Section 308-03 .

Clutch disc surface glazed or damaged.

INSPECT the clutch disc surface for a glazed, hardened or damage condition. CARRY OUT a disc check. INSTALL a new clutch disc as necessary. REFER to Section 308-01 .

Damaged or worn clutch pressure plate.

INSPECT the clutch pressure plate for wear or damage. INSTALL a new clutch pressure plate as necessary. REFER to Section 308-01 .

Flywheel surface damaged or glazed.

INSPECT the flywheel for damage or wear. CARRY OUT a flexplate/flywheel runout check. INSTALL a new flywheel as necessary. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine.

Clutch chatter noise—noise when clutch pedal is released at initial take-off—clutch is hard to engage and disengage

Pilot bearing worn, damaged or not correctly aligned in bore.

INSPECT the clutch pressure plate release fingers for uneven wear, clutch components burnt or a seized pilot bearing. INSTALL a new pilot bearing as necessary. REFER to Section 308-01 .

Clutch vibration

Loose flywheel bolts. Damaged or loose clutch pressure plate. Excessive flywheel runout.

Go to PinPoint Test K .

Transmission rattling/clattering noise—noise at idle or on light acceleration from a stop—gear selection difficult

Gearshift lever joint worn or damaged.

INSTALL a new gearshift lever. REFER to Section 308-06 .

Gearshift lever loose.

TIGHTEN the bolts to specification. REFER to Section 308-06 .

Gearshift linkage rods worn or damaged.

CHECK the linkage bushings for wear. INSTALL new linkage rods as necessary. REFER to Section 308-06 .

Incorrect fluid level or fluid quality.

CHECK that the transmission is filled to the correct level and with the specified fluid. REFER to Section 308-03 .

Transmission rattling/clattering noise—occurs in neutral or in gear, at idle

G72679 en

01/2003 2003.0 BA Falcon


100-04-33

Noise, Vibration and Harshness

100-04-33

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Worn or rough reverse idler gear.

CHECK the reverse idler gear. REPAIR as necessary. REFER to Section 308-03 .

Rough running engine, cylinder misfire.

CHECK the ignition system. CARRY OUT a cylinder power test. REFER to Section 303-00 .

Excessive backlash in gears

CHECK the gear backlash. ADJUST as necessary. REFER to Section 308-03 .

Worn countershaft gears.

REPAIR as necessary. REFER to Section 308-03 .

Transmission whine—a mild whine at extreme speeds or high rpm

Rotating gears/geartrain.

Acceptable noise.

Transmission whine—a high pitched whine, also described as a squeal

Transmission gears are worn (high mileage vehicle).

Result of normal gear wear. REPAIR as necessary. REFER to Section 308-03 .

Mismatched gear sets.

INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as necessary. REFER to Section 308-03 .

Damaged or worn transmission bearing.

INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .

Transmission growling/humming—noise occurs in the forward gears—the noise is more prominent when the gear is loaded—the problem gear can be located as the noise occurs in a specific gear position

Gear is cracked, chipped or rough.

INSPECT the transmission gears for damage or wear. INSTALL new gears as necessary. REFER to Section 308-03 .

Transmission hissing—noise in neutral or in forward gears—as bearings wear or break up, the noise changes to a thumping noise

Damaged or worn bearings.

INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .

Transmission knocking/thudding—noise at low speeds in forward gears

Bearings with damaged balls or rollers or with pitted and spalled races.

INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .

Transmission rumble/growl—noise at higher speeds in forward gears, more pronounced in a coast/deceleration condition

Incorrect driveline angle.

CHECK the driveline angle. REPAIR as necessary. REFER to Section 205-00 .

Driveshaft out of balance or damaged.

CHECK the driveshaft for damage, missing balance weights or undercoating. Using the EVA, CHECK the driveshaft balance. CARRY OUT a driveline vibration test. REFER to Section 205-01 . REPAIR as necessary.

Damaged or worn transmission bearing or gears (high mileage vehicles).

CHECK transmission fluid for excessive metal particles. REPAIR as necessary. REFER to Section 308-03 .

Transmission rattling/clattering noise—noise at idle in neutral

Transmission rumble/growl—noise at all speeds in forward gears, more pronounced in a heavy acceleration condition

Symptom Chart—Transmission (Automatic) Noise/Vibration Condition Rattle—occurs at idle or at light acceleration from a stop

G72679 en

Source Damaged engine or transmission mounts.

Action CHECK the powertrain/drivetrain mounts for damage. INSTALL new mounts as necessary. REFER to 303.

01/2003 2003.0 BA Falcon


100-04-34

Noise, Vibration and Harshness

100-04-34

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

A loose front exhaust pipe heat shield.

REPAIR or INSTALL a new heat shield as necessary.

Loose inspection plate or dust cover plate.

CHECK for loose bolts. TIGHTEN to specifications. REFER to Section 307-01 .

Loose flex plate to converter nuts.

CHECK for loose nuts. TIGHTEN to specifications. REFER to Section 307-01 .

Whine—pitch increases with vehicle speed—starts in first and second gear, decreases or goes away at higher gears

Damaged or worn low one-way clutch. Damaged or worn intermediate one-way clutch. Friction elements. Damaged or worn planetary or sun gear.

INSPECT the transmission for wear or damage. REPAIR or INSTALL new components as necessary. REFER to Section 307-01 .

Whine—the pitch changes with engine speed

A worn or damaged accessory drive component.

CARRY OUT the Engine Accessory Test. REPAIR or INSTALL new components as necessary. REFER to Section 303-05 .

Incorrect fluid level.

CHECK that the transmission is filled to the correct level. ADD fluid as necessary. REFER to Section 307-01 .

Partially blocked filter.

INSPECT the filter. CLEAN or INSTALL a new filter as necessary.

Worn or damaged torque converter.

CARRY OUT the torque converter service and replacement check. REFER to Section 307-01 .

Worn or damaged front pump.

INSPECT the front pump. INSTALL a new front pump as necessary. REFER to Section 307-01 .

Whine—pitch changes with vehicle speed

Speedometer gears.

REPAIR or INSTALL new gears as necessary.

Whine/moan type noise—pitch increases or changes with vehicle speed

Damaged engine or transmission mount.

CHECK the powertrain/drivetrain mounts for damage. CARRY OUT Powertrain/Drivetrain Mount Neutralizing in this section.

U-joints worn or damaged.

INSPECT the U-joints for wear or damage. INSTALL new U-joints as necessary. REFER to Section 205-01 .

Damaged or worn differential ring and pinion.

INSPECT the differential ring and pinion for damage. CARRY OUT the Checking Tooth Contact Pattern and Condition of the Ring and Pinion component test in this section. REPAIR or INSTALL a new differential ring and pinion as necessary. REFER to Section 205-02 .

Planetary gears nicked or chipped.

CHECK the planetary gears for damage. INSTALL new components as necessary. REFER to Section 307-01 .

Hydraulic pressure in the main control.

INSPECT the main control. REPAIR or INSTALL new components as necessary. REFER to Section 307-01 .

Incorrect band/clutch apply pressure.

CARRY OUT the line pressure tests. REPAIR or INSTALL components as necessary. REFER to Section 307-01 .

Whistle—noise is high pitched, constant—changes in pitch with throttle position

G72679 en

01/2003 2003.0 BA Falcon


100-04-35

Noise, Vibration and Harshness

100-04-35

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Worn or damaged torque converter.

CARRY OUT the torque converter service and replacement check. REFER to Section 307-01 .

Damaged powertrain mounts.

INSPECT the powertrain mounts for damage. INSTALL new mounts as necessary. REFER to Section 307-01 .

Damaged or worn pinion bearings.

CHECK for abnormal bearing play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02 .

Worn driveshaft CV joint.

INSPECT the CV joint. INSTALL a new driveshaft as necessary. REFER to Section 205-01 .

Worn friction elements or excessive clutch pack end plate play.

INSPECT the transmission for wear. CHECK that all end play and clearances are within specification. REPAIR or INSTALL new components as necessary. REFER to Section 307-01 .

Bump—occurs when shifting from PARK to a drive or reverse position—similar to Clunk but with no sound

Initial gear engagement.

Acceptable condition.

Buzz or hiss

Incorrect driveline angles.

CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .

Worn or damaged main control solenoids or valves.

INSTALL new components as necessary. REFER to Section 307-01 .

Transmission cooler lines grounded out.

CHECK the transmission cooler lines. REPAIR as necessary.

Flexplate to torque converter nuts loose.

CHECK the flexplate nuts. TIGHTEN to specification. REFER to Section 307-01 .

Fluid filler tube grounded out.

CHECK the fluid filler tube. REPAIR as necessary.

Electrical inputs/outputs. Vehicle wiring harness. Incorrect inputs/outputs from the powertrain control module (PCM), digital transmission range (TR) sensor, brake pedal position (BPP) sensor, throttle position (TP) sensor, transmission speed sensor (TSS), output speed shaft (OSS) sensor or the torque converter clutch (TCC).

CARRY OUT a Torque Converter Clutch Operation Test. RUN on-board diagnostics or self–test. CLEAR the DTCs, ROAD TEST and RERUN on-board diagnostics or self–test.

Clunk—occurs when shifting from PARK to a drive or reverse position

Vibration—a high frequency (20–80 Hz) that is felt through the seat or gear shifter—changes with engine speed

Shutter or chatter—occurs with light to medium acceleration from low speeds or a stop

system for normal operation. Sometimes, it is necessary to remove various vehicle components to The pinpoint tests are a step-by-step diagnostic gain access to the component requiring testing. For process designed to determine the cause of a additional information, refer to the appropriate section condition. It may not always be necessary to follow a for removal and installation procedures. Reinstall all pinpoint test to its conclusion. Carry out only the steps components after verifying system operation is necessary to correct the condition. Then, test the normal.

Pinpoint Tests

G72679 en

01/2003 2003.0 BA Falcon


100-04-36

Noise, Vibration and Harshness

100-04-36

DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A : BRAKE VIBRATION/SHUDDER Test Step A1

Result / Action to Take

ROAD TEST THE VEHICLE—LIGHT BRAKING Check that the wheel and tyres are correct for the vehicle. Inspect the tyres for abnormal wear patterns. Road test the vehicle. Warm the brakes by slowing the vehicle a few times from 80–32 km/h (50 to 20 mph) using light braking applications. At highway speeds of 89–97 km/h (55-60 mph), apply the brake using a light pedal force.

Yes

Go to A4.

No

Go to A2.

Is there a vibration/shudder felt in the steering wheel, seat or brake pedal?

A2

ROAD TEST THE VEHICLE—MODERATE TO HEAVY BRAKING Road test the vehicle. At highway speeds of 89–97 km/h (55-60 mph), Yes apply the brake using a moderate to heavy pedal force. For vehicles with ABS, Go to A3. For vehicles with standard brakes, Go to A4. Is there a vibration/shudder?

No

Vehicle is OK. VERIFY condition with customer. TEST the vehicle for normal operation.

A3

NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS During moderate to heavy braking, noise from the hydraulic control unit (HCU) and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct functioning of the ABS system. Pedal pulsation or steering wheel nibble whose frequency is proportioned to the vehicle speed indicates a concern with a brake or suspension component.

Yes

Go to A5.

No

The brake system is operating correctly.

Is the vibration/shudder vehicle speed sensitive?

A4

APPLICATION OF THE PARKING BRAKE NOTE: Begin at the front of the vehicle unless the vibration or shudder has been isolated to the rear.

This test is not applicable to vehicles with drum-in-hat type parking brakes. For vehicles with drum-in-hat parking brakes, proceed to the next test. For all other vehicles, apply the parking brake to identify if the problem is in the front or rear brake. At highway speeds of 89–97 km/h (55-60 mph), lightly apply the parking brake until the vehicle slows down. Release the parking brake immediately after the test.

Yes

Go to A8.

No

Go to A5.

Is there a vibration/shudder?

A5

CHECK THE FRONT WHEEL BEARINGS Yes

Check the front wheel bearings. Refer to Wheel Bearing Check in this section.

Go to A6.

Are the wheel bearings OK?

No

INSPECT the wheel bearings. ADJUST or REPAIR as necessary. TEST the system for normal operation.

G72679 en

01/2003 2003.0 BA Falcon


100-04-37

Noise, Vibration and Harshness

100-04-37

DIAGNOSIS AND TESTING (Continued) Test Step A6

Result / Action to Take

CHECK THE FRONT SUSPENSION Check the front suspension for: broken or loose bolts damaged springs worn or damaged lower control arm bushings loose or rough front bearings

Yes

Go to A7.

No

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

uneven tyre wear Are all the suspension components in satisfactory condition?

A7

RESURFACE THE FRONT BRAKE DISCS CAUTION: Do not use a bench lathe to machine brake discs. NOTE: Follow the manufacturer’s instructions to machine the brake discs. After machining, make sure the brake disc meets the thickness specification.

Yes

Go to A8.

No

Vehicle is OK.

Refer to Brake Disc Machining in this section. Resurface the front brake discs. Road test the vehicle. Is the vibration/shudder present?

A8

CHECK THE REAR SUSPENSION Check the rear suspension for: broken or loose bolts damaged or worn springs or spring bushings worn or damaged upper and lower control arm bushings worn or damaged trailing arms loose or rough rear bearings

Yes

Go to A9.

No

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

uneven tyre wear Are all the suspension components in satisfactory condition?

A9

RESURFACE THE REAR BRAKE DISC OR DRUM CAUTION: Do not use a bench lathe to machine brake discs.

Yes

CHECK the front suspension for wear or damage, RESURFACE the front brake discs. NOTE: Follow the manufacturers instructions to machine the brake discs. TEST the system for normal operation. After machining, make sure the brake disc meets the thickness specification. No Vehicle is OK. Refer to Brake Disc Machining in this section. Resurface the rear brake disc or drums. Road test the vehicle. Is the vibration/shudder present?

PINPOINT TEST B : ENGINE TICKING NOISE Test Step B1

Result / Action to Take

CHECK FOR TICKING NOISE AT THE FUEL RAIL Disconnect the first fuel line clip. Is the ticking noise gone?

Yes

CHECK for TSB for applicable vehicle. REPAIR as necessary. TEST the system for normal operation.

No

Go to B2.

G72679 en

01/2003 2003.0 BA Falcon


100-04-38

Noise, Vibration and Harshness

100-04-38

DIAGNOSIS AND TESTING (Continued) Test Step B2

Result / Action to Take

CHECK FOR TICKING NOISE AT THE FUEL INJECTOR Using an EngineEAR, listen at the fuel injectors by placing a probe on Yes each injector. To isolate the faulty injector, disconnect the injector INSTALL a new fuel injector. REFER to Section electrical connector and listen for the noise. 303-04a for 2.0L Zetec engine or Section 303-04b for 3.0L (4V) engine. TEST the system Is the fuel injector the source of the ticking noise? for normal operation.

No

Go to B3.

B3

CHECK THE BELT TENSIONER FOR TICKING NOISE Inspect the front engine accessory drive (FEAD). Check for the belt tensioner bottoming at end of travel or not at end of stroke. Using an EngineEAR, listen at the belt tensioner. Is the belt tensioner the source of the noise?

Yes

INSTALL a new belt tensioner. REFER to Section 303-05 . TEST the system for normal operation.

No

Go to B4.

B4

CHECK THE WATER PUMP FOR TICKING NOISE Using an EngineEAR, listen at the water pump for ticking noise. Is the water pump the source of the noise?

Yes

INSTALL a new water pump. REFER to Section 303-03 . TEST the system for normal operation.

No

Go to B5.

B5

CHECK FOR AN OBSTRUCTION OF THE COOLING FAN Inspect the cooling fan for obstructions. Check the cooling fan and shroud for wear or damage. Was there an obstruction or does the cooling fan show signs of damage?

Yes

REPAIR or INSTALL a new cooling fan. REFER to Section 303-03 . TEST the system for normal operation.

No

Go to B6.

B6

CHECK THE OIL PUMP FOR TICKING NOISE Check the oil pump using EngineEARs and probe at the oil filter adapter to verify the oil pump as a source. Is the oil pump the source of the noise?

Yes

INSTALL a new oil pump. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine. TEST the system for normal operation.

No

Go to B7.

B7

CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR CORRECT OPERATION Check valve lifter/lash adjuster for correct operation, using EngineEARs. Are the valve lifters/lash adjusters operating correctly?

Yes

VERIFY customer concern. CONDUCT a diagnosis of other suspect components.

No

INSTALL a new valve lifter/lash adjuster(s). TEST the system for normal operation.

G72679 en

01/2003 2003.0 BA Falcon


100-04-39

Noise, Vibration and Harshness

100-04-39

DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : FRONT ENGINE ACCESSORY DRIVE BEARING HOOT Test Step C1

Result / Action to Take

CHECK THE ACCESSORY DRIVE IDLER AND TENSIONER PULLEY BEARINGS Carry out the Vehicle Cold Soak Procedure in this section.

Yes

INSTALL a new pulley/idler. REFER to Section 303-05 . CARRY OUT the Vehicle Cold Soak Place an EngineEAR probe directly on the pulley center post or bolt to Procedure and TEST the system for normal operation. verify which bearing is making the noise. Key in START position.

Key in OFF position.

No

Is either bearing making the noise?

CONDUCT a diagnosis on other suspect accessory drive components.

PINPOINT TEST D : POWER STEERING MOAN Test Step D1

Result / Action to Take

CHECK THE POWER STEERING SYSTEM Carry out the Vehicle Cold Soak Procedure in this section. Key in START position. Turn the steering wheel while the noise is occurring and listen for changes in sound pitch or loudness. Key in OFF position.

Yes

Go to D2.

No

CONDUCT a diagnosis on other suspect accessory drive components.

Does the sound pitch or loudness change while turning the steering wheel?

D2

VERIFY THE SOURCE Key in START position. Place an EngineEAR probe near the power steering pump/reservoir while the noise is occurring. While an assistant turns the steering wheel, listen for changes in sound pitch or loudness. Key in OFF position. Does the sound pitch or loudness change while turning the steering wheel?

Yes

VERIFY that the supply tube to the pump is unobstructed. CHECK the fluid condition and level. DRAIN the fluid and REFILL. CARRY OUT the Vehicle Cold Soak Procedure and TEST the system for normal operation. REFER to Section 211-02 .

No

Normal system operation.

G72679 en

01/2003 2003.0 BA Falcon


100-04-40

Noise, Vibration and Harshness

100-04-40

DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E : DRUMMING NOISE Test Step E1

Result / Action to Take

CHECK THE EXHAUST SYSTEM Key in START position.

Yes

CARRY OUT Exhaust System Neutralizing in Increase the engine rpm until the noise is the loudest. Note the engine this section. TEST the system for normal rpm. operation. Key in OFF position.

No

Add approximately 9 kg (20 lb) of weight to the exhaust system. Place Go to E2. the weight at the tailpipe and test. Key in START position. Increase the engine rpm and listen for the drumming noise. Note the engine rpm if the noise occurs. Key in OFF position. Using a vibration analyzer, determine the amount of vibration that occurs with the drumming noise. Is the noise/vibration reduced or eliminated, or does the noise/vibration occur at a different rpm?

E2

POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING Carry out Powertrain/Drivetrain Mount Neutralizing in this section. Test the system for normal operation. Is the noise reduced or eliminated?

Yes

Vehicle is OK. TEST the system for normal operation.

No

CONDUCT diagnosis of other suspect components.

PINPOINT TEST F : ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE Test Step F1

Result / Action to Take

CHECK FOR NOISE AT THE VALVE COVERS AND THE FRONT COVERS (OHC ENGINES) Carry out the Vehicle Cold Soak Procedure in this section.

Yes

REMOVE the appropriate cover and INSPECT for loose, worn/broken components. REPAIR as necessary. TEST the system for normal NOTE: For a short-duration ticking noise, multiple engine starts may operation. be necessary. Key in START position.

Using an EngineEAR, listen closely at the valve covers and the front covers by placing the probe near the surface of the valve cover and then on the surface front cover.

No

Go to F2.

Key in OFF position. Is the noise source apparent?

F2

CHECK FOR NOISE AT THE CYLINDER BLOCK Key in START position. Using an EngineEAR, listen closely at the cylinder block by placing a probe on or near each freeze plug. Key in OFF position. Is the noise source apparent?

G72679 en

Yes

REPAIR or INSTALL new components as necessary.

No

Go to F3.

01/2003 2003.0 BA Falcon


100-04-41

Noise, Vibration and Harshness

100-04-41

DIAGNOSIS AND TESTING (Continued) Test Step F3

Result / Action to Take

CHECK FOR NOISE WHILE DISCONNECTING EACH FUEL INJECTOR ELECTRICAL CONNECTOR, ONE AT A TIME Key in START position.

Yes

Key in OFF position.

INSTALL a new fuel injector. REFER to Section 303-04a for 2.0L Zetec engine or Section 303-04b for 3.0L (4V) engine. TEST the system for normal operation.

Is the noise reduced or eliminated?

No

Disconnect each fuel injector electrical connector, one at a time, to decrease piston force and listen for the noise.

INSPECT accessory drive or the transmission as a possible source.

PINPOINT TEST G : FRONT SUSPENSION NOISE Test Step G1

ROAD TEST THE VEHICLE Test drive the vehicle. During the road test, drive the vehicle over a rough road. Using ChassisEARs, determine from which area/component the noise is originating. Is there a squeak, creak or rattle noise?

G2

Result / Action to Take

Yes

Go to G2.

No

The suspension system is OK. CONDUCT a diagnosis on other suspect systems.

INSPECT THE STEERING SYSTEM Raise and support the vehicle. For additional information, refer to Section 100-02 . Check the steering system for wear or damage. Carry out a steering linkage test. Inspect the tyre wear pattern. Refer to Tyre Wear Patterns chart in this section.

Yes

REPAIR the steering system. INSTALL new components as necessary. TEST the system for normal operation.

No

Go to G3.

Are the steering components worn or damaged?

G3

FRONT SHOCK ABSORBER/STRUT CHECK Check the front shock absorbers/strut mounts for loose bolts or nuts.

Yes

TIGHTEN to specifications if loose. INSTALL Check the front shock absorbers/struts for damage. Carry out a shock new front shock absorbers/struts if damaged. absorber check. TEST the system for normal operation. Are the front shock absorbers/struts loose or damaged?

No

Go to G4.

G4

CHECK THE FRONT SPRINGS Check the front spring and front spring mounts/brackets for wear or damage. Are the front springs or spring mounts/brackets worn or damaged?

Yes

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

No

Go to G5.

G72679 en

01/2003 2003.0 BA Falcon


100-04-42

Noise, Vibration and Harshness

100-04-42

DIAGNOSIS AND TESTING (Continued) Test Step G5

Result / Action to Take

CHECK THE CONTROL ARMS/RADIUS ARMS Inspect the control arm bushings for wear or damage. Inspect for twisted or bent control arm/radius arm. Are the control arm/radius arms damaged or worn?

Yes

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

No

Go to G6.

G6

CHECK THE STABILIZER BAR/TRACK BAR Check the stabilizer bar/track bar bushings and links for damage or wear.

Yes

Check the stabilizer bar/track bar for damage.

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

Check for loose or damaged stabilizer bar/track bar isolators or brackets.

No

Are the stabilizer bar/track bar components loose, worn or damaged?

Suspension system is OK. CONDUCT diagnosis on other suspect systems.

PINPOINT TEST H : REAR SUSPENSION NOISE Test Step H1

ROAD TEST THE VEHICLE Test drive the vehicle. During the road test, drive the vehicle over a rough road. Using ChassisEARs, determine from which area/component the noise is originating. Is there a squeak, creak or rattle noise?

H2

Yes

Go to H2.

No

The suspension system is OK. Conduct a diagnosis on other suspect systems.

REAR SHOCK ABSORBER/STRUT CHECK Raise and support the vehicle. REFER to Section 100-02 . Check the rear shock absorber/strut mounts for loose bolts or nuts. Check the rear shock absorbers/struts for damage. Carry out a shock absorber check. Are the rear shock absorbers/struts loose or damaged?

H3

Result / Action to Take

Yes

TIGHTEN to specifications if loose. INSTALL new rear shock absorbers/struts if damaged. TEST the system for normal operation.

No

Go to H3.

CHECK THE REAR SPRINGS Check the rear springs and rear spring mounts/brackets for wear or damage. Are the rear springs or spring mounts/brackets worn or damaged?

Yes

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

No

Go to H4.

H4

CHECK THE CONTROL ARMS/TRAILING ARMS Inspect the control arm/trailing arm bushings for wear or damage. Check for loose control arm/trailing arm bolts. Inspect for twisted or bent control arms/trailing arms. Are the control arms/trailing arms loose, damaged or worn?

Yes

REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

No

Suspension system is OK. CONDUCT diagnosis on other suspect systems.

G72679 en

01/2003 2003.0 BA Falcon


100-04-43

Noise, Vibration and Harshness

100-04-43

DIAGNOSIS AND TESTING (Continued) PINPOINT TEST I : WHEEL AND TYRE Test Step I1

Result / Action to Take

ROAD TEST THE VEHICLE NOTE: Wheel or tyre vibrations felt in the steering wheel are most likely related to the front wheel or tyre. Vibration felt through the seat are most likely related to the rear wheel or tyre. This may not always be true, but it can help to isolate the problem to the front or rear of the vehicle. Test drive the vehicle at different speed ranges.

Yes

Go to I2.

No

The wheel and tyres are OK. CONDUCT a diagnosis on other suspect systems.

During the road test, if the vibration can be eliminated by placing the vehicle in neutral or is affected by the speed of the engine, the cause is not the wheels or tyres. Is there a vibration and noise?

I2

CHECK THE FRONT WHEEL BEARINGS Yes

Check the front wheel bearings. Refer to Wheel Bearing Check in this section.

Go to I3.

Are the wheel bearings OK?

No

INSPECT the wheel bearings. ADJUST or REPAIR as necessary. TEST the system for normal operation.

I3

INSPECT THE TYRES Check the tyres for missing weights.

Yes

CORRECT the condition that caused the abnormal wear. INSTALL new tyre(s). TEST the Inspect the tyre wear pattern. Refer to the Tyre Wear Patterns chart in system for normal operation. this section. Check the wheels for damage.

Do the tyres have an abnormal wear pattern?

I4

No

Go to I4.

TIRE ROTATION DIAGNOSIS Spin the tyres slowly and watch for signs of lateral runout. Spin the tyres slowly and watch for signs of radial runout. Are there signs of visual runout?

G72679 en

Yes

Go to I5.

No

CHECK the wheel and tyre balance. CORRECT as necessary. TEST the system for normal operation.

01/2003 2003.0 BA Falcon


100-04-44

Noise, Vibration and Harshness

100-04-44

DIAGNOSIS AND TESTING (Continued) Test Step I5

Result / Action to Take

RADIAL RUNOUT CHECK ON THE TIRE Measure the radial runout of the wheel and tyre assembly. A typical specification for total radial runout is 1.15mm (0.059inch).

Yes

Go to I8.

No

Go to I6.

Is the radial runout within specifications?

I6

RADIAL RUNOUT CHECK ON THE WHEEL Measure the radial runout of the wheel. A typical specification for total radial runout is 1.14mm (0.045 inch). Is the radial runout within specifications?

Yes

INSTALL a new tyre. TEST the system for normal operation.

No

Go to I7.

I7

CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR BOLT CIRCLE RUNOUT Measure the pilot or bolt circle runout. A typical specification for radial runout is: pilot runout— less than 0.15 mm (0.006 inch) bolt circle runout— less than 0.38 mm (0.015 inch) Is the radial runout within specifications?

G72679 en

Yes

INSTALL a new wheel. TEST the system for normal operation.

No

REPAIR or INSTALL new components as necessary. REFER to 204-01 for the front suspension or 204-02 for the rear suspension.

01/2003 2003.0 BA Falcon


100-04-45

Noise, Vibration and Harshness

100-04-45

DIAGNOSIS AND TESTING (Continued) Test Step I8

Result / Action to Take

LATERAL RUNOUT CHECK ON THE TIRE Measure the lateral runout of the wheel and tyre assembly. A typical specification for total lateral runout is 2.5mm (0.098inch).

Yes

Wheel and tyres are OK. CONDUCT diagnosis on other suspect systems.

No

Go to I9.

Is the lateral runout within specifications?

I9

LATERAL RUNOUT CHECK ON THE WHEEL Measure the lateral runout of the wheel. A typical specification for total radial runout is 1.2mm (0.047inch). Is the lateral runout within specifications?

Yes

INSTALL a new tyre. TEST the system for normal operation.

No

Go to I10.

I10

CHECK THE FLANGE FACE LATERAL RUNOUT Measure the flange face lateral runout. A typical specification for lateral runout is: hub/brake disc— less than 0.13mm (0.005inch) axle shaft— less than 0.25 mm (0.010 inch) Is the lateral runout within specifications?

Yes

INSTALL a new wheel. TEST the system for normal operation.

No

REPAIR or INSTALL new components as necessary. REFER to Section 204-01 for the front suspension or Section 204-02 for the rear suspension.

PINPOINT TEST J : HIGH SPEED SHAKE OR SHIMMY Test Step J1

Result / Action to Take

CHECK FOR FRONT WHEEL BEARING ROUGHNESS Chock the rear wheels. Raise and support the front end of the vehicle so that the front wheel and tyre assemblies can spin. Refer to Section 100-02 . Spin the front tyres by hand. Do the wheel bearings feel rough?

G72679 en

Yes

INSPECT the wheel bearings. REPAIR as necessary. TEST the system for normal operation.

No

Go to J2.

01/2003 2003.0 BA Falcon


100-04-46

Noise, Vibration and Harshness

100-04-46

DIAGNOSIS AND TESTING (Continued) Test Step J2

Result / Action to Take

CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS Check the end play of the front wheel bearings. Is the end play OK?

Yes

Go to J3.

No

ADJUST or REPAIR as necessary. TEST the system for normal operation.

J3

MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT OF THE FRONT WHEELS ON THE VEHICLE Measure the lateral runout and the radial runout of the front wheels on Yes the vehicle. Go to Pinpoint Test I. Go to J4. Are the measurements within specifications?

No

INSTALL new wheels as necessary and BALANCE the assembly. TEST the system for normal operation.

J4

MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE Yes

Measure the lateral runout of the front tyres on the vehicle. Go to Pinpoint Test I.

Go to J5.

Is the runout within specifications?

No

INSTALL new tyres as necessary and BALANCE the assembly. TEST the system for normal operation.

J5

MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE Measure the radial runout of the front tyres on the vehicle. Go to Pinpoint Test I. Is the runout within specifications?

Yes

BALANCE the front wheel and tyre assemblies. If any tyre cannot be balanced, INSTALL a new tyre. TEST the system for normal operation.

No

Go to J6.

J6

MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY Mark the high runout location on the tyre and also on the wheel. Break the assembly down and rotate the tyre 180 degrees (halfway around) on the wheel. Inflate the tyre and measure the radial runout.

Yes

Is the runout within specifications?

No

BALANCE the assembly. TEST the system for normal operation.

If the high spot is not within 101.6 mm (4 inches) of the first high spot on the tyre, Go to J7.

G72679 en

01/2003 2003.0 BA Falcon


100-04-47

Noise, Vibration and Harshness

100-04-47

DIAGNOSIS AND TESTING (Continued) Test Step J7

Result / Action to Take

MEASURE THE WHEEL FLANGE RUNOUT Dismount the tyre and mount the wheel on a wheel balancer. Measure the runout on both wheel flanges. Go to Pinpoint Test I. Is the runout within specifications?

Yes

LOCATE and MARK the low spot on the wheel. INSTALL the tyre, matching the high spot on the tyre with the low spot on the wheel. BALANCE the assembly. TEST the system for normal operation. If the condition persists, Go to J8.

No

INSTALL a new wheel. CHECK the runout on the new wheel. If the new wheel is within limits, LOCATE and MARK the low spot. INSTALL the tyre, matching the high spot on the tyre with the low spot on the wheel. BALANCE the assembly. TEST the system for normal operation. If the condition persists, Go to J8.

J8

CHECK FOR VIBRATION FROM THE FRONT OF THE VEHICLE Yes WARNING: If only one drive wheel is allowed to rotate, speed SUBSTITUTE known good wheel and tyre

must be limited to 55 km/h (34 mph) using the speedometer reading, since actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tyre disintegration or differential failure, which can cause serious personal injury and extensive vehicle damage.

Spin the front wheel and tyre assemblies with a wheel balancer while the vehicle is raised on a hoist. Feel for vibration in the front fender or while seated in the vehicle.

assemblies as necessary. TEST the system for normal operation.

No

For front wheel drive vehicles, check the driveline components. TEST the system for normal operation. For rear wheel drive vehicles, Go to J9.

Is the vibration present?

J9

CHECK FOR VIBRATION FROM THE REAR OF THE VEHICLE Yes WARNING: If only one drive wheel is allowed to rotate, speed Go to J10.

must be limited to 55 km/h (34 mph) using the speedometer reading, since actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tyre disintegration or differential failure, which can cause serious personal injury and extensive vehicle damage.

No

TEST the system for normal operation.

Chock the front wheels. Raise and support the rear end of the vehicle so that the rear wheel and tyre assemblies can spin. Refer to Section 100-02 . Engage the drivetrain and carefully accelerate the drive wheels while checking for vibration. Is the vibration present?

G72679 en

01/2003 2003.0 BA Falcon


100-04-48

Noise, Vibration and Harshness

100-04-48

DIAGNOSIS AND TESTING (Continued) Test Step J10

Result / Action to Take

CHECK THE DRIVETRAIN Yes WARNING: If only one drive wheel is allowed to rotate, speed CHECK/TEST the drivetrain and driveline

must be limited to 55 km/h (34 mph) using the speedometer reading, since actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tyre disintegration or differential failure, which can cause serious personal injury and extensive vehicle damage.

Remove the rear wheel and tyre assemblies. Refer to Section 204-04 .

components. TEST the system for normal operation.

No

SUBSTITUTE known good wheel and tyre assemblies as necessary. TEST the system for normal operation.

Secure the brake drums (if so equipped), by installing wheel hub bolt nuts, reversed. Carefully accelerate the drivetrain while checking for vibration. Is the vibration present?

PINPOINT TEST K : CLUTCH VIBRATION Test Step K1

Result / Action to Take

CHECK ENGINE COMPONENTS FOR GROUNDING Yes

NOTE: Make sure the clutch is the cause of the vibration concern. The vibration should occur during clutch operation. The clutch can also be difficult to engage or disengage. Eliminate all related systems before checking the clutch components.

REPAIR as necessary. TEST the system for normal operation.

NOTE: Check the driveline angles and driveshaft runout before

Go to K2.

No

disassembling the clutch system. Refer to Section 205-00 for the correct driveline angle specifications. Check the powertrain/drivetrain mounts, exhaust manifolds or other engine components for grounding on the chassis. Are any mounts or engine components grounded?

K2

CHECK THE ACCESSORY DRIVE BELT Remove the accessory drive belt. Does the vibration stop with the accessory drive belt removed?

Yes

DIAGNOSE the accessory drive components.

No

Go to K3.

K3

CHECK FOR LOOSE CLUTCH PRESSURE PLATE BOLTS Check for loose clutch pressure plate bolts. Inspect the clutch pressure plate for damage or for material between the pressure plate and flywheel. Are there any loose bolts or damage?

Yes

TIGHTEN the bolts to specifications or if damaged, INSTALL a new clutch pressure plate. REFER to Section 308-01 . TEST the system for normal operation.

No

Go to K4.

K4

CHECK THE CLUTCH DISC SPRINGS Check for worn, broken or loose clutch disc springs. Are the clutch springs worn, broken or loose?

Yes

INSTALL a new clutch disc. REFER to Section 308-01 . TEST the system for normal operation.

No

Go to K5.

G72679 en

01/2003 2003.0 BA Falcon


100-04-49

Noise, Vibration and Harshness

100-04-49

DIAGNOSIS AND TESTING (Continued) Test Step K5

Result / Action to Take

CHECK THE CLUTCH DISC SPLINES Inspect the clutch disc splines for damage or wear. Is there damage or wear?

Yes

INSTALL a new clutch disc. REFER to Section 308-01 . TEST the system for normal operation.

No

Go to K6.

K6

CHECK THE FLYWHEEL BOLTS Check for loose flywheel bolts. Are the bolts loose?

Yes

TIGHTEN the bolts to specifications. REFER to Section 308-01 . TEST the system for normal operation.

No

Go to K7.

K7

CHECK THE FLYWHEEL SURFACE Inspect the flywheel surface for wear or damage. Check the flywheel runout. Is there any damage or excessive wear?

Yes

INSTALL a new flywheel. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine. TEST the system for normal operation.

No

Clutch system is normal. CONDUCT a diagnosis on other suspect systems.

scored or forcibly damaged gear teeth and is usually quite audible over the entyre speed range. The Steering Gear Grunt/Shudder Test second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can 1. Start and run the vehicle to operating be recognized as it produces a cycling pitch or whine. temperature. Ring and pinion noise tends to peak in a narrow 2. Set engine idle speed to 1,200 rpm. speed range or ranges, and will tend to remain CAUTION: Do not hold the steering wheel constant in pitch. 1. Raise and support the vehicle. Refer to Section against the stops for more than three to five 100-02. seconds at a time. Damage to the power steering pump will occur. 2. Drain the axle lubricant. Refer to Section 205-02. 3. Rotate the steering wheel to the RH stop, then 3. Remove the carrier assembly or the axle housing turn the steering wheel 90 degrees back from that cover depending on the axle type. Refer to position. Turn the steering wheel slowly in a 15 to Section 205-02. 30 degree arc. 4. Inspect the gear set for scoring or damage. 4. Turn the steering wheel another 90 degrees. Turn the steering wheel slowly in a 15 to 30 degree arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard or a strong shudder is felt, fill and purge the power steering system.

Component Tests

Checking Tooth Contact Pattern and Condition of the Ring and Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, G72679 en

01/2003 2003.0 BA Falcon


100-04-50

Noise, Vibration and Harshness

100-04-50

DIAGNOSIS AND TESTING (Continued)

5. In the following steps, the movement of the contact pattern along the length is indicated as toward the “heel” or “toe” of the differential ring gear.

Item 1 2

8. A high, thick contact pattern that is worn more toward the toe. Tooth contact pattern shown on the drive side of the gear teeth. The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear.

Description Heel Toe

6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is 9. A high, thin contact pattern that is worn toward the toe. obtained. Inspect the contact patterns on the ring gear teeth. Tooth contact pattern shown on the drive side of the gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There The drive pinion depth is correct. Increase the should always be some clearance between the differential ring gear backlash. contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth.

G72679 en

01/2003 2003.0 BA Falcon


100-04-51

Noise, Vibration and Harshness

100-04-51

DIAGNOSIS AND TESTING (Continued)

10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. Tooth contact pattern shown on the drive side of the gear teeth. The low contact pattern indicates that the drive pinion is installed too deep into the carrier. The differential ring gear backlash is correct. A thicker drive pinion shim is needed.

11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. Tooth contact pattern shown on the drive side of the gear teeth. The pinion gear depth is correct. Decrease the differential ring gear backlash.

G72679 en

01/2003 2003.0 BA Falcon


100-04-52

Noise, Vibration and Harshness

100-04-52

DIAGNOSIS AND TESTING (Continued) Tyre Wear Patterns and Frequency Calculations Tyre Wear Chart

G72679 en

01/2003 2003.0 BA Falcon


100-04-53

Noise, Vibration and Harshness

100-04-53

DIAGNOSIS AND TESTING (Continued) Wheel and tyre NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tyres can vibrate at more than one speed. A vibration that is affected by the engine rpm, or is eliminated by placing the transmission in NEUTRAL is not related to the tyre and wheel. As a general rule, tyre and wheel vibrations felt in the steering wheel are related to the front tyre and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tyre and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tyre and wheels. There are several symptoms that can be caused by damaged or worn tyre and wheels. Carry out a careful visual inspection of the tyres and wheel assemblies. Spin the tyres slowly and watch for signs of lateral or radial runout. Refer to the tyre wear chart to determine the tyre wear conditions and actions. For a vibration concern, use the vehicle speed to determine tyre/wheel frequency and rpm. Calculate tyre and wheel rpm and frequency by carrying out and following: Measure the diameter of the tyre. Record the speed at which the vibration occurs. Obtain the corresponding tyre and wheel rpm and frequency from the Tyre Speed and Frequency Chart. If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tyre rpm listed for that tyre diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tyres. 40 รท10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Tyre Speed and Frequency Chart Tyre Diameter Tyre RPM/Hz mm (inch) @ 16 km/h (10 mph) 483 (19) 182 508 (20) 173 533 (21) 165 560 (22) 158 585 (23) 151 610 (24) 145 635 (25) 139 660 (26) 134 685 (27) 129 710 (28) 124 735 (29) 119 760 (30) 115 G72679 en

Tyre RPM/Hz @ 80 km/h (50 mph) 910/15 865/14 825/14 790/13 755/13 725/12 695/12 670/11 645/11 620/10 595/10 575/10

Tyre RPM/Hz @ 97 km/h (60 mph) 1092/18 1038/17 990/16 948/16 906/15 870/14 834/14 804/13 774/13 744/12 714/12 690/11

Tyre RPM/Hz @ 113 km/h (70 mph) 1274/21 1211/20 1155/19 1106/18 1057/18 1015/17 973/16 938/16 903/15 868/14 833/14 805/13

01/2003 2003.0 BA Falcon


100-04-54

Noise, Vibration and Harshness

100-04-54

DIAGNOSIS AND TESTING (Continued) Tyre Diameter 785 (31) 810 (32) 835 (33) 864 (34)

G72679 en

Tyre RPM/Hz 111 108 105 102

Tyre RPM/Hz 555/9 540/9 525/9 510/8

Tyre RPM/Hz 666/11 648/11 630/10 612/10

Tyre RPM/Hz 777/13 756/13 735/12 714/12

01/2003 2003.0 BA Falcon


100-04-55

Noise, Vibration and Harshness

100-04-55

GENERAL PROCEDURES

Brake Disc Machining

Using the match marks, mount the brake disc on the hub. 12. Install the caliper. 13. Install the tyre and wheel assembly. 14. Test the system for normal operation.

CAUTION: Do not install brake discs that are less than the minimum thickness specified. Do not machine a brake disc below the minimum thickness specification. Powertrain/Drivetrain Mount 1. Check wheel bearing end-play and correct as Neutralizing necessary. 1. Raise and support the vehicle. For additional 2. Remove the tyre and wheel. information, refer to Section 100-02. NOTE: Begin at the front of the vehicle unless the 2. Loosen, but do not remove, the vibration has been isolated to the rear. powertrain/drivetrain mount fasteners. 3. Remove the brake caliper. 3. Lower the vehicle. 4. Inspect the brake linings. Install new brake linings 4. Move the vehicle in forward and reverse 0.6-1.2 if below specification. For additional information, meters (2-4 ft). refer to the appropriate brake section. 5. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is stamped on the brake disc. Do not machine a new brake disc. 6. For vehicles with a two-piece hub and brake disc assembly: Match-mark before disassembly. Remove the brake disc. Using a die grinder with a mild abrasive (Scotch BriteŽ type), remove any rust or corrosion from the hub and brake disc mounting surfaces. Align the match-marks and reinstall the brake disc on the hub. 7. Using the special tool, machine the brake discs. Follow the manufacturer’s instructions. After machining, make sure the brake disc still meets the thickness specification. CAUTION: Do not use a bench lathe to machine brake discs. NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish. 8. Using a dial indicator, verify that the brake disc lateral runout is now within specification. 9. Remove the special tool hub adapter. 10. Remove any remaining metal chips from the machining operation. 11. For vehicles with a two-piece hub and brake disc assembly: Remove the brake disc from the hub. Remove any remaining metal chips from hub and brake disc mounting surfaces and from the ABS sensor. Apply a high temperature anti-seize lubricant to the mounting surfaces. G72682 en

5. 6. 7. 8.

CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Raise and support the vehicle. Tighten the powertrain/drivetrain mount fasteners. Lower the vehicle. Test the system for normal operation.

Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. Failure to follow these instructions may result in personal injury. WARNING: Exhaust system components are hot. Failure to follow these instructions may result in personal injury. NOTE: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. Raise and support the vehicle. For additional information, refer to Section 100-02.

2. 3. 4. 5.

CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. Loosen all exhaust flange joints. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. Tighten the muffler connection.

01/2003 2003.0 BA Falcon


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

G72682 en

4. If the tyre and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, install a new wheel hub.

01/2003 2003.0 BA Falcon


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

01/2003 2003.0 BA Falcon


204-00-2

Suspension System — General Information

204-00-2

DESCRIPTION AND OPERATION

Suspension System — General Information Front Wheel Alignment Suggested method and sequence for checking steering wander or drift 1. Check and adjust tyre pressures to specification. 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.

where necessary at kerb height. NOTE: When checking ute and wagon front caster it is important that the rear ride height is correct. This can be achieved by ensuring the vehicle unladen. The following charts show wheel alignment data for the various models. Toe settings are provided in degrees.

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 G22340 en

01/2003 2003.0 BA Falcon


204-00-3

Suspension System — General Information

204-00-3

DESCRIPTION AND OPERATION (Continued) Front Wheel Alignment Sedan / Wagon Ride Camber Height Min. ° Opt. ° Max. ° 350 360 370 380 390 400 410 420

-1.91 -1.66 -1.44 -1.23 -1.07 -0.92 -0.81 -0.72

-1.41 -1.16 -0.94 -0.73 -0.57 -0.42 -0.31 -0.22

-0.91 -0.66 -0.44 -0.23 -0.07 -0.08 -0.19 -0.28

XR Sedan Ride Camber Height Min. ° Opt. ° Max. ° 340 350 360 370 380 390 400 Ute Ride Height 370 380 390 400 410 420

-1.52 -1.22 -0.95 -0.71 -0.50 -0.33 -0.17

-1.02 -0.72 -0.45 -0.21 0.00 0.17 0.33

-0.52 -0.22 0.05 0.29 0.50 0.67 0.83

Camber Min. ° Opt. ° Max. ° -1.24 -1.05 -0.88 -0.73 -0.62 -0.54

-0.74 -0.55 -0.38 -0.23 -0.12 -0.04

-0.24 -0.05 -0.12 -0.27 -0.38 -0.46

Castor Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 0.7 7 7.50 8 0.7 0.7 6.9 7.40 7.9 0.7 0.7 6.8 7.30 7.8 0.7 0.7 6.69 7.19 7.69 0.7 0.7 6.59 7.09 7.59 0.7 0.7 6.48 6.99 7.48 0.7 0.7 6.38 6.88 7.38 0.7 0.7 6.27 6.77 7.27 0.7

Total Toe at kerb height Min. ° Opt. ° Max. °

Castor Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 0.7 7.32 7.82 8.32 0.7 0.7 7.21 7.71 8.21 0.7 0.7 7.10 7.60 8.10 0.7 0.7 6.99 7.49 7.99 0.7 0.7 6.88 7.38 7.88 0.7 0.7 6.77 7.27 7.77 0.7 0.7 6.65 7.15 7.65 0.7

Total Toe at kerb height Min. ° Opt. ° Max. °

Castor Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 0.7 6.81 7.31 7.81 0.7 0.7 6.7 7.20 7.7 0.7 0.7 6.59 7.09 7.59 0.7 0.7 6.48 7.99 7.48 0.7 0.7 6.38 7.88 7.38 0.7 0.7 6.27 6.77 7.27 0.7

Total Toe at kerb height Min. ° Opt. ° Max. °

XR Ute, XLS Ute with standard sports suspension Ride Camber Castor Height Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° 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 0.7 380 -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

-0.02

0.06

-0.02

0.08

0.16

0.08

0.18

0.26

0.18

Total Toe at kerb height Min. ° Opt. ° Max. °

0.06

0.16

0.26

01/2003 2003.0 BA Falcon


204-00-4

Suspension System — General Information

204-00-4

DESCRIPTION AND OPERATION (Continued) Rear Wheel Alignment Sedan Ride Height

350 360 370 380 390 400 410 420

Min. °

Camber Opt. ° Max. °

-1.96 -1.76 -1.57 -1.38 -1.19 -1 -0.81 -0.61

-1.71 -1.51 -1.32 0.13 -0.94 -0.75 -0.56 -0.36

-1.46 -1.26 -1.07 -0.88 -0.69 -0.50 -0.31 -0.11

Max. Variation ° 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Total Toe at kerb height Min. ° Opt. ° Max. °

0.14

0.24

0.34

NOTE: Sedan camber settings cannot be adjusted, for reference only. XR Sedan Ride Height

340 350 360 370 380 390 400

G22340 en

Min. °

Camber Opt. ° Max. °

-1.35 -1.14 -0.95 -0.75 -0.56 -0.37 -0.18

-1.10 -0.89 -0.70 -0.50 -0.31 -0.12 0.07

-0.85 -0.64 -0.45 -0.25 -0.06 0.13 0.32

Max. Variation ° 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Total Toe at kerb height Min. ° Opt. ° Max. °

0.06

0.16

0.26

01/2003 2003.0 BA Falcon


204-00-5

Suspension System — General Information

204-00-5

DIAGNOSIS AND TESTING these symptoms are also common to suspension frame, and wheel and tyre troubles. For this reason, be sure that the cause of a concern is in the steering gear or linkage before adjusting, repairing, or replacing any of the steering parts.

Suspension System — General Information Inspection and Verification NOTE: Table 1 lists various steering gear and linkage trouble symptoms and possible causes. Several of

Symptom Chart Condition

Source

Action

Jerky Steering

Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Air in Power Steering System Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Obstruction Within Steering Gear

Remove/Repair as required

Loose Steering

Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment

Remove/Repair as required

Hard Steering and/ or Loss of Power Assist

Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Front Wheel Alignment Excessive Wear of Steering Pump Internal Parts Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear

Remove/Repair as required

Hard Turning When Stationary

Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear

Remove/Repair as required

G22341 en

01/2003 2003.0 BA Falcon


204-00-6

Suspension System — General Information

204-00-6

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Steering and Suspension Noises

Power Steering Fluid Level Low Leak Sagging or Broken Spring Glazed, Loose or Broken Power Steering Pump Belt Broken Rear Spring Tie Bolts (Wagon) Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Bent Rear Axle Housing Excessive Wear of Steering Pump Internal Parts

Remove/Repair as required

Shimmy or Wheel Tramp

Incorrect Tyre Pressure Broken Rear Spring Tie Bolts (Wagon) Air in Power Steering System Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel

Remove/Repair as required

Pull to One Side

Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon/Ute) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon/Ute) Bent Spindle Arm Bent Spindle Loose or Worn Suspension Arm Bushings Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Frame or Underbody Out of Alignment Bent Rear Axle Housing Steering Gear Valve Sleeve or Seals Worn

Remove/Repair as required

G22341 en

01/2003 2003.0 BA Falcon


204-00-7

Suspension System — General Information

204-00-7

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Side- to- side Wander

Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment

Remove/Repair as required

Body Sway or Roll

Incorrect Tyre Pressure Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Loose or Weak Shock Absorber Incorrect Steering Gear Adjustment

Remove/Repair as required

Tyre Squeel on Turns

Incorrect Tyre Pressure Tyre Sizes Not Uniform Bent Spindle Arm Bent Spindle Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Front Wheel Alignment

Remove/Repair as required

Binding or Poor Recovery

Incorrect Tyre Pressure Lack of Lubrication Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Alignment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear

Remove/Repair as required

Abnormal or Irregular Tyre Wear

Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon/Ute) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon/Ute) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel Frame or Underbody Out of Alignment Bent Rear Axle Housing

Remove/Repair as required

G22341 en

01/2003 2003.0 BA Falcon


204-00-8

Suspension System — General Information

204-00-8

DIAGNOSIS AND TESTING (Continued) Condition

Source

Action

Sag at One Wheel

Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Loose or Worn Suspension Arm Bushings

Remove/Repair as required

Hard or Rough Ride

Incorrect Tyre Pressure Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Lack of Lubrication Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Wheel Out of Balance Out-of-Round Wheel

Remove/Repair as required

Rear Suspension Misalignment (DogTracking)

Rear Spring Tie Bolt Off Centre (Wagon/Ute) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon/Ute) Loose or Worn Suspension Arm Bushings Frame or Underbody Out of Alignment Bent Rear Axle Housing

Remove/Repair as required

Shock Absorbers

Hand Test

1. With the shock absorber removed from the vehicle, hold the shock absorber such that it is in Grasp the vehicle bumper bar and bounce the a vertical position, as it would be installed in the corner of the vehicle up and down. If the shock vehicle. Fully compress and extend the shock absorbers are in serviceable condition the vehicle absorber unit three times to bleed the shock will settle to it’s original position within two absorber. Compress the unit and observe that the bounces after the bumper is released. piston rod extends under it’s own internal gas Check the shock absorber to be sure that it is pressure. There should be a smooth movement of securely and properly installed on the vehicle. the shock absorber rod over the complete stroke Check the shock absorber mounting bushes and as the shock extends. Any noticeable slowing of body insulators for damage and / or wear. the rod, loss of movement or drag, especially as Replace any defective body insulators and tighten the piston rod nears the top of its stroke, will attachments to the specified torque. If wear or indicate low internal gas pressure, loss of shock damage is visible on shock absorber mounting fluid or faulty internal valve operation. bushes, the entire shock absorber should be 2. Extend and compress the shock as fast as replaced. possible, using as much travel of the shock as Check the compression rubbers or bumpers fitted possible. The action of the shock should become on the shock rod for signs of damage. Replace if smooth and uniform throughout each stroke. It is necessary. normal for the shock to have higher resistance to extension than compression. Faint fluid "swishing" Inspect the shock absorber for evidence of fluid noises are also normal during extension and leakage. It is important to be sure that any fluid compression of the shock. observed is from the shock absorber and not from any other source. 3. If the action is smooth, but the shock absorbers are suspected of being weak, repeat Step 2 on a If the leakage is severe, replace the shock new shock absorber or on the mating shock absorber if leakage. (Some evidence of fluid absorber fitted to the opposite side of the vehicle. weepage on the shock body is not considered Compare the results of both tests. harmful to the shock provided that the on-vehicle and hand tests described below are acceptable).

On Vehicle Tests 1.

2.

3. 4.

5.

G22341 en

01/2003 2003.0 BA Falcon


204-00-9

Suspension System — General Information

204-00-9

GENERAL PROCEDURES

Toe Adjustment

Front Wheel Lock Angle Adjustment

1. Toe is the inward point of both front wheels at the 1. When the inside wheel is turned 20°, the turning front. The checking and optimum resetting toe-in angle of the outside wheel should be specified in in specifications are specified in the Description the Description and Operation section. and Operation section. 2. If the turning angles are incorrect or uneven when 2. Check the toe with the steering wheel in the compared with the figures obtained on the other straight-ahead position. lock, first check the toe. If this is correct, examine the tie rods which should be approximately the 3. On vehicles with power steering, the steering same length. It they are appreciably different (i.e. wheel must be in the straight-ahead position when 3.0mm) the turning angles will be adversely the engine is switched off. affected. It should be noted that minor differences 4. If it is necessary to again move the steering wheel in tie rod length are acceptable and, in fact, on a power steering vehicle the engine must be sometimes necessary to compensate for restarted. production tolerances in the build up of the 5. Measure the angle of each front wheel from the suspension and steering assembly. straight-ahead position and add the angles 3. If the toe and the tie rod lengths are satisfactory together. examine the tie rods for distortion. The tie rod ball joints should also be checked for wear or Front Wheel Alignment looseness. 1. The Caster, Camber and King Pin Inclination Upper & Lower Ball Joint Inspection angles are set in production and are not adjustable. 1. Raise the vehicle. 2. The tie rods, part of the steering rack assembly, 2. Grasp the tyre at the top and bottom and try to are adjustable for length to permit the setting of move it in and out. Toe and wheel lock angles. 3. There should be no perceptible movement in 3. Do not attempt to carry out alignment checks either joint. If movement is detected in either joint, without first making a preliminary check of the that joint should be replaced. serviceability of the front end components.

Toe & Steering Wheel Spoke Adjustments

XR Rear Camber Adjustment

1. Measure ride height. Refer to wheel Alignment charts in this section for ride heights vs. camber. NOTE: Check the steering wheel spoke position when Select appropriate camber setting. the front wheels are in the straight-ahead position. If 2. Complete RLCA (Rear Lower Control Arm) to the spoke is not in its correct position, it can be subframe cam bolt adjustment (set Toe). corrected while toe is being adjusted. 3. With toe set and locked in position, adjust left 1. Clean and lubricate the exposed threads on the camber to specification using the cambolt. tie-rods. Loosen the clips on the outer ends of the 4. Adjust the right camber to specification using the rack bellows and ensure that the bellows are free cambolt. on the tie-rods. 5. Re-adjust left camber if necessary. Tighten both 2. Hold the tie-rod and loosen the lock nut on each nuts to the specified torque (126 ± 24 Nm). rod. 6. Take care during the above procedure to ensure NOTE: Both rods have right hand threads. the brake hose bracket is located correctly. 3. Adjust toe-in. If the steering wheel spokes are in RLCA (Rear Lower Control Arm) to their correct position, lengthen or shorten both rods equally to obtain correct toe. If the steering Subframe Cambolt Adjustment wheel spoke is not in its correct position, make 1. Loosen both bolts and adjust as required to reach the necessary rod adjustments to obtain correct spesified toe. toe and steering wheel spoke alignment. 2. Tighten both nuts to the specified torque 4. When the toe and steering wheel spoke alignment (105 ± 10 Nm). are both correct tighten the lock nut on each rod. 5. Position each tie-rod end ball joint at the centre of its articulation and tighten the clips on the rack bellows.

G22346 en

01/2003 2003.0 BA Falcon


204-01-1

Front Suspension

204-01-1

SECTION : 204-01 Front Suspension VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

SPECIFICATIONS Specifications .........................................................................................................................204-01-2 DESCRIPTION AND OPERATION Front Suspension ...................................................................................................................204-01-3 Suspension ..........................................................................................................................204-01-3 DIAGNOSIS AND TESTING Front Suspension ...................................................................................................................204-01-4 REMOVAL AND INSTALLATION Lower Control Arm .................................................................................................................204-01-5 Lower Control Arm Ball Joint .................................................................................................204-01-5 Upper Control Arm .................................................................................................................204-01-6 Upper Control Arm Ball Joint .................................................................................................204-01-7 Stabilizer Bar ..........................................................................................................................204-01-8 Stabilizer Bar Centre Bushing (Front or Rear Bar) ...............................................................204-01-8 Stabilizer Bar Link Bushing ....................................................................................................204-01-9 Lower Arm Bushing ................................................................................................................204-01-9 Lower Arm - Large Bushing .................................................................................................204-01-11 Upper Arm Bushing ..............................................................................................................204-01-11 Front Wheel Spindle and Hub ..............................................................................................204-01-13 Spring and/or Shock Absorber Assembly ............................................................................204-01-15

01/2003 2003.0 BA Falcon


204-01-2

Front Suspension

204-01-2

SPECIFICATIONS Torque Specifications Description Upper Arm to Mounting Bracket Upper Arm Mounting Bracket to Body Lower Control Arm to Sub-frame Shock Absorber to Upper Attachment Shock Absorber to Lower Control Arm Spring Seat to Body Ball Joint to Spindle Stabilizer Bar Bracket Stabilizer Bar Link Nuts Wheel Bearing Nut Wheel Nut Brake Caliper to Spindle

G48690 en

Nm 50 35 115 35 80 35 90 35 55 300 125 115

01/2003 2003.0 BA Falcon


204-01-3

Front Suspension

204-01-3

DESCRIPTION AND OPERATION

Front Suspension Suspension The suspension is so designed that it allows an individual wheel to compensate for changes in the road’s surface level without considerably affecting the opposite wheel. Each wheel is independently connected to the frame and body by a spindle, ball joint assemblies, and upper and lower control arms. The control arms are specifically designed and positioned to allow the steering spindle to move in a prescribed three dimensional arc. The front wheels are held in proper relationship to each other by two tie rods that are connected to the steering rack and to the spindles. Coil chassis springs are mounted between the spring housings on the front end sheet metal and the spring seats that are integral with the shock absorber body. Ride control is provided by double, direct acting shock absorbers mounted inside the coil springs and attached to the lower control arms by bolts. The upper portion of each shock absorber extends through the dual path shear mount and is secured with two grommets, two grommet retainers, and a nut.

Item 1 2 3

Item Description 4 Bracket Assy 5 Insulator 6 Shock Absorber Frt 7 Arm & Shaft Assy Frt Susp Upr 8 Bolt Hex M14 9 Nut M14 10 Arm Assy Frt Susp Lwr 11 Nut M10 Flange 12 Spring Frt Susp Coil 13 Nut Side roll of the suspension is controlled by a spring steel stabilizer bar. It is mounted in rubber bushings held to the frame side rails by brackets. The ends of the stabilizer are connected to the lower control arms. Rubber grommets at these connections provide flexibility and ride features. The upper control arm is attached to the body through isolating rubber bushings connected to brackets that are bolted to the body. The upper ball joint is a press fit into the upper control arm, and the stud is fitted into the upper control end of the spindle forging. A nylok nut and bolt clamps the spindle to the ball joint. The lower ball joint is a press fit into the lower arm, and secures to the lower end of the spindle forging by a tapered stud and nylok nut. The inner ends of the lower control arms have pressed in bushings and are attached to the cross members by a single bolt through each bushing. The suspension mounting points are all rubber insulated to minimise the transmission of road noise and vibration to the vehicle body. Compliance in the lower arm bushes permits the wheel a small amount of fore and aft movement and so reduce the shock loading on the steering linkage when the wheel hits a sudden irregularity in the road surface.

Description Nut Washer Insulator

G48691 en

01/2003 2003.0 BA Falcon


204-01-4

Front Suspension

204-01-4

DIAGNOSIS AND TESTING

Front Suspension Refer to Section 204-00.

G48797 en

01/2003 2003.0 BA Falcon


204-01-5

Front Suspension

204-01-5

REMOVAL AND INSTALLATION

Lower Control Arm Special Tools

7. Lower the vehicle and tighten the pivot bolts and shock absorber bolt with the vehicle at curb attitude.

E9332 Removal 1. Raise the vehicle and support it under the body rails. 2. Remove the wheel. 3. Loosen the ball joint nut. Using Tool No. E9332 free the taper. Remove the nut. 4. Disconnect the stabilizer bar link. 5. Loosen the hardware securing the front crossmember and lower the crossmember sufficiently to allow the front boss of the arm to be withdrawn. 6. Remove the shock absorber bolt. 7. Remove the control arm pivot bolts and remove the arm. Installation 1. Fit the lower arm to the crossmembers. 2. Install but do not tighten the pivot bolts. 3. Install the shock absorber bolt from the rear and install the washer and a new nut on the strut. Do not tighten either at this time. 4. Position the ball joint stud in the spindle. Tighten with new nylok nut. 5. Install the wheel. 6. Tighten the hardware securing the front crossmember.

Item 1 2 3

Description Arm Assy Frt Susp Lower Nut Lock Spindle Assy Frt Wheel

Lower Control Arm Ball Joint Special Tools 204-236

204-230

Removal NOTE: Eye protection must be worn during the following procedures. 1. Place small end of Installer/Remover tool 204-236-Item 3 over shaft of ball joint. 2. Place Receiver 204-236-Item 2 above lower control arm.

G48693 en

01/2003 2003.0 BA Falcon


204-01-6

Front Suspension

204-01-6

REMOVAL AND INSTALLATION (Continued) 3. Using a hydraulic press, push ball joint out using 6 tonne removal force.

Item 1 2

Description Receiver 204-236-Item 2 204-236-Item 3

Installation 1. Carefully remove rubber boot & retaining ring prior to installation. 2. Place ball joint into position in casting. 3. Place large end of installer/remover 204-230-Item 8 over butt of ball joint. 4. Place receiver 204-230-Item 3 under lower control arm.

G48693 en

5. Press home using a hydraulic press using 6.5 tonne installing force.

Item 1 2 3

Description An appropriate plate to support hydraulic ram 204-230-Item 8 Receiver 204-230-Item 3

Upper Control Arm Removal 1. Raise the vehicle and support it under the body rails. 2. Remove the wheel. 3. Separate the upper ball joint from the upper arm. Tie the spindle to prevent it from failing away from the body and straining the brake hose. 4. Remove the four nuts securing the upper arm brackets to the suspension tower and remove the assembly from the vehicle. 5. Remove the two bolts and the bracket assemblies from the control arm. Installation 1. Position the bracket assemblies on the upper arm and loosely install new prevailing torque nuts. 2. Position the control arm on the suspension tower and install and tighten the attaching nuts. 01/2003 2003.0 BA Falcon


204-01-7

Front Suspension

204-01-7

REMOVAL AND INSTALLATION (Continued) 3. Attach the ball joint to the spindle, tighten the clamp joint. Remove the spindle tie. 4. Install the wheel and lower the vehicle. 5. With the vehicle at curb attitude tighten the spindle pivot bolts to specification.

Item 1 2 3 4

2. Using a hydraulic press with two tonne approx. force push out ball joint using tool 204-229-2, small diameter down.

Description Arm Assy Frt Susp Upper Receiver Bolt Spindle Assy Nut

Upper Control Arm Ball Joint Special Tools 204-229

Removal NOTE: Eye protection must be worn during the following procedures. 1. Place receiver 204-229-Item 1 large diameter facing up, under upper arm casting.

G48695 en

Item 1 2 3 4

Description 204-229-Item 2 Ball Joint 204-229-Item 1 Receiver Upper Control Arm

Installation 1. Remove rubber boot from the new ball joint, ensuring not to damage the boot or retainer ring clip. 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.

01/2003 2003.0 BA Falcon


204-01-8

Front Suspension

204-01-8

REMOVAL AND INSTALLATION (Continued) 5. Reinstall protective rubber boot and retainer ring clip.

Item 1 2 3 4

3. Fit the bolt and nut securing the shock absorber 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.

Description 204-229-Item 2 Upper Control Arm 204-229-Item 1 Receiver Ball Joint with Boot Removed

Stabilizer Bar Removal 1. Raise the vehicle supporting the body by the side-rails. 2. Disconnect the stabilizer bar from each link. Remove the retaining brackets. 3. Remove the wheel and disconnect the upper ball joint stud from the spindle. 4. Remove the shock absorber lower bolt. 5. Move the shock absorber to allow the end of the stabilizer bar to be brought rearwards past it. 6. Remove the stabilizer bar. Installation 1. Place one end of the bar into position. 2. Move the other side shock absorber to allow that end of the bar to be brought into position in front of the shock absorber. G48695 en

Stabilizer Bar Centre Bushing (Front or Rear Bar) Removal 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. 1. Raise the vehicle on a hoist positioning the suspension in the curb load position. 2. Remove the hardware and brackets attaching the centre section of the stabilizer bar. 3. Remove the insulators from the bar. Installation 1. Position the insulators on the front bar. Position the insulator on the rear bar.

01/2003 2003.0 BA Falcon


204-01-9

Front Suspension

204-01-9

REMOVAL AND INSTALLATION (Continued) 2. Ensure that the links on each end of the bar are located at approximately the same angle relative to the centre line of the vehicle and install the attaching brackets. 3. Lower the vehicle.

Stabilizer Bar Link Bushing 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.

Scenario 1-Replacement of small bush only 1. Clamp lower control arm in vice using soft jaws with both bushes at top. 2. Apply a graphite grease to forcing screw thread before usage. 3. Screw the holding nut fully onto the forcing screw 204- 230-Item 5.

Item 1 2 3 4 5

Description Locating collar 204-230-Item 8 204-230-Item 9 Forcing screw 204-230-Item 5 Holding Nut 204-230-Item 10 Orient anvil so stamping is to top (this positions eccentric hole)

Installation 1. Install the bolt, washers, insulators, spacer and nut as illustrated. Ensure that the insulators are 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

01/2003 2003.0 BA Falcon


204-01-10

Front Suspension

204-01-10

REMOVAL AND INSTALLATION (Continued) 2. Screw the Holding Nut fully on to the Forcing Screw (204-230-Item 5).

Scenario 3-Replacement of both large and small 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. 5. Position assembly over the inside end of Small Bush. 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 1 2 3 4 5

Description Locating collar 204-230-Item 1 204-230-Item 2 Forcing screw 204-230-Item 5 Holding Nut 204-230-Item 3 Orient anvil so stamping is to top (this positions eccentric hole)

3. Place narrow end of Small Bush Anvil Locator (204-230-Item 4) in to empty small bush socket. 4. Orient Small Bush Anvil so stamping ‘UP’ is on Top. 5. Position assembly over the exposed end of Small Bush Anvil Locator. 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 1 2 3 4 5

Description Locating collar 204-230-Item 1 204-230-Item 2 Forcing screw 204-230-Item 5 Holding Nut 204-230-Item 3 Orient anvil so stamping is to top (this positions eccentric hole)

8. Slide Locating Collar over Large Bush Tool to prevent assembly slipping during use. 9. With suitable spanners, clamp Holding Nut and 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

01/2003 2003.0 BA Falcon


204-01-11

Front Suspension

204-01-11

REMOVAL AND INSTALLATION (Continued)

Lower Arm - Large Bushing

3. Place the shaft of the installer 204-230-Item 8 into the bush.

Special Tools 204-230

Installation Large bush 1. Position large bush in arm orientating keyway along central access of arm. NOTE: Large bush keyway must be positioned ± 5° from centreline of control arm.

Item 1 2 3

Description Installer 202-230-Item 8 Small Bush Receiver 204-230-Item 3

4. Using a hydraulic press and suitable “V” blocks place a steel plate over the installer and press the bush home (2.5-3 tonne req’d). CAUTION: Always wear safety glasses and try to protect your body by placing yourself at the side of the press frame during operation or use a transparent ballistic nylon protective blanket 1230PB.

Upper Arm Bushing Item 1 2 3

Description Installer 204-230-Item 1 Large Bush Receiver 204-230-Item 10

2. Place the open side of the installer 204-230-Item 2 onto the bush. 3. Place receiver 204-230-Item 10 under the arm, cup upwards. 4. Using a hydraulic press on the installer press the bush home (2.5-3 tonne req’d). Installation Small bush 1. Position small bush in arm. 2. Place the receiver 204-230-Item 3 cup upward onto the shaft of the installer 204-230-Item 8.

G48701 en

Special Tools 204-228

Removal NOTE: For introduced at AV Falcon are different bushes in front of arm to rear of arm. Front bushes are visually different & are voided around the circumference. NOTE: Eye protection must be worn during the following procedures.

01/2003 2003.0 BA Falcon


204-01-12

Front Suspension

204-01-12

REMOVAL AND INSTALLATION (Continued) 1. Support receiver tool 204-228-Item 1 under bush.

Item 1 2

Description Upper control arm Receiver 204-228-Item 1

2. Press receiver tool 204-228-Item 1 onto bush until it supports on casting.

3. Insert mandrel 204-228-Item 2 into bush sleeve. Insert aligning bush 204-228-Item 3 into bottom of receiver. Proceed to push bush out until it releases itself from the upper arm casting.

Item 1 2

Description Mandrel 204-228-Item 2 Aligning bush 204-228-Item 3

Installation NOTE: Insert voided bush into forward housing in arm. Insert non-voided bush into rear housing in arm. 1. Place receiver tool 204-228-Item 1 under upper control arm. 2. Insert aligning bush 204-228-Item 3 into receiver. 3. Insert reducing bush tool 204-228-Item 4 on top of upper control arm. 4. Insert suspension bush onto mandrel 204-228-Item 2 and insert into reducing bush. 5. Lubricate bush in soapy water. Item 1 2

Description Upper control arm Receiver 204-228-Item 1

G48701 en

01/2003 2003.0 BA Falcon


204-01-13

Front Suspension

204-01-13

REMOVAL AND INSTALLATION (Continued) 6. Insert bush until bush is correctly inserted into Item upper control arm. 4 NOTE: Correct insertion can be viewed by cutouts 5 in receiver. Bush should be central to the control arm.

Description Aligning bush 204-228-Item 3 Reducing bush 204-228-Item 4

Front Wheel Spindle and Hub

Item 1 2 3

Description Mandrel 204-228-Item 2 Upper control arm Receiver 204-228-Item 1

G48702 en

Removal 1. Raise the vehicle and support it under the body rails. 2. Remove the wheel. 3. Remove the brake caliper from the spindle and suspend it so that there is no strain on the brake hose. 4. Remove the hub and disc from the spindle. 5. Loosen the tie rod end nut and using a taper breaker free the stud taper. Remove the nut and detach the tie rod end from the spindle. 6. Loosen the nuts on the spindle ball joint studs and free the tapers using a taper breaker. 7. Remove the bolt and nut securing the upper ball joint stud and move the stud out of the spindle. 8. Remove the nut from the lower ball joint stud and remove the spindle from the vehicle. Installation 1. Locate the lower ball joint stud into the spindle and attach the nut. 2. Locate the upper ball joint stud into the spindle and fit the clamp bolt and nut. 3. Torque the nuts to specification. 4. Install the tie rod end in the spindle. Torque the nut. 5. Install the hub and disc on the spindle. Torque nut to specification. 6. Install the brake caliper. 7. Install the wheel and lower the vehicle.

01/2003 2003.0 BA Falcon


204-01-14

Front Suspension

204-01-14

REMOVAL AND INSTALLATION (Continued)

Item 1 2 3 4 5 6 7 8 9 10 11

Description Nut M14x2 Bolt and Retainer Arm Assembly Front Susp. Lower Nut Lock Spindle Assembly Nut 3/8-24 UNF Stabilizer Bar Link Nut Front Stabilizer Bar Bolt M8x26 Stab. Bar Mounting Bracket

G48702 en

Item 1 2 3 4

Description Hub & Bearing Assy Frt Brake Nut & Washer Assy Seal Frt Wheel Hub Spindle Assy Frt Wheel

01/2003 2003.0 BA Falcon


204-01-15

Front Suspension

204-01-15

REMOVAL AND INSTALLATION (Continued)

Spring and/or Shock Absorber Assembly Removal 1. Remove the coolant bottle or the air cleaner box depending upon which side is to be removed.

Item 1 2 3 4

Description Shock Absorber Ftr Bolt Hex Hd M14 Nut M14 Arm Assy Frt Susp Lwr

2. Remove the two of the three nuts securing the shock absorber/sprlng assembly to the suspension tower and loosen the third nut. 3. Raise the vehicle - supporting it under the body rails. 4. Remove the wheel and separate the upper ball joint stud from the spindle. 5. Remove the shock absorber lower mounting bolt. 6. Remove the third nut supporting the shock absorber/spring assembly to the suspension tower, gently ease down the lower arm and remove the assembly, taking care to ensure that the shock absorber lower brackets do not damage the dust boot of the lower ball joint. Also take care not to damage the ABS wire (where fitted). 7. Install the shock absorber/spring assembly onto the spring compressor and compress the spring to relieve the tension from the shock absorber piston rod.

Installation 1. Ensure that the bumpstop, washer and dirtshield fitted are correctly fitted onto the shock absorber; compress the spring in the spring compressor and assemble the shock absorber into it. 2. Set the stop of the shock absorber spring seat, against the spring lower end, fit the upper spring seat insulator and rotate it’s stop against the upper end of the spring. Fit the spring cap with any of the three studs at the specified angle relative to the centre line of the shock absorber assembly to lower control arm mounting bolt (lower spring seat stop end). 3. Assemble the dual path shear mount and nut onto the shock absorber piston rod. 4. Partly release the spring compressor and torque the nut to specification whilst preventing the spring cap from rotating by use of a soft lever (eg: piece of wood) against two of the three studs. 5. Fully release the spring compressor. 6. Install the shock absorber/spring assembly into the vehicle. The lower spring tail is to be to the front on LHS and to the rear on RHS. Take care not to damage boot of the lower ball joint, or the ABS wire (where fitted) and loosly fit one of the nuts supporting the assembly to suspension tower. 7. Fit the shock absorber lower mounting bolt and loosely fit the nut. NOTE: Bolt thread must point towards the front of the vehicle. 8. Fit the upper ball joint stud to the spindle; fit the clamp bolt and nut. torque the nut. 9. Fit the two remaining nuts securing the upper spring seat cap to the tower. 10. Fit the wheel. 11. With the vehicle weight on it’s wheels, torque the shock absorber lower mounting hardware and the three nuts on the suspension tower, to specification.

WARNING: Do not attempt to separate the spring from the shock absorber until the spring is restrained by the use of a spring compressor. 8. Remove the nut, dual path shear mount and spring seat insulator from the shock absorber piston rod and withdraw the shock absorber. 9. Release the tension from the spring if the spring is to be changed.

G48703 en

01/2003 2003.0 BA Falcon


204-01-16

Front Suspension

204-01-16

REMOVAL AND INSTALLATION (Continued)

Item 1 2 3 4 5 6 7 8

Description Nut Washer Insulator Bracket Assy Insulator Spring Frt Susp Coil Shock Absorber Assy Frt Nut

Item 1 2 3

G48703 en

Description 2A Crossmember 2B Crossmember Nut Nyloc M12

01/2003 2003.0 BA Falcon


204-02a-1

Rear Suspension — IRS

204-02a-1

SECTION : 204-02a Rear Suspension — IRS VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

SPECIFICATIONS Specifications .......................................................................................................................204-02a-2 DESCRIPTION AND OPERATION Rear Suspension — IRS ......................................................................................................204-02a-3 Components .......................................................................................................................204-02a-3 DIAGNOSIS AND TESTING Inspection and Verification ...................................................................................................204-02a-6 Stabiliser Bar ......................................................................................................................204-02a-6 Diagnosis ...........................................................................................................................204-02a-6 GENERAL PROCEDURES FPV Cam bolt adjustment ....................................................................................................204-02a-7 RLCA to subframe cam adjustment .....................................................................................204-02a-7 REMOVAL AND INSTALLATION Upper Control Arm Assembly (UCA) ...................................................................................204-02a-8 Front Lower Control Arm Assembly (FLCA) ........................................................................204-02a-9 Rear Lower Control Arm Assembly (RLCA) ......................................................................204-02a-10 Knuckle ..............................................................................................................................204-02a-13 Rear Lower Control Arm (RLCA) park brake cable bracket ..............................................204-02a-15 Abutment bracket ...............................................................................................................204-02a-15 Control Blade .....................................................................................................................204-02a-16 Shock Absorber .................................................................................................................204-02a-17 Spring and Upper Spring Insulator ....................................................................................204-02a-18 Stabiliser bar ......................................................................................................................204-02a-20 Upper Stabiliser Bar Insulator ............................................................................................204-02a-21 Jounce Bumper ..................................................................................................................204-02a-22 Body Brace ........................................................................................................................204-02a-22 IRS Module ........................................................................................................................204-02a-23

01/2003 2003.0 BA Falcon


204-02a-2

Rear Suspension — IRS

204-02a-2

SPECIFICATIONS Stabiliser Bar Specifications Description Specification Stabiliser bar diameter: 18 ± 0.2mm Stabiliser bar diameter: 19 ± 0.2mm Stabiliser bar/droplink M10 X 1.25 flanged head attachment nut: nut / Zinc plated Stabiliser bar/droplink M10 X 1.25 flanged head attachment bolt: bolt / Zinc plated Torque Specifications Description Nut - M12 - RLCA to Subframe Bolt - M12 - Diff Blade to Diff Bolt - M16 - Front Diff Bush (subframe) to Diff Nut - M14 - RLCA to Knuckle Nut - M14 - FLCA to Subframe Nut - M14 - UCA to Subframe Nut - M12 - FLCA to Knuckle Nut - M12 - UCA to Knuckle Bolt - M14 - Diff Rear Cover to Subframe Bolt - M14 - Diff Rear Cover to Subframe with Mass Damper Nut - M24 - Wheel End Pacnut Bolt - M12 - Caliper to Knuckle Screw - M8 - Stabiliser Bar Bracket to Subframe Nut - M10 - Stabiliser Bar Droplink to RLCA Nut - M10 - Stabiliser Bar Lower Attachment Screw - M8 - Abutment Bracket to Knuckle Screw - M6 - ABS Sensor to Knuckle Nut - M10 - Body Brace to Subframe Screw - M12 - Control Blade to Knuckle Bolt - M14 - Shock Absorber to Knuckle Shock Absorber to Upper Mount (upper bolt) Nut - M12 - Subframe to Body (rear spring area) Nut - M12 - Subframe to Body (front area of subframe) Nut - M12 - Control Blade to Body Bolt - M10 - Body Brace to Body Bolt - M10- Vee Brace to Subframe (rear diff bush mount frame) * Torque at ride height.

G765430 en

Nm 105 ± 15 88 ± 17 140 ± 28 140 ± 28 * 140 ± 28 * 140 ± 28 * 126 ± 24 126 ± 24 200 ± 40 200 ± 40 325 ± 25 103 ± 16 25 ± 5 25 ± 5 52.5 ± 2.5 25 ± 5 10.4 ± 2 50 ± 9.5 88 ± 17 121 ± 18 70 108 ± 17 108 ± 17 100 50 ± 9.5 108 ± 17

01/2003 2003.0 BA Falcon


204-02a-3

Rear Suspension — IRS

204-02a-3

DESCRIPTION AND OPERATION

Rear Suspension — IRS

The Independent Rear Suspension (IRS) design is based on three control arms attached to the subframe and knuckle. The Rear Lower Control Arms (RLCA) seat the base of the spring and also allow for adjusting wheel alignment. Torque is transmitted to the wheels via a centrally located differential and two independent halfshafts. The design allows for servicing on either side of the module. Alternatively, the entire module may be removed from the vehicle.

press-fitted rubber bush in the lower control arm. At the other end the droplink also has a press fitted rubber bush for the attachment to the stabiliser bar. The stabiliser bar and droplink can be replaced individually or altogether as an assembly if necessary.

Components Wheel Knuckle Assembly carries the wheel hub. carries the brake caliper assembly. carries the parkbrake assembly. carries the ABS sensor. carries the shock absorber. is supported by three arms and a knuckle support blade each side.

Stabiliser Bar Assembly The stabiliser bar assembly consists of the stabiliser bar and two droplinks. The assembly is attached to the subframe with two brackets with rubber d-blocks. The droplink serves as a linkage between the lower control arm and the stabiliser bar. The droplink has a spigot at one end, which is bolted inside the G765431 en

Item 1 2 3 4

Description Droplink Stabiliser Bar Attachment Bolt Attachment Nut

01/2003 2003.0 BA Falcon


204-02a-4

Rear Suspension — IRS

204-02a-4

DESCRIPTION AND OPERATION (Continued) Upper Control Arm Assembly (UCA)

Front Lower Control Arm Assembly (FLCA)

Assembly consists of a forged arm with a rubber bush Assembly consists of a stamped arm with rubber on the subframe end and a cross axis ball joint bushes on the subframe end and a CABJ on the (CABJ) on the Wheel Assembly end. Wheel Assembly end.

Item 1 2 3 4 5 6 7

Description Bushing Nut-UCA to Subframe UCA without Bushing Bolt-UCA to Knuckle Nut-UCA to Knuckle Cross Axis Ball Joint (CABJ) Bolt-UCA to Subframe

Item 1 2 3 4 5 6 7

Description Nut FLCA to Subframe FLCA without Bushing Bolt-FLCA to Knuckle Cross Axis Ball Joint (CABJ) Nut-FLCA to Knuckle Bolt-FLCA to Subframe Bushing - Upper Inner

Rear Lower Control Arm Assembly (RLCA) Assembly consists of a stamped arm with rubber bushes on the subframe end and a CABJ on the wheel assembly end. A cam bolt fixes the RLCA to the subframe.

G765431 en

01/2003 2003.0 BA Falcon


204-02a-5

Rear Suspension — IRS

204-02a-5

DESCRIPTION AND OPERATION (Continued)

Item 1 2 3 4 5 6 7 8 9

Description Cam Washer Nut RLCA to Subframe Bolt RLCA to Knuckle Cross Axis Ball Joint (CABJ) Nut RLCA to Knuckle Rear Lower Control Arm RLCA Bolt RLCA to Subframe Cam Washer Bush - Lower Inner

Control Blade Assembly Assembly consists of a stamped blade with a rubber bush on the end connecting to the body and is retained by 3 bolts at the knuckle end.

G765431 en

01/2003 2003.0 BA Falcon


204-02a-6

Rear Suspension — IRS

204-02a-6

DIAGNOSIS AND TESTING

Inspection and Verification

4. Inspect rubber bush for damage.

Stabiliser Bar 1. Inspect the stabiliser bar for signs of corrosion, deep scoring or cracks, which can dramatically reduce the fatigue life of the stabiliser bar. Replace if necessary. 2. Check the stabiliser bar for permanent deformation. This can be checked by laying the stabiliser bar on a flat bench as shown in figure below. Measure the height of the eyes from the bench and they should be within 4mm from each other. Do not attempt to heat the stabiliser bar and bend the eyes into position, as doing so will affect the fatigue properties of the material. Replace if necessary. NOTE: The droplink and its rubber bush must be replaced as a unit.

3. Inspection of press fit.

G765432 en

Diagnosis 1. Inspect the droplink for signs of corrosion or deep scoring which can dramatically reduce the life of the product. Replace if necessary. 2. Check the integrity of the press-fit for the rubber bushes in the droplinks. Measure the distances shown in the figure below. If the measurements are outside the tolerances shown the press-fit has probably worked itself loose under excessive loads. If the facilities are available, the integrity of the press-fit can also be checked by applying a 3kN (300kg) load to the bush. The bush should be capable of taking the load without slipping. Do not attempt to refit the rubber bushes into the droplinks. Replace if necessary. 3. Inspect the rubber bush for any signs of tearing or the failure of the bond from the steel sleeves in the region shown in the figure above. Replace if necessary.

01/2003 2003.0 BA Falcon


204-02a-7

Rear Suspension — IRS

204-02a-7

GENERAL PROCEDURES

FPV Cam bolt adjustment Refer to section Section 204-00.

RLCA to subframe cam adjustment Refer to section Section 204-00.

G765434 en

01/2003 2003.0 BA Falcon


204-02a-8

Rear Suspension — IRS

204-02a-8

REMOVAL AND INSTALLATION

Upper Control Arm Assembly (UCA)

Item 1 2 3 4 5 6 7

Description Bushing Nut-UCA to Subframe UCA without Bushing Bolt-UCA to Knuckle Nut-UCA to Knuckle Cross Axis Ball Joint (CABJ) Bolt-UCA to Subframe

Removal 1. Hoist vehicle and remove rear wheels. Refer to Section 100-02. 2. Remove IRS module. Refer to IRS Module in this section. 3. Set the suspension to ride height. Refer to Section 204-00. 4. Loosen and remove UCA-knuckle nut. 5. Remove UCA-knuckle bolt.

G765435 en

6. Loosen and remove UCA-subframe nut. 7. Remove UCA-subframe bolt. 8. Slide UCA free. Installation 1. Locate UCA in subframe as shown. 2. Attach UCA-subframe bolt and loosely attach UCA Subframe nut. NOTE: Bolt head faces the front of the module. 3. Set the suspension to the correct ride height. Refer to Section 204-00. 4. Locate UCA into knuckle attachment point with UCA-knuckle bolt and loosely attach UCA-Knuckle nut. NOTE: Bolt head faces the front of the module. 5. Torque UCA-knuckle bolt and UCA-knuckle nut to 126 ± 24 Nm.

01/2003 2003.0 BA Falcon


204-02a-9

Rear Suspension — IRS

204-02a-9

REMOVAL AND INSTALLATION (Continued) 6. Torque UCA-subframe bolt and UCA-Subframe nut to 140 ± 28 Nm.

2. Set suspension to design height with springs installed. Refer to Section 204-00. Support wheel ends under the knuckle positions and under RLCAs as indicated. 3. Remove nut on FLCA bolt to knuckle. 4. Remove nut on FLCA bolt to subframe.

7. Install the IRS module back into the vehicle. Refer to IRS Module in this section.

Front Lower Control Arm Assembly (FLCA)

Item 1 2 3 4 5 6 7

Description Nut FLCA to Subframe FLCA without Bushing Bolt-FLCA to Knuckle Cross Axis Ball Joint (CABJ) Nut-FLCA to Knuckle Bolt-FLCA to Subframe Bushing - Upper Inner

Removal 1. Hoist vehicle and remove rear wheels. Refer to Section 100-02.

5. Remove both FLCA-knuckle and FLCA-subframe bolts. 6. Slide FLCA free.

Installation 1. Locate FLCA to subframe. NOTE: The FLCA should be oriented so that the CABJ fits to the knuckle, that the face with the "REAR" label faces the rear of the module and that the upper and lower flanges face the rear of the module. 2. Fit nut to bolt loosely. NOTE: Ensure bolt head faces the rear of the module. This is the only bolt head that faces the rear of the vehicle. 3. Set suspension to ride height. See Section 204-00.

G765436 en

01/2003 2003.0 BA Falcon


204-02a-10

Rear Suspension — IRS

204-02a-10

REMOVAL AND INSTALLATION (Continued) 4. Locate FLCA to knuckle and fit nut to bolt loosely. Removal NOTE: Ensure bolt head faces the front of the 1. Hoist vehicle so that the wheels are fully module. supported. 2. Set suspension to ride height. See Section 204-00. 3. Remove rear wheels. 4. Disconnect Control Blade from Wheel End Assembly.

5. Torque FLCA-knuckle bolt to 126 ± 24 Nm. 6. Torque FLCA-subframe bolt to 140 ± 28 Nm. 7. Attach wheels and lower vehicle. CAUTION: Care should be taken when removing transmission jack from under RLCA due to the high compressive force in the spring.

5. Remove Knuckle-RLCA bolt.

Rear Lower Control Arm Assembly (RLCA)

6. Disconnect Stabiliser Bar links by removing nut/washer.

Item 1 2 3 4 5 6 7 8 9

Description Cam Washer Nut RLCA to Subframe Bolt RLCA to Knuckle Cross Axis Bolt Joint (CABJ) Nut RLCA to Knuckle Rear Lower Control Arm RLCA Bolt RLCA to Subframe Cam Washer Bush - Lower Inner

G765436 en

01/2003 2003.0 BA Falcon


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.

8. Rotate stabiliser bar away from RLCA, and towards Control Blade. 9. Unclip park brake cable from RLCA park brake cable bracket.

12. Remove spring and Spring Insulators when spring becomes fully extended. CAUTION: Springs have high spring rate and extreme care should be taken when 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.

G76555 en

01/2003 2003.0 BA Falcon


204-02a-12

Rear Suspension — IRS

204-02a-12

REMOVAL AND INSTALLATION (Continued) Installation 1. Ensure that park brake cable and stabiliser bar links are positioned away from the RLCA position within module. 2. Locate RLCA and locate RLCA cam bolt assembly through RLCA bush and subframe.

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.

5. Insert jack underneath RLCAs. Extend jack so that spring is compressed and return the halfshafts to a horizontal position.

G76555 en

6. Locate and loosely fit RLCA-knuckle bolt. Ensure bolt head faces the front of the module, and that the nut is fully closed over the bolt shank.

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.

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. 11. Clip park brake cable into RLCA cable bracket.

01/2003 2003.0 BA Falcon


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.

13. Attach wheels and lowere vehicle.

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 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 1 2

G76540 en

Description Hand Brake Cable Retaining Spring Clip

01/2003 2003.0 BA Falcon


Thank you very much for your reading. Please Click Here Then Get More Information.

2004 ford ba falcon service repair manual  
2004 ford ba falcon service repair manual  
Advertisement