Ford Falcon 2003 User Manual

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 A warning, caution or note is placed at the beginning
and include similar content in each manual worldwide. of a series of steps if it applies to multiple steps. If the

This manual provides general descriptions for
accomplishing service and repair work with tested,
effective techniques. Following them will help assure
reliability.

Replacement Parts

Ford and Motorcraft parts are made to the same This manual is structured into groups and sections,
exacting standards as the original factory fitted with specific system sections collected together under
components. For this reason, it is recommended that their relevant group.
only genuine Ford or Motorcraft parts are installed
during service or repair.

Special Tools

The Special Tool(s) Table provided at the beginning number of a section number.
of each procedure shows all special tools required to
carry out a repair. Where possible, illustrations are
provided to assist in identifying the special tool
required.

Special tools may be ordered from:

Australia

SPX AUSTRALIA

Tel: [phone]

Fax: [phone]

Important Safety Instructions

Appropriate service methods and correct repair
procedures are essential for the safe, reliable
operation of all motor vehicles as well as the personal
safety of the individual carrying out the work.

This manual cannot possibly anticipate all such
variations and provide advice or cautions as to each.
Anyone who departs from the instructions provided in
this manual must first establish that he compromises
neither his personal safety nor the vehicle integrity by
his choice of methods, tools or parts.

Warnings, Cautions and Notes in This
Manual

WARNING: Warnings are used to indicate
that failure to follow a procedure correctly may
result in personal injury.

CAUTION: Cautions are used to indicate that
failure to follow a procedure correctly may result
in damage to the vehicle or equipment being
used.

NOTE:

information required to carry out a complete and
satisfactory repair.

As you read through this manual, you will come
across WARNINGS, CAUTIONS and NOTES.

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

This manual covers service and repair procedures.

A group covers a specific portion of the vehicle. The
manual is divided into five groups, General
Information, Chassis, Powertrain, Electrical and Body
and Paint. The number of the group is the first

Pages at the start of the manual list all sections
available. Each section has a contents list detailing
General Specifications, Description and Operation
and Service Adjustment and Checks.

If components need to be removed or disassembled
in sequence, the sequence will be identified
numerically in a graphic and the corresponding text
will be numbered accordingly (refer to ‘Samples’).

All left and right-hand references to the vehicle are
taken from a position sitting in the driver seat looking
forward.

All left and right-hand references to the engine are
taken from a position at the flywheel looking towards
the front camshaft pulley.

Where appropriate, instructions will be given for the
use of WDS, diagnostic equipment.

Inspection and Verification
Visual Inspection Charts, Symptom Charts and other

information charts (such as diagnostic routines),
supplement test procedures with technical
specifications, or navigate the user to a specific test
procedure.

Sympton Chart
The symptom chart indicates symptoms, sources and

actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are used to

identify the source of a concern in a logical,
step-by-step manner. Pinpoint tests have two
columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.

The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and the
DETAILS/RESULTS/ACTIONS column provides

Notes are used to provide additional essential

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DESCRIPTION AND OPERATION (Continued)

direction to another test step or specific corrective Before using any product the Materials Safety Data
actions. Sheet supplied by the manufacturer or supplier should

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 Used in batteries and cleaning materials.
the pinpoint test.

Graphics throat. Cause burns. Can destroy ordinary protective
Test graphics show the measurement or test to be

performed in a test step. Avoid splashes to the skin, eyes and clothing. Wear
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 Display Eye Hazard sign.
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 See also Fire, Chemical Materials
pin number.

Samples

Special Tools and Torque Figures
Any requirement for special tools will picture the tool, panel and side impact Airbags.

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.

be consulted.

Acids and Alkalis

See also Battery Acids.
For example caustic soda, sulphuric acid.

Irritant and corrosive to the skin, eyes, nose and

clothing.

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.

Air Bags

Highly flammable, explosive – observe No Smoking
policy.

Used as a safety restraint system mounted in the
steering wheel and passenger side of the instrument

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.

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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.

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.

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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 cleaned.
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 inadequate container labelling; fire and explosion
damp wiping is preferred. hazards.

Asbestos dust waste should be dampened, placed in Do wash before job breaks, before eating,
a sealed container and marked for safe disposal. If smoking, drinking or using toilet facilities when
any cutting or drilling is attempted on materials handling chemical 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.

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

Do organise work practices and protective
clothing to avoid soiling of the skin and eyes;
breathing vapours, aerosols, dusts or fumes;

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

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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.

Chlorofluorocarbons (CFC)

There is concern in the scientific community that
CFCs and Halons are depleting the upper ozone layer
which filters out harmful ultraviolet radiation.
Decreased filtration of ultraviolet radiation may result
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.

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.

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
acceptable substitutes are commercially available.

Clutch Fluids

See Brake fluids.

Clutch Linings and Pads

See Asbestos.

Corrosion Protection Materials

See also Solvents, Fire.
Highly flammable, flammable – observe No Smoking

policy.
These materials are varied and the manufacturers

instructions should be followed. They may contain
solvents, resins or petroleum products. Skin and eye
contact should be avoided. They should only be
sprayed in conditions of adequate ventilation and not
in confined spaces.

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.

Make sure that flexes, cables, plugs and sockets are
not frayed, kinked, cut, cracked or otherwise
damaged.

Make sure that electrical equipment and flexes do not
come into contact with water.

Never misuse electrical equipment and never use

Make sure that the cables of mobile electrical

Make sure that the designated electrical workers are
trained in basic First Aid.

In cases of electrocution:

switch off the power supply before approaching
the victim.

if this is not possible push or drag the victim from
the source of electricity using dry non-conductive
material.

commence resuscitation if trained to do so.
SUMMON MEDICAL ASSISTANCE.

Engine Oils

See Lubricants and Grease.

Exhaust Fumes

These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic

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DESCRIPTION AND OPERATION (Continued)

hydrocarbons. Engines should be run only under
conditions of adequate exhaust extraction or general
ventilation and not in confined spaces.

Gasolene (petrol) engine

There may not be adequate warning of odour or of
irritation before toxic or harmful effects arise. These
may be immediate or delayed.

Diesel engine

Soot, discomfort and irritation usually give adequate
warning of hazardous fume concentrations.

Fibre Insulation

See also Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can

cause skin irritation. This is usually a physical and not
a chemical effect.

Precautions should be taken to avoid excessive skin
contact through careful organization of work practices
and the use of gloves.

Fire

See also Welding, Foams, Legal Aspects.
Many of the materials found on or associated with the

repair of vehicles are highly flammable. Some give off
toxic or harmful fumes if burnt.

Observe strict fire safety when storing and handling
flammable materials or solvents, particularly near
electrical equipment or welding processes.

Make sure, before using electrical or welding
equipment, that there is no fire hazard present.

Have a suitable fire extinguisher available when using
welding or heating equipment.

First Aid

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 drowsiness and unconsciousness. Small amounts can

affected area in cool to cold water. be fatal to children. Aspiration of liquid into the lungs,
Individuals affected by inhalation of gases and fumes

should be removed to fresh air immediately. If effects Gasolene dries the skin and can cause irritation and
persist, consult a doctor. dermatitis on prolonged or repeated contact. Liquid in

If liquids are swallowed inadvertently, consult a doctor
giving him the information on the container or label. Motor gasolene may contain appreciable quantities of
Do not induce vomiting unless this action is indicated benzene, which is toxic upon inhalation, and the
on the label. concentration of gasolene vapours must be kept very

Fluoroelastomer

See Viton.

Foams - Polyurethane

See also Fire.
Used in sound and noise insulation. Cured foams

used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be

harmful to the skin and eyes. Wear gloves and
goggles.

Individuals with chronic respiratory diseases, asthma,
bronchial medical problems, or histories of allergic
diseases should not work in or near uncured
materials.

The components, vapours or spray mists can cause
direct irritation, sensitivity reactions and may be toxic
or harmful.

Vapours and spray mists must not be inhaled. These
materials must be applied with adequate ventilation
and respiratory protection. Do not remove the
respirator immediately after spraying, wait until the
vapour/mists have cleared.

Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
equipment during foaming operations and until
vapours/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
foams should be conducted with extraction ventilation.
See also the vehicle Body Repair Manual.

Freon

See Air Conditioning Refrigerant.

Fuels

See also, Fire, Legal Aspects, Chemicals and
Solvents.

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

Gasoline (Petrol)

Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation

and absorption from the stomach can result in

through vomiting, is a very serious hazard.

the eye causes severe smarting.

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.

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DESCRIPTION AND OPERATION (Continued)

Make sure there is adequate ventilation when checked for integrity following the specified
handling and using gasolene. Great care must be procedures.
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 See also Fire.
must not be siphoned by mouth. See First Aid.

Gas-oil (Diesel Fuel)

Combustible.
Gross or prolonged skin contact with high boiling point

gas oils may also cause serious skin disorders
including skin cancer.

Kerosene (Paraffin)

Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from

swallowing. The main hazard from swallowing arises if
liquid aspiration into the lungs occurs.

Liquid contact dries the skin and can cause irritation
or dermatitis. Splashes in the eye may be slightly
irritating.

In normal circumstances the low volatility does not
give rise to harmful vapours. Exposure to mists and
vapours from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there is
adequate ventilation.

Alternative Fuel

Highly flammable. Observe “NO SMOKING” signs. maintained in good condition and the correct safety
Make sure there is adequate ventilation when working

on alternative fuelled vehicles. Great care must be Never use tools or equipment for any purpose other
taken to avoid the serious consequences of inhalation than that for which they were designed. Never
in the event of vapour build up in confined spaces. overload equipment such as hoists, jacks, axle and

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. Wear a suitable breathing mask when using abrasive

LPG/CNG fuel leaks could cause a fire and be a
hazard to health that can lead to personal injury,
illness or even death. Make sure there is adequate ventilation to control

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

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

Gases such as oxygen, acetylene, argon and propane
are normally stored in cylinders at pressures of up to
138 bar (2000 psi) and great care should be taken in
handling these cylinders to avoid mechanical damage
to them or to the valve gear attached. The contents of
each cylinder should be clearly identified by
appropriate markings.

Cylinders should be stored in well ventilated
enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene and
propane, should not be stored in close proximity to
oxygen cylinders.

Care should be exercised to prevent leaks from gas
cylinders and lines, and to avoid sources of ignition.

Only trained personnel should undertake work
involving gas cylinders.

Gases

See Gas Cylinders.

Gaskets (Fluoroelastomer)

See Viton.

General Workshop Tools and Equipment

It is essential that all tools and equipment are

equipment is used where required.

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.

blasting equipment, working with asbestos-based
materials or using spraying equipment.

dusts, mists and fumes.

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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 boilers can be recommended only for units of
environmental pollution, workshops should be familiar, approved design. If in doubt check with the
in detail, with the many health and safety laws and appropriate local authority and manufacturer of
regulations within their country, published by both approved appliances.
national and local authorities.

Lubricants and Greases

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.

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.

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

Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensed
waste disposal sites, or to the waste oil reclamation

It is illegal to pour used oil on to the ground, down
sewers or drains, or into water courses.

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.

Health Protection Precautions

Paints

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 Can also contain harmful and toxic unreacted resins
immediately for open cuts and wounds. and resin hardening agents. The manufacturers

Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin.

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

instructions should be followed. See also Resin-based
Adhesives and Isocyanate Adhesives and Sealers
under Adhesives and Sealers.

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DESCRIPTION AND OPERATION (Continued)

Spraying should preferably be carried out in Avoid splashes to the skin, eyes and clothing. Wear
exhausted ventilated booths removing vapour and protective gloves, goggles and clothing if necessary.
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.

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 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.

See Corrosion Protection.

Viton

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.

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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.

Welding

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

Welding), Arc Welding and Gas Welding.

Resistance Welding

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

Arc Welding

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.

Gas Welding (and Cutting)

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 .

Warning Symbols on Vehicles

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.

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.

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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.

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

4. Displaying the caution circle with a deleted lighted
match symbol, caution against the use of naked
lights or flames within the immediate vicinity due
to the presence of highly flammable or explosive
liquids or vapours. See Fire in this subsection.

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

White Spirit

See Solvents.

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.

there is adequate room to raise the vehicle and
remove the wheels, if necessary.

fender covers are always fitted if any work is to be
carried out in the engine compartment.

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DESCRIPTION AND OPERATION (Continued)

the battery is disconnected if working on the do not work on the fuel lines or system
engine. components unless the alternative fuel has been

evacuated and the pressure in the system is

CAUTION: When electric arc welding on a
vehicle, always disconnect the generator wiring to
prevent the possibility of a surge of current
causing damage to the internal components of the
generator.

If using welding equipment on the vehicle, a
suitable fire extinguisher is readily available.

Alternative Fuel

WARNING: When servicing the fuel system
always follow the recommended procedures.
Failure to follow these instructions may result in
personal injury.

If the odour of liquified petroleum gas (LPG) or
compressed natural gas (CNG) is present in the air in
the workshop, warn all persons in the area to:

extinguish all flames and lighted tobacco.
shut off electrical and air powered equipment.
evacuate the area.
ventilate the area.
contact fire control authorities.
remove the vehicle to a dedicated, ventilated

area.

Alternative Fuel — Do’s

do work on the vehicle in a designated area that
is well ventilated and its access restricted to
qualified personnel only

install new warning labels to their original
locations

if possible always isolate the alternative fuel tank,
run the vehicle on the alternative fuel until it
automatically switches to its normal fuel prior to
taking the vehicle into the workshop/service area

only use tested and approved components and
pipes when repairing or servicing LPG and CNG
systems

reduced to atmospheric, or less
do not use anything other than the specified leak

detector fluid to trace fuel leaks

Be aware of situations that may cause the LPG or
CNG fuel system to vent off fuel, such as:

extremely hot days
parking by a space heater
hoisting a vehicle up near a ceiling heater

Only personnel fully trained to Ford and local
standards are to work on alternative fuel vehicles.

Towing the Vehicle

WARNING: When the vehicle is being towed
the ignition switch must be in position II (steering
lock released and warning lights illuminated).
Only then will the steering, turn signal lamps,
horn and stop lamps be operational. Failure to
follow these instructions may result in personal
injury.

When a vehicle with automatic transmission is towed,
the gear selector must be in position N (Neutral).
Never tow a vehicle with automatic transmission
faster than 30 mph (50 km/h) or further than 30 miles
(50 km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off the
ground.

Alternatively the vehicle can be transported on a low
loader or a trailer.

Connecting a Slave Battery Using Jumper
Cables

WARNING: If the slave battery has recently
been charged and is gassing, cover the vent plugs
or covers with a damp cloth to reduce the risk of
explosion should arcing occur when connecting
the jumper cables. Failure to follow these
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 01/2003 2003.0 BA Falcon

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.

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.

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.

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: 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

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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.

General SAM-1C-9107A

SAM-1C-9107A

Spark plug threads ESE-M1244-A

Sealers

Application Ford Spec. Manufacturer and Identification
For camshaft bearing caps ESK-M4G260-A Loctite 518
For cylinder block WSK-M4G320-A Hylosil 502
For fitting rear lamp assembly WSK-M4G329-ABC
For transmission housing (80 gram can) Finis Code 6 160 443

Adhesives

Application Ford Spec.

PU for windscreen, side and rear glass Finis Code 6 997 259

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.

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.

Pre-Test Checks

Starting the Engine

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 01/2003 2003.0 BA Falcon

NOTE:

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:

On initial drive away from cold and within the

The handbrake is applied.
The gear lever is in neutral.

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.

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.

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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 CODE

XT Sedan SW
XT Wagon WA
Futura Sedan SW
Futura Wagon WA
XR Sedan SW
XR Ute CM
GT Sedan SW
Fairmont Sedan SW
Fairmont Wagon WA
Fairmont Ghia Sedan SW
Fairlane Ghia LW
LTD LW
XL Ute CM
XLS Ute CM

Model Code

Body Type Body Style Model Code

Sedan XT 18333
Wagon XT 18363
Sedan Futura 18334
Wagon Futura 18364
Sedan XR 18335
Sedan FMT 18332
Wagon FMT 18332
Sedan FMT Ghia 18338
Sedan Fairlane Ghia 18349
Sedan LTD 18346
Ute XL Tray 45313
Ute XL SSB 45373
Ute XR Tray 45375
Ute XLS Tray 45314
Ute XLS SSB 45374

G86656 en 01/2003 2003.0 BA Falcon

100-01-5 Identification Codes 100-01-5

DESCRIPTION AND OPERATION (Continued)

Paint Colour and Code

Colour Code

Winter W hite A1
Venom VF
Ice Mint Silver EI
Barossa Reb B7
Congo Green DG
Silhouette ST
Blue Print UU
Narooma Blue NR
Phantom P3
Mercury Silver M7
Blue Pearl CP
Acid Rush RH
Citric Acid JA
Blood Orange HO
Victorian Taxi Yellow 44
Taxi Orange 22

Trim Colour and Code

Colour Code

Stone S1
Warm Charcoal B1

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

Penalties

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)

. Where State/Territory Laws differ from the

Substantial Financial

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

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.

CAUTION: The service jack provided with the
vehicle is only intended to be used in an
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

Jacking/Lifting Points - Ute

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.

2. The rear jacking\lifting point for the ute is on the
leaf spring hanger bracket.

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.

Acceptable Noise, Vibration and
Harshness

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.

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.

Ambient Temperature

The surrounding or prevailing temperature.

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.

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.

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 by gusting winds. An example would be wind gusts
repairs or sudden change. against the side glass.

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 vehicle.

concern has been corrected or brought back to

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

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

G72678 en 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.

Item Description
1 True vertical
2 Positive caster
3 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.

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.

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

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100-04-4 Noise, Vibration and Harshness 100-04-4

DESCRIPTION AND OPERATION (Continued)

applied and the transmission engaged. This test is from side-to-side (wobble). Dynamically unbalanced
used for noise and vibration checks. wheel and tyre assemblies can cause wheel shimmy.

Driveline Angles Engine Imbalance

The differences of alignment between the A condition in which an engine’s center mass is not
transmission output shaft, the driveshaft, and the rear concentric to the rotation center, causing excessive
axle pinion centerline. 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.

Float

Item Description
1 Engine
2 Driveshaft
3 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.

Drivetrain Damper

A weight attached to the engine, the transmission, the
transfer case, or the axle. It is tuned by weight and
placement to absorb vibration.

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.

Hiss

Steady high frequency (200–800 Hz) noise. Vacuum
leak sound.

Drone

A low frequency (100-200 Hz) steady sound, like a
freezer compressor. Also described as a moan.

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.

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 01/2003 2003.0 BA Falcon

Hoot

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

Howl

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

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.

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.

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.

Item Description
1 Lateral runout
2 Radial runout

Rattle

A random and momentary or short duration noise.

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.

Outboard

Away from the centerline of the vehicle.

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.

Ring Gear

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

Road Test

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

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

G72678 en 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 warm. Also, irregular tyre wear patterns in the tyre
sensitive. Also referred to as a shimmy or wobble. tread resulting from wheel-locked skids.

Shimmy Tyre Force Vibration

An abnormal vibration or wobbling, felt as a A tyre vibration caused by variations in the
side-to-side motion of the steering wheel in the construction of the tyre that is noticeable when the
driveshaft rotation. Also described as waddle. tyre rotates against the pavement. This condition can

Shudder

A low-frequency vibration that is felt through the
steering wheel or seat during light brake application.

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.

Slip Yoke/Slip Spline

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

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.

Transient

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

Two-Plane Balance

Radial and lateral balance.

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 sensitive to torque. A drive engine run-up (DERU) or a

proceed its appearance? neutral engine run-up (NERU) test identifies noises

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 following is a brief overview of each test in the

3: Preparing for the Road Test

Observe the following when preparing for the road
test:

Review the information recorded on the NVH
Diagnostic Guide. It is important to know the
specific concern the customer has with the
vehicle.

Do not be misled by the reported location of the
noise or vibration. The cause can actually be
some distance away, transferred from another
part of the vehicle.

Remember that the vibrating source component
(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
other components (transfer path).

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
is possible to operate the vehicle at the speed in
which the condition occurs.

If possible, lower the radio antenna in order to
minimize turbulence. Identify anything that could
potentially make noise or be a source of wind
noise. Inspect the vehicle for add-on items that
create vibration/noise. Turn off the radio and the
heating and cooling system blower.

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

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:

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.

order in which it appears. A review of this information
helps to quickly identify the most appropriate process
necessary to make a successful diagnosis. After
reviewing this information, select and carry out the
appropriate test(s), proceeding to the next step of this
process.

It may be necessary to have the customer ride

The Slow Acceleration Test is normally the first
test to carry out when identifying an NVH concern,
especially when a road test with the customer is
not possible.

The Heavy Acceleration Test helps to determine if
the concern is torque-related.

The Neutral Coast Down Speed Test helps to
determine if the concern is vehicle speed-related.

The Steering Input Test helps to determine how
the wheel bearings and other suspension

The Brake Test helps to identify vibrations or
noise that are brake-related.

The Road Test Over Bumps helps isolate a noise
that occurs when driving over a rough or bumpy
surface.

The Engine Run-Up Tests consist of the Neutral
Run-up Test and the Engine Load Test. These

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.

Slow Acceleration Test

To carry out this test, proceed as follows:

Slowly accelerate to the speed where the reported
concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the
vibration frequency.

Attempt to identify from what part of the vehicle
the concern is coming.

Attempt to identify the source of the concern.
Proceed as necessary.

Heavy Acceleration Test

To carry out this test, proceed as follows:

Accelerate hard from 0-64 km/h (0-40 mph).
Decelerate in a lower gear.
The concern is torque-related if duplicated while

carrying out this test.
Proceed as necessary.

Neutral Coast Down Speed Test

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.

If the concern goes away or gets worse, the
wheel bearings, hubs, U-joints (contained in the
axles of 4WD applications), and tyre tread wear
are all possible sources.

Proceed as necessary.

Brake Test

To carry out this test, proceed as follows:

Warm the brakes by slowing the vehicle a few
times from 80–32 km/h (50–20 mph) using light
braking applications. At highway speeds of 89–97
km/h (50–60 mph), apply the brake using a light
pedal force.

Accelerate to 89–97 km/h (55–60 mph).
Lightly apply the brakes and slow the vehicle to

30 km/h (20 mph).
A brake vibration noise can be felt in the steering

wheel, seat or brake pedal. A brake noise can be
heard upon brake application and diminish when
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 01/2003 2003.0 BA Falcon

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

100-04-12 Noise, Vibration and Harshness 100-04-12

DIAGNOSIS AND TESTING (Continued)

engine rpm and, if possible, determine the If the vibration/noise is duplicated when carrying
vibration frequency. out this test, the belts and accessories are not

Attempt to identify what part of the vehicle the
concern is coming from. If the vibration/noise was not duplicated when

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:

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.

A serpentine drive belt decreases the

sources.

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.

G72679 en 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, deceleration. Goto Tire
the engine, engine accessory or engine firing Noise/Vibration.
frequencies should be calculated. Noise varies with wind/vehicle speed

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. Acceleration

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 Light/moderate acceleration

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.

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

3. Turning noise. Goto Steering Noise/Vibration.

4. Braking.

5. Clutching.

6. Shifting

7. Engaged in four-wheel drive. Goto
Transmission (Manual) and Transfer Case
Noise/Vibration.

8. Cruising speeds

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).

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.

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.

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.

A noise occurring during clutch operation.
Goto Transmission (Manual) and Transfer
Case Noise/Vibration.
Vibration. Goto Transmission (Manual)
and Transfer Case Noise/Vibration.

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.

Accelerator pedal vibration. Goto Engine
Noise/Vibration.
Driveline vibration. Goto Driveline
Noise/Vibration.

G72679 en 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 Source Action

Air leak around door perimeter Loose fit seal.

Seal installed incorrectly. REINSTALL the seal.

Door misaligned.

Scuff plate installed incorrectly. REINSTALL the scuff plate.

Seal or seal push pins damaged. INSTALL a new seal.

Air leak around glass run Door glass misaligned. ADJUST the door glass.

Glass run installed incorrectly.

Leak path behind glass run.

Glass run channel spread wide.

Blow-out clip bent or contacting door ADJUST the blow-out clip or INSTALL
glass.

Glass run damaged. INSTALL a new glass run.

Air leak at inner belt line

Belt line seal installed incorrectly on ADJUST the seal. (Do not bend the
flange. flange.)

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

No contact with side glass. ADJUST the door glass.

No contact with glass runs at both ADJUST the belt line seal or ADD
ends of belt line seal. foam at the seal ends.

PINCH the seal carrier to improve

retention on the seal flange.

REALIGN the door. CHECK door gaps

and fit in the door opening and
ADJUST as necessary.

ADJUST the glass run. INSERT foam

in the glass run carrier.

INSTALL foam rope behind the glass

run.

PINCH the glass run channel to

reduce the size of the opening.

a new glass run/blow-out clip molding
assembly.

REINSTALL the door trim.

Belt line seal damaged. INSTALL a new seal.

G72679 en 01/2003 2003.0 BA Falcon

100-04-15 Noise, Vibration and Harshness 100-04-15

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Air leak at outer belt line ADJUST the seal.

Draft at inner door handle/speaker

opening

Wind noise from exterior rear view REALIGN with the edges shingled

mirror correctly and no gaps.

Air leak around perimeter of fixed

glass

Air leak at cowl Cowl gasket misaligned/damaged.

Air leak around liftgate perimeter Loose fit seal.

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

Belt line seal does not contact the
glass.

No contact with glass runs at both ADJUST the belt line seal/ADD foam
ends of belt line seal. at the seal ends.

Belt line seal damaged. INSTALL a new seal.

Hole in watershield. SEAL the hole with a suitable tape.

Watershield misaligned.

Exterior door handle seal REALIGN or INSTALL a new seal as
misaligned/damaged. necessary.

Exterior mirror housing misaligned.

Mirror sail gasket folded/misaligned.

Mirror housing trim cap installed REINSTALL with the edges shingled to
incorrectly. the air flow.

Air leak through mirror housing hinge.

Inner sail trim installed incorrectly.

Inner sail gasket/barrier installed REINSTALL the trim cover with the
incorrectly. gasket/barrier aligned correctly.

Air path through wiring bundle/fastener
access holes.

Exposed fastener access hole on
mirror housing/sail.

Gaps in the sealant bead. APPLY approved sealant.

Air traveling up windshield molding INSTALL foam rope the full length of
along A-pillar. the A-pillar.

Windshield/backlite misaligned or not
installed correctly.

Rear hood seal at base of windshield REALIGN or INSTALL a new seal as
misaligned/damaged. necessary.

Seal misaligned. REINSTALL the seal.

Liftgate misaligned.

ADJUST the door glass.

REALIGN the watershield. INSTALL a

new watershield if the pressure
sensitive adhesive fails.

REINSTALL with the gasket unfolded

and aligned correctly.

Fully ENGAGE the mirror into its

operating position/USE foam to block
the air path through the hinge.

REINSTALL the sail trim/ADJUST the

door trim.

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

INSTALL a new cap if it is missing.

REINSTALL the windshield/backlite.

REALIGN or INSTALL a new seal as

necessary.

PINCH the seal carrier to improve

retention on the seal flange or INSERT
foam in the carrier.

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.

G72679 en 01/2003 2003.0 BA Falcon

100-04-16 Noise, Vibration and Harshness 100-04-16

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Air leak around the liftgate flip window PINCH the seal carrier to improve the

perimeter retention to the seal flange.

Wind noise from antenna Shape of antenna.

Air leak from closed roof opening

panel

Buffeting from an open roof opening REPAIR or INSTALL a new wind

panel

Loose fit seal.

Seal misaligned. REINSTALL the seal.

Glass misaligned. REALIGN the glass.

Seal damaged. INSTALL a new seal.

INSTALL an antenna boot or a spiral

antenna.

Air leak around antenna cable access INSPECT the antenna access hole
hole. grommet. REPAIR as necessary.

Seal installed incorrectly. REINSTALL the seal.

Roof opening panel glass/door REALIGN the roof opening panel
misaligned. glass/door.

Roof opening panel damaged.

Wind deflector inoperative/damaged.

INSTALL a new roof opening panel.

REFER to Section 501-17 .

deflector as necessary. REFER to
Section 501-17 .

Wind deflector height incorrect. ADJUST the wind deflector higher.

Wind noise created by airflow over or

behind body panels

Wind noise created by grille opening Grille relationship to leading edge on ADJUST the grille opening panel

panel hood. forward to eliminate wind noise.

Wind noise from air extractor REINSTALL the air extractor housing.

Noise from roof rack Roof rack rails or crossbars loose. TIGHTEN the fasteners.

Fender splash shield misaligned. REALIGN the fender splash shield.

Body panel misaligned (exposed
edge).

Hood misaligned (front margin).

Front grille edge noise.

Sharp edges due to material REMOVE the sharp edges (no
imperfections. damage to visible surface).

Air extractor housing seated
incorrectly.

Air extractor housing or flaps
damaged.

Roof rack fasteners missing. INSTALL the approved fasteners.

Roof rack crossbars installed
backward.

Roof rack rub strips partially lifting from REAPPLY adhesive or fasteners or
roof. INSTALL new rub strips as necessary.

REALIGN the appropriate body panel.

CHECK hood gaps and fit. ADJUST

the hood as necessary.

APPLY foam in the hollow areas

behind the louvers.

INSTALL a new air extractor.

REINSTALL the crossbars.

Roof rack gaskets loose or misaligned. REINSTALL the gasket.

Wind noise from bug shield/exterior Turbulence created by location and REMOVE per customer direction if it is

windshield sun visor shape. a dealer installed option.

01/2003 2003.0 BA FalconG72679 en

100-04-17 Noise, Vibration and Harshness 100-04-17

DIAGNOSIS AND TESTING (Continued)

Symptom Chart — Brake Noise/Vibration

Condition Source Action

Rattling noise Caliper mounting bolts loose.

Damaged or worn caliper pins or CHECK the caliper pins and retainers
retainers.

Missing or damaged anti-rattle clips or CHECK the brake pads for missing
springs.

Loose brake disc shield.

Clicking noise—with brakes applied

with ABS brakes

Squealing noise—occurs on first Acceptable condition. Caused by

(morning) brake application

Squealing noise—a continuous squeal

Squealing noise—an intermittent

squeal brought on by cold, heat, water,
mud or snow

Groaning noise—occurs at low speeds

with brake lightly applied (creeping)

Grinding noise—continuous

Moaning noise

Brake vibration/shudder—occurs when Uneven disc or drum wear.

brakes are applied

Brake vibration/shudder—occurs when INSPECT the brake pads and shoes

the brake pedal is released

ABS hydraulic control unit. Acceptable condition.

Disc brake pads.

Disc brake pads worn below minimum INSTALL new disc brake pads.
thickness. REFER to Section 206-03 .

Disc brake pads. Acceptable condition.

Disc brake pads. Acceptable condition.

Disc brake pads worn below minimum INSPECT the brake pads, shoes,
thickness.

Brake linings contaminated with INSPECT the brake pads and shoes
grease or oil.

Uneven disc brake pad or lining
transfer.

Suspension components.

Brake drag.

CHECK the caliper bolts. TIGHTEN to

specifications. REFER to Section
206-03 .

for lubrication and correct fit.
LUBRICATE or INSTALL new

components as necessary.

clips or broken springs. INSTALL new
components as necessary. REFER to

Section 206-03 .

TIGHTEN the brake disc shield bolts to

specification. REFER to Section
206-03 .

humidity and low disc brake pad
temperature.

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.

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.

Go to PinPoint Test A .

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.

Symptom Chart—Driveline Noise/Vibration

Condition Source Action

Axle howling or whine—rear axle or CHECK the lubricant level. FILL the

transfer case axle to specification.

Axle lubricant low.

G72679 en 01/2003 2003.0 BA Falcon

100-04-18 Noise, Vibration and Harshness 100-04-18

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Axle housing damage.

Damaged or worn wheel bearings or CHECK for abnormal wheel bearing
axle bearings.

Damaged or worn differential ring and INSPECT the ring and pinion ring for
pinion.

Damaged or worn differential side or CHECK for abnormal bearing play or
pinion bearings.

Damaged or worn differential side DISASSEMBLE the differential carrier.
gears and pinion gears.

Transfer case housing or internal gear INSPECT the transfer case for
damage or low lubricant.

Driveline clunk—loud clunk when CHECK the lubricant level. FILL the

shifting from reverse to drive axle to specification.

Driveline clunk—occurs as the vehicle Worn driveshaft constant velocity (CV) INSPECT the CV joint and U-joints for

starts to move forward following a stop joint or U-joints with excessive play.

Clicking, popping or grinding—occurs Inadequate or contaminated lubrication CHECK the CV joint boots and joints

while vehicle is turning in the CV joints.

Incorrect axle lubricant level.

Excessive backlash in the axle or
transmission.

Damaged or worn pinion bearings.

Damaged or worn universal joints INSPECT the U-joints for wear or
(U-joints).

Loose suspension components.

Broken powertrain mounts.

Idle speed too high. CHECK for the correct idle speed.

Loose rear axle mount.

INSPECT the axle housing for

damage. REPAIR or INSTALL a new
axle as necessary. REFER to Section

205-02 .

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.

abnormal wear patterns or broken
teeth. INSTALL a new ring and pinion
as necessary. REFER to Section

205-02 .

roughness. INSTALL new bearings as
necessary. REFER to Section 205-02 .

INSPECT the side and pinion gears for
abnormal wear patterns or broken
teeth. INSTALL new gears as

necessary. REFER to Section 205-02 .

damage. CHECK the lubricant level
and fill transfer case to specification.

REFER to Section 308-07b .

CARRY OUT a total backlash check.

CHECK for abnormal bearing play or

roughness. INSTALL new bearings as
necessary. REFER to Section 205-02 .

damage. INSTALL new U-joints as
necessary. REFER to Section 205-01 .

INSPECT the suspension for damage

or wear. REPAIR or INSTALL new
components as necessary. REFER to

Section 204-00 .

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.

a worn condition. INSTALL a new
Driveshaft as necessary. REFER to

Section 205-01 .

CHECK the axle for loose bolts.

TIGHTEN to specification.

for wear or damage. REPAIR or
INSTALL new components as

necessary. REFER to Section 205-04 .

G72679 en 01/2003 2003.0 BA Falcon

100-04-19 Noise, Vibration and Harshness 100-04-19

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Another component contacting the CHECK the halfshafts and the area
halfshaft.

Brake components.

Steering components.

Suspension components.

Damaged or worn wheel bearings.

High pitched chattering—noise from CHECK the vehicle by driving in tight

the rear axle when the vehicle is circles (5 clockwise, 5
turning

Buzz—buzzing noise is the same at CHECK for abnormal tyre wear or

cruise or coast/deceleration

Rumble or boom—noise occurs at CHECK the driveshaft for damage,

coast/deceleration, usually driveshaft missing balance weights or
speed related and noticeable over a undercoating. Using the Driveline

wide range of speeds

Grunting—normally associated with a CLEAN the CV joint and INSTALL a

shudder experienced during new driveshaft as necessary. REFER
acceleration from a dead stop to Section 205-01 .

Incorrect or contaminated lubricant.

Damaged or worn differential DISASSEMBLE the differential
(differential side gears and pinion assembly. INSPECT the differential

gears).

Damaged or worn tyres.

Incorrect driveline angles.

Driveshaft is out-of-balance.

U-joints binding or seized.

Excessive pinion flange runout.

Driveshaft CV joint binding.

Loose rear axle mount bolts or INSPECT the rear suspension and
suspension fasteners

around the halfshafts. REPAIR as
necessary.

INSPECT the front brakes for wear or

damage. REPAIR as necessary.
REFER to Section 206-03 .

INSPECT the drag link, inner and

outer tie-rods or idler arm for wear or
damage. REPAIR as necessary.

REFER to Section 211-00 .

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.

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.

counterclockwise). FLUSH and
REFILL with the specified rear axle
lubricant and friction modifier as

necessary.

case, pin and gears for wear or
damage. REPAIR or INSTALL a new
differential as necessary. REFER to

Section 205-02 .

damage. INSTALL a new tyre as
necessary. REFER to Section 204-04 .

CHECK for correct driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .

balancer, CHECK the driveshaft
balance. CARRY OUT a driveline
vibration test. REFER to Section

205-00 . REPAIR as necessary.

ROTATE the driveshaft and CHECK

for rough operation or seized U-joints.
INSTALL new U-joints as necessary.

REFER to Section 205-01 .

CARRY OUT a runout check. REPAIR

as necessary.

axle. TIGHTEN the fasteners to
specification.

G72679 en 01/2003 2003.0 BA Falcon

100-04-20 Noise, Vibration and Harshness 100-04-20

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Howl—can occur at various speeds Incorrect ring and pinion contact, CHECK the ring and pinion and

and driving conditions—affected by incorrect bearing preload or gear bearings for damage. INSPECT the
acceleration and deceleration damage.

Chuckle—heard at Incorrect ring and pinion contact or by CHECK the ring and pinion for

coast/deceleration—also described as damaged teeth on the coast side of damage. INSPECT the ring and pinion
a knock the ring and pinion.

Knock—noise occurs at various Gear tooth damage to the ring and CHECK the differential case and ring

speeds—not affected by acceleration and pinion for damage. INSTALL new
or deceleration

Scraping noise—a continuous low CHECK the pinion bearings. INSTALL

pitched noise starting at low speeds

Driveline shudder—occurs during Rear drive axle assembly CHECK the axle mounts and the rear

acceleration from a slow speed or stop mispositioned.

pinion.

Excessive axle shaft end play CHECK the axle end play using a dial
(vehicles with integral axles).

Worn or damaged pinion bearings.

Loose rear axle bolts.

Incorrect or high CV joint operating CHECK vehicle ride height is within
angle. limits. REPAIR as necessary.

Damaged or worn front suspension CHECK for a loose stabilizer bar,
components.

Driveline angles out of specification.

U-joints binding or seized.

Binding the driveshaft CV joint.

Loose rear axle bolts.

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 .

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 .

components as necessary. REFER to
Section 205-02 .

indicator. INSTALL a new axle shaft or
side gears as necessary. REFER to

Section 205-02 .

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

suspension for damage or wear.
REPAIR as necessary.

INSPECT the bolts. TIGHTEN the bolt

nuts to specification.

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 .

CHECK for correct driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .

ROTATE the driveshaft and CHECK

for rough operation or seized U-joints.
INSTALL new U-joints as necessary.

REFER to Section 205-01 .

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.

INSPECT the bolts. TIGHTEN the

bolts to specification.

G72679 en 01/2003 2003.0 BA Falcon

100-04-21 Noise, Vibration and Harshness 100-04-21

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Driveline vibration—occurs at cruising CHECK for wear or incorrect seating.

speeds

U-joints are worn.

Worn or damaged driveshaft center CHECK the insulator for damage or
bearing support.

Loose axle pinion flange bolts.

Excessive axle pinion flange runout.

Driveshaft is out-of-balance.

Binding or damaged driveshaft CV INSPECT the driveshaft CV joint for
joint.

Driveshaft runout.

Incorrect lateral and radial tyre/wheel INSPECT the tyre and wheels.
runout.

Driveline angles out of specification.

Incorrectly seated CV joint in the front CHECK the outer CV joint for correct
wheel hub.

INSTALL new driveshaft as necessary.
REFER to Section 205-01 .

wear. ROTATE the driveshaft and
CHECK for rough operation. INSTALL
a new center bearing support as

necessary. REFER to Section 205-01 .

INSPECT the axle pinion flange.

TIGHTEN the pinion flange bolts to
specification. REFER to Section

205-01 .

CARRY OUT a Runout Check. REFER

to Section 205-01 . REPAIR as
necessary.

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.

wear or damage. INSTALL a new
driveshaft assembly as necessary.
REFER to Section 205-01 . REPAIR

as necessary.

CARRY OUT a runout check. REFER

to Section 205-01 . REPAIR as
necessary.

MEASURE tyre runouts. REPAIR or
INSTALL new components as

necessary. REFER to Section 204-04 .

CHECK for correct driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .

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 Source Action

Grinding noise—occurs during engine INSPECT the starter motor for correct

cranking

Incorrect starter motor mounting.

Starter motor.

Incorrect starter motor drive INSPECT the starter motor drive and
engagement.

mounting. REPAIR as necessary.
REFER to Section 303-06 .

CHECK the starter motor. REPAIR or

INSTALL a new starter motor as
necessary. REFER to Section 303-06 .

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.

G72679 en 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 Go to PinPoint Test B .

Engine drumming noise—normally CARRY OUT Powertrain/Drivetrain

accompanied by vibration Mount Neutralizing in this section.

Whistling noise—normally CHECK the air intake ducts, air

accompanied with poor idle condition

Clunking noise

Pinging noise Exhaust system leak.

Knocking noise—light knocking noise, Excessive clearance between the Engine cold and at high idle. Using an

also described as piston slap—noise is EngineEAR, pull a spark plug or fuel
most noticeable when engine is cold injector connector until the noise goes
with light to medium away. CARRY OUT a cylinder bore
acceleration—noise disappears as clearance to piston check. INSTALL a

engine warms new piston.

Fuel injector.
Fuel line.
Oil pump.
Valve lifter.
Belt tensioner.
Water pump.

Obstruction of cooling fan.

Powertrain mount.

Damaged or misaligned exhaust INSPECT the exhaust system for
system.

Air intake system.

Water pump has excessive end play or CHECK the water pump for excessive
imbalance.

Alternator has excessive end play.

Gasoline octane too low.

Knock sensor operation.

Incorrect spark timing.

High operating temperature.

Foul-out spark plug.

Catalytic converter. Acceptable noise.

piston and the cylinder wall.

loose or broken clamps and brackets,
flex coupling or damper (2.0L Zetec).
CARRY OUT Exhaust System

Neutralizing in this section.

cleaner, throttle body and vacuum
hoses for leaks and correct fit.
REPAIR or ADJUST as necessary.

REFER to Section 303-12 .

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 .

CHECK the generator for excessive

end play. REPAIR or INSTALL a new
alternator. REFER to Section 414-02 .

INSPECT the exhaust system for

leaks. REPAIR as necessary.

VERIFY with customer the type of

gasoline used. CORRECT as
necessary.

CHECK the knock sensor. INSTALL a

new knock sensor as necessary.
REFER to Section 303-14 .

CHECK the spark timing. REPAIR as

necessary.

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.

CHECK the spark plugs. REPAIR or

INSTALL new spark plugs as
necessary.

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 Excessive clearance between the

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

Knocking noise—light knocking noise Excessive clearance between the Engine warm and at idle. PULL a

is most noticeable when engine is connecting rod bearings and the spark plug or fuel injector connector
warm—noise tends to decrease when until the noise goes away. INSTALL

vehicle is coasting or in neutral new bearings.

Knocking—deep knocking Worn or damaged crankshaft main CARRY OUT DERU test. CHECK for

noise—noise is most noticeable when noise with vehicle at operating
engine is warm, at lower rpm and temperature, during medium to heavy

under a light load and then at float

Knocking noise—occurs mostly with CHECK the spark plug for damage or

warm engine at light/medium wear. INSTALL new spark plugs as
acceleration necessary.

Whine or moaning noise Air intake system.

Drone type noise Exhaust system.

Sputter type noise—noise worse when Damaged or worn exhaust system INSPECT the exhaust system for leaks

cold, lessens or disappears when or damage. REPAIR as necessary.
vehicle is at operating temperature REFER to Section 309-00 .

Rattling noise—noise from the upper

engine (valve train)—worse when
engine is cold

piston and the piston pin.

crankshaft.

bearings.

Spark plugs.

Carbon accumulation in combustion REMOVE carbon from combustion
chamber. chamber.

Alternator electrical field or bearings.

A/C compressor.

Powertrain mounts.

components.

Low oil level. CHECK oil level. FILL as necessary.

Thin or diluted oil.

Low oil pressure.

Worn rocker arms/fulcrums or CARRY OUT a valve train analysis.
followers.

Worn valve guides.

INSTALL a new piston or piston pin.

acceleration. CHECK at idle with
injector disconnected, noise does not

change. INSTALL new main bearings.

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 .

CARRY OUT alternator load test.

REPAIR or INSTALL a new alternator
as necessary. REFER to Section

412-02 .

CARRY OUT the Exhaust System

Neutralizing in this section. REPAIR as
necessary.

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 .

CARRY OUT the Exhaust System

Neutralizing in this section.

INSPECT the oil for contamination. If

oil is contaminated, CHECK for the
source. REPAIR as necessary.

CHANGE the oil and filter.

CARRY OUT an oil pressure test. If

not within specifications, REPAIR as
necessary. REFER to Section 303-00 .

INSTALL new valve train components
as necessary. REFER to Section 303.

CARRY OUT a valve train analysis.

INSTALL new valve guides as
necessary. REFER to Section 303.

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 CARRY OUT a valve seat runout test.
valve face.

Rattling noise—from the bottom of the Loose muffler shields or catalytic CHECK the exhaust system for loose

vehicle converter shields. shields. REPAIR as necessary.

Thumping noise—from the bottom of Exhaust pipe/muffler grounded to CHECK the exhaust system to chassis

the vehicle, worse at acceleration chassis.

Engine vibration—increases intensity CARRY OUT Neutral Engine Run-up

as engine rpm is increased

Engine vibration—is felt with increases CARRY OUT the Exhaust System

and decreases in engine rpm

Engine vibration—vibration felt at all CARRY OUT Engine Accessory Test.

times

Engine vibration—mostly at CHECK the ignition system. INSTALL

coast/neutral coast—condition
improves with vehicle accelerating

Engine vibration or shudder—occurs INSPECT the spark plugs for cracks,

with light to medium acceleration high resistance or broken insulator.
above 56 km/h (35 mph)

Engine out-of-balance.

Strain on exhaust mounts.

Damaged or worn powertrain/drivetrain CHECK the powertrain/drivetrain
mounts.

Engine or transmission grounded to INSPECT the powertrain/drivetrain for
chassis.

Excessive engine pulley runout.

Damaged or worn accessory CARRY OUT Engine Accessory Test.
component.

Combustion instability.

Worn or damaged spark plugs.

Plugged fuel injector.

Damaged spark plug wire.

Contaminated fuel.

Worn or damaged torque converter.

INSPECT the valve face and seat.
INSTALL new valves as necessary.

REFER to Section 303.

clearance. CHECK the exhaust system
hangers for damage. REPAIR as

necessary.

(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.

Neutralizing procedure in this section.
REPAIR as necessary.

mounts for damage. REPAIR as
necessary.

correct clearances. REPAIR as
necessary.

INSTALL a new engine pulley as
necessary. REFER to Section 303.

REPAIR or INSTALL a new
component as necessary. REFER to

Section 303-05.

new components as necessary.

INSTALL a new spark plug(s) as
necessary.

REPAIR or INSTALL a new injector as

necessary.

INSPECT the spark plug wires for

damage. INSTALL a new spark plug
wire(s) as necessary.

INSPECT the fuel for contamination.

DRAIN the fuel system and refill.

CHECK the torque converter. INSTALL

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

Symptom Chart—Idle Noise/Vibration

Condition Source Action

Idle air control (IAC) valve moan — GO to Component Tests in this

occurs on throttle tip-out section.

IAC valve is contaminated with oil.

G72679 en 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 Accessory drive belt worn, or pulley is INSPECT for loose or misaligned

idle or high idle, cold or hot—most pulleys. CHECK the drive belt for wear
common occurrence is during humid or damage. INSTALL new pulley(s) or

weather

Accessory drive bearing hoot — Accessory drive idler or tensioner

occurs at idle or high idle in cold pulley bearing is experiencing stick/slip
temperatures of approximately +4°C between ball bearings and bearing
(+40°F) or colder at first start of the

day

Power steering moan — occurs at high High fluid viscosity, or plugged

idle and possibly at idle during the first reservoir screen in power steering
cold start of the day in temperatures of reservoir starves pump causing
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

Alternator whine — during high CHECK for changes in the noise level

electrical loads at idle or high idle, a while changing electrical loads (such
high pitch whine or moan is emitted as rear defrost, headlamps etc.).

from the alternator

Drumming noise — occurs inside the Exhaust system vibration excites the

vehicle during idle or high idle, hot or body resonances inducing interior
cold—very low-frequency drumming is noise.

very rpm dependent

Hissing noise — occurs during idle or Vacuum leak or idle air control (IAC) CHECK the air intake system from the

high idle that is apparent with the hood inlet to each cylinder intake port.
open

Automatic transmission buzz or hiss Incorrect driveline angles.

Manual Transmission Clutch throw-out INSTALL a new throw-out bearing.

bearing whine—a change in noise
pitch or loudness while depressing the

clutch pedal

Heating, vacuum and air conditioning Damaged or worn HVAC blower INSTALL a new blower motor. REFER

(HVAC) system chirp — most audible
inside the vehicle—listen for a change
in noise pitch or loudness while
changing the HVAC system blower

speed

Air conditioning (A/C) clutch ticking — Acceptable noise. LISTEN to the clutch to determine if

occurs when the compressor clutch the noise occurs with clutch
engages

misaligned or loose.

accessory drive belt, as necessary.
REFER to Section 303-05 .

Go to PinPoint Test C .

race.

Go to PinPoint Test D .

cavitation.

Alternator electrical field noise.

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 .

Go to PinPoint Test E .

Engine vibration excites the body
resonances inducing interior noise.

valve flow noise.

Worn or damaged main control Using a transmission tester,
solenoids or valves.

Worn throw-out bearing.

bearing. to Section 412-02 .

Incorrect air gap.

DISCARD the leaking parts, and
INSTALL a new component.

CHECK for correct driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .

ACTIVATE the solenoids to duplicate
sound. INSTALL new components as

necessary. REFER to Section 307-01 .

REFER to Section 308-01 .

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 Source Action

Intermittent rattle, or scraping/rubbing INSPECT the exhaust system for

noise

Engine ticking or knocking noise — Piston noise or valvetrain noise (bled

occurs during idle or high idle during
the first cold start of the day

A continuous, speed-dependent rattle Piston noise or valvetrain noise (bled

from the engine — occurs during idle
or high idle during the first cold start of
the day and disappears as the engine

warms up

Idle vibration—a low-frequency Using the diagnostic tool, CHECK the

vibration (5-20 Hz) or mild shake that ignition system. CARRY OUT a
is felt through the seat/floorpan

Idle vibration—a high-frequency VERIFY concern occurs at engine

vibration (20–80 Hz) or buzz, that is firing frequency. CHECK that the
felt through the steering wheel or seat

Loose exhaust heat shield(s).

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

down lifter/lash adjuster).

down lifter/lash adjuster).

Cylinder misfire.

Engine or torque converter out of VERIFY the torque converter to
balance.

Exhaust system mounts bound up.

Power steering lines grounded out.

Engine mounts binding.

loose parts using a glove or clamps to
verify cause. REPAIR as necessary.

REFER to Section 309-00 .

closely verifying there is adequate
clearance to all rotating components.

REPAIR as necessary.

Go to PinPoint Test F .

Go to PinPoint Test F .

cylinder power test. REFER to Section
303-00 .

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 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.

INSPECT that the power steering lines

are not contacting the chassis or each
other. REPAIR as necessary.

NEUTRALIZE the powertrain/drivetrain

mounts. CARRY OUT
Powertrain/Drivetrain Mount

Neutralizing in this section.

Symptom Chart—Squeak and Rattle

Condition Source Action

Squeak—heard inside the vehicle Insufficient lubrication on the door

when closing/opening the door hinge or check strap.

Internal door components loose, CHECK the inside of the door.
rubbing or misaligned.

Squeak—heard inside the vehicle REPAIR or INSTALL a new glass

when closing/opening the window

Squeak—heard outside of vehicle Exhaust shield rubbing against the CHECK the exhaust system. REPAIR

when closing/opening the door chassis or exhaust pipe.

Worn or damaged glass run/channel.

LUBRICATE the hinge or check strap.

TIGHTEN or ALIGN as necessary.
USE the Rotunda Squeak and Rattle
Kit to ISOLATE any rubbing

components.

run/channel. REFER to Section 501-11
.

as necessary. REFER to Section
309-00 .

G72679 en 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 Under certain conditions, asbestos free

pedal application

Squeak—a constant noise that occurs INSPECT the pads for oil, grease or

with brake pedal applications

Squeak—noise occurs over bumps or INSPECT the control arm bushings.

when turning

Rattle—heard when closing/opening Loose internal door mechanism, REPEAT the motion or CARRY OUT a

the door or window bracket or attachment.

Squeak or rattle—heard inside the Misaligned glove compartment

vehicle over rough roads/bumps door/hinge.

Squeak or rattle—noise with a INSPECT the upper and lower

vibration concern

Disc brake pads.

Damaged or worn disc brake pads.

Worn control arm bushings.

Worn or damaged shock INSPECT the shock absorber for
absorber/strut.

Instrument panel trim loose or INSPECT the instrument panel trim for
misaligned.

Loose interior component or trim.

Damaged or worn sub-frame mounts.

pads can generate a squeak noise.
This noise is normal and does not

indicate a concern.

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 .

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.

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.

“tap test” to duplicate the noise.
INSPECT the door for loose
components. TIGHTEN loose

components.

ALIGN the glove compartment door.

missing or loose clips or screws.
REPAIR as necessary.

CARRY OUT a “touch test”.

ELIMINATE the noise by pressing or
pulling on interior trim and

components.

absorbers for damage or wear.
CHECK the sub-frame for damage.
CHECK the nuts and bolts are
tightened to specifications. TIGHTEN

as necessary.

Symptom Chart—Steering Noise/Vibration

Condition Source Action

Steering grunt or shudder — occurs GO to Steering Gear Grunt/Shudder

when turning into or out of a turn at
low speeds (temperature sensitive)

Steering System clonk—hydraulic CHECK for leaks in the system.

knocking sound

Power steering pump moan — loud Power steering hose grounded out to INSPECT the power steering hoses.

humming noise occurs when the
steering wheel is rotated to the stop
position. Produces a 120-600 Hz

frequency that changes with rpm

Steering gear or power steering hoses.

Air in the steering hydraulic system.

chassis. REPAIR as necessary.

Test component test in this section.

PURGE the air from the system.
REFER to Section 211-00 .

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.

Steering gear isolators.

Low fluid.

Power steering pump brackets loose CHECK bolts, brackets and bracket
or misaligned.

Steering gear clunk — occurs only INSPECT the steering gear for loose

while cornering over a bump (can be mounting bolts. TIGHTEN as
temperature sensitive) necessary. REFER to Section 211-02 .

Feedback (rattle, chuckle or knocking Column intermediate/flexible shaft INSTALL a new intermediate/flexible

noise in the steering gear) — a
condition where roughness is felt in the
steering wheel when the vehicle is

driven over rough surfaces

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

Accessory drive belt ADJUST or INSTALL a new accessory

squeal/chirp—when rotating the belt as necessary. REFER to Section
steering wheel from stop to stop 303-05 .

Power steering gear hiss

Steering gear.

joints damaged or worn. shaft. REFER to Section 211-04 .

Loose, damaged or worn tie-rod ends.

Steering gear insulators or mounting TIGHTEN the bolts or INSTALL new
bolts loose or damaged.

Steering column intermediate shaft
bolts are loose.

Steering column damaged or worn.

Loose suspension bushings, bolts or INSPECT the suspension system.
ball joints.

Lateral runout in the tyre or wheel. GO to Pinpoint Test G.

Loose or worn accessory drive belt.

Steering column intermediate/flexible REPAIR or INSTALL a new
shaft-to-steering gear is binding or intermediate/flexible shaft as

misaligned. necessary. REFER to Section 211-04 .

Grounded or loose steering column
boot at the dash panel.

Damaged or worn steering gear input REPAIR or INSTALL a new steering
shaft and valve.

CHECK for leaks in the system.

PURGE the air from the system.
REFER to Section 211-00 .

INSPECT the isolators for wear or

damage. REPAIR as necessary.

CHECK the fluid level. REFILL as

necessary.

alignment. TIGHTEN bolts to
specification. REPAIR or INSTALL
new brackets as necessary. REFER to

Section 211-02.

TIGHTEN the nuts to specification or

INSTALL new tie-rod ends as
necessary. REFER to Section 211-03 .

bolts as necessary. REFER to Section
211-02 .

TIGHTEN the bolts to specification.

REPAIR or INSTALL a new steering

column as necessary. REFER to
Section 211-04 .

TIGHTEN or INSTALL new
components as necessary. REFER to
Section 204-01 for front suspension or

Section 204-02 for rear suspension.

REPAIR as necessary.

gear as necessary. REFER to Section
211-02 .

Steering column rattle Loose bolts or attaching brackets. TIGHTEN the bolts to specifications.

Loose, worn or insufficiently lubricated LUBRICATE or INSTALL new steering
column bearings.

column bearings as necessary.
REFER to Section 211-04 .

G72679 en 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 INSTALL new insulators. REFER to
worn. Section 211-04 .

Intermediate/flexible shaft compressed INSTALL a new intermediate/flexible
or extended. shaft. REFER to Section 211-04 .

Steering column squeak or cracks

Power steering pump noisy

Power steering pump swish noise Acceptable condition.

Power steering pump whine noise Aerated fluid.

Power steering pump clicking Power steering pump rotor slippers too REPAIR or INSTALL a new power

(mechanical) noise

Power steering pump clatter noise

Insufficiently lubricated steering shaft LUBRICATE the steering shaft and
bushings. shaft tube seals.

Loose or misaligned steering column TIGHTEN or ALIGN the steering
shrouds. column shrouds.

Steering wheel rubbing against REPOSITION the steering column
steering column shrouds. shrouds.

Insufficient lubricated speed control LUBRICATE the speed control slip
slip ring. ring.

Upper or lower bearing sleeve out of
position.

Incorrect assembly of components. REPAIR or INSTALL a new power
Imperfections on the outside diameter steering pump as necessary. REFER
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.

Power steering fluid flow into the
bypass valve of the pump valve
housing with fluid temperature below

54°C (130°F).

Damaged power steering pump.

Damaged valve cover O-ring seal.

long, excessive rotor slipper-to-slot steering pump as necessary. REFER
clearance or damaged or worn rotor

assembly.

Damaged corners on the outside REPAIR or INSTALL a new power
diameter or the power steering rotor or steering pump as necessary. REFER

distorted rotor slipper ring. to Section 211-02 .

REPOSITION the bearing sleeves.

to Section 211-02 .

PURGE the air from the system.

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

REPAIR or INSTALL a new power

steering pump as necessary. REFER
to Section 211-02 .

REPAIR or INSTALL a new power

steering pump as necessary. REFER
to Section 211-02 .

to Section 211-02 .

Symptom Chart—Suspension Noise/Vibration

Condition Source Action

Squeak or grunt—noise from the front Under these conditions, the noise is

suspension, occurs more in cold
ambient temperatures—more
noticeable over rough roads or when

turning

Clunk—noise from the front INSPECT for loose nuts or bolts.

suspension, occurs in and out of turns

Front stabilizer bar insulators.

Loose front struts or shocks.

acceptable. CHECK TSBs.

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 INSPECT for loose or damaged rear

suspension, occurs when shifting from suspension components. REPAIR or
reverse to drive

Click or pop—noise from the front CARRY OUT a ball joint inspection.

suspension—more noticeable over INSTALL new control arm as
rough roads or over bumps necessary. REFER to Section 204-01 .

Front suspension noise—a squeak, Steering components.

creak or rattle noise—occurs mostly Loose or bent front struts or shock
over bumps or rough roads

Rear suspension noise—a squeak, Loose or bent rear shock absorbers.

creak or rattle noise—occurs mostly Damaged spring or spring mounts.
over bumps or rough roads

Shudder—occurs during acceleration Rear drive axle assembly CHECK the axle mounts and the rear

from a slow speed or stop mispositioned.

Shimmy—most noticeable on CHECK the caster alignment angle.

coast/deceleration—also hard steering CORRECT as necessary. REFER to
condition Section 204-00 .

Loose rear suspension components.

INSTALL new components as
necessary. REFER to Section 204-02 .

Worn or damaged ball joints.

Go to PinPoint Test G .

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 H .

Damaged or worn control arm
bushings.

suspension for damage or wear.
REPAIR as necessary.

Incorrect or high CV joint operating CHECK vehicle ride height is within
angle. limits. REPAIR as necessary.

Damaged or worn front suspension CHECK for a loose stabilizer bar,
components.

Excessive positive caster.

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.

Symptom Chart—Tyre Noise/Vibration

Condition Source Action

Tyre noise—hum/moan at constant SPIN the tyre and CHECK for tyre

speeds

Tyre noise—noise tone lowers as the BALANCE the tyre and road test.

vehicle speed is lowered

Tyre noise — ticking noise, changes INSPECT the tyre. REPAIR as

with speed necessary.

Wheel and tyre—vibration and noise

concern is directly related to vehicle
speed and is not affected by

acceleration, coasting or decelerating

Tyre wobble or shudder — occurs at SPIN the tyre and CHECK for

lower speeds

Abnormal wear patterns.

Out-of-balance tyre.

Nail puncture or stone in tyre tread.

Damaged or worn tyre. Go to PinPoint Test I .

Damaged wheel bearings.

wear. INSTALL a new tyre as
necessary. INSPECT for
damaged/worn suspension
components. CARRY OUT wheel

alignment.

INSTALL a new tyre as necessary.
REFER to Section 204-04 .

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.

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100-04-31 Noise, Vibration and Harshness 100-04-31

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Damaged wheel.

Damaged or worn suspension INSPECT the suspension components
components.

Loose wheel nuts.

Damaged or uneven tyre wear.

Tyre shimmy or shake— occurs at

lower speeds

High speed shake or shimmy—occurs Excessive wheel hub runout.

at high speeds

Wheel/tyre out of balance. BALANCE the wheel/tyre assembly.

Uneven tyre wear.

Excessive radial runout of wheel or CARRY OUT a radial runout test of the
tyre.

Worn or damaged wheel studs or INSPECT the wheel studs and wheels.
elongated stud holes.

Excessive lateral runout of the wheel CARRY OUT a lateral runout test of
or tyre.

Foreign material between the brake CLEAN the mounting surfaces of the
disc and hub or in the brake disc fins.

Damaged or worn tyres.
Damaged or worn wheel bearings.
Worn or damaged suspension or
steering linkage components.

Brake disc or drum imbalance.

INSPECT the wheel for damage.

INSTALL a new wheel as necessary.
REFER to Section 204-04 .

for wear or damage. REPAIR as
necessary.

CHECK the wheel nuts. TIGHTEN to

specification. REFER to Section
204-04 .

SPIN the tyre and CHECK for

abnormal tyre wear or damage.
INSTALL a new tyre as necessary.

REFER to Section 204-04 .

CHECK for abnormal tyre wear.

INSTALL a new tyre as necessary.
REFER to Section 204-04 .

wheel and tyre. INSTALL a new tyre
as necessary. REFER to Section

204-04 .

INSTALL new components as
necessary.

the wheel and tyre. CHECK the wheel,
tyre and hub. REPAIR or INSTALL

new components as necessary.

brake disc and hub. CHECK the brake
disc fins for material.

Go to PinPoint Test J .

Symptom Chart—Transmission (Manual) Vibration

Condition Source Action

Clutch rattling noise—occurs with Flywheel bolts, clutch housing bolts or TIGHTEN the bolts to specifications.

clutch engaged, noise
changes/disappears with clutch pedal

depressed

Clutch squeaking noise—noise is INSTALL a new pilot bearing. REFER

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

Clutch squeaking noise—occurs with INSPECT the clutch pedal for wear or

clutch pedal depressed/released

Clutch whirring/rattle noise—occurs Worn, damaged or misaligned clutch INSTALL a new clutch release

when clutch pedal is depressed release bearing. bearing. REFER to Section 308-02 .

clutch pressure plate bolts loose. CHECK the bolts for damage.

Pilot bearing seized or damaged.

Worn clutch pedal shaft or bushings.

to Section 308-01 .

damage. REPAIR as necessary.
REFER to Section 308-02 .

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DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Clutch grating/grinding noise—occurs Clutch pressure plate fingers bent or INSPECT the clutch pressure plate

when clutch pedal is depressed worn.

Contact surface of clutch release INSTALL a new clutch release
bearing worn or damaged. bearing. REFER to Section 308-01 .

Clutch chatter—a small amount of

noise when clutch pedal is released at
initial take-off

Clutch chatter/grabs—in some cases a Damaged or worn powertrain/driveline INSPECT the powertrain/drivetrain

shudder is felt—occurs with clutch mounts. INSTALL new mounts as
pedal depressed/released necessary. REFER to Section 308-03 .

Clutch chatter noise—noise when Pilot bearing worn, damaged or not INSPECT the clutch pressure plate

clutch pedal is released at initial release fingers for uneven wear, clutch
take-off—clutch is hard to engage and components burnt or a seized pilot

disengage

Clutch vibration Go to PinPoint Test K .

Transmission rattling/clattering INSTALL a new gearshift lever.

noise—noise at idle or on light
acceleration from a stop—gear

selection difficult

Transmission rattling/clattering CHECK that the transmission is filled

noise—occurs in neutral or in gear, at to the correct level and with the
idle

Clutch engagement. Acceptable operating condition.

mounts.

Binding or dragging plunger of the CHECK the master and slave cylinder
clutch master cylinder or slave operation. INSPECT the components

cylinder.

Grease or oil on the clutch disc facing.

Clutch disc surface glazed or INSPECT the clutch disc surface for a
damaged.

Damaged or worn clutch pressure INSPECT the clutch pressure plate for
plate.

Flywheel surface damaged or glazed.

correctly aligned in bore.

Loose flywheel bolts.
Damaged or loose clutch pressure
plate.

Excessive flywheel runout.

Gearshift lever joint worn or damaged.

Gearshift lever loose.

Gearshift linkage rods worn or CHECK the linkage bushings for wear.
damaged.

Incorrect fluid level or fluid quality.

release fingers. INSTALL a new
pressure plate as necessary. REFER

to Section 308-01 .

for damage or wear. INSTALL a new
master or slave cylinder as necessary.

REFER to Section 308-02 .

CHECK the input shaft seal and rear

main oil seal. REPAIR as necessary.
INSTALL a new clutch disc. REFER to

Section 308-03 .

glazed, hardened or damage
condition. CARRY OUT a disc check.
INSTALL a new clutch disc as

necessary. REFER to Section 308-01 .

wear or damage. INSTALL a new
clutch pressure plate as necessary.

REFER to Section 308-01 .

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.

bearing. INSTALL a new pilot bearing
as necessary. REFER to Section

308-01 .

REFER to Section 308-06 .

TIGHTEN the bolts to specification.

REFER to Section 308-06 .

INSTALL new linkage rods as
necessary. REFER to Section 308-06 .

specified fluid. REFER to Section
308-03 .

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100-04-33 Noise, Vibration and Harshness 100-04-33

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Transmission rattling/clattering CHECK the reverse idler gear.

noise—noise at idle in neutral

Transmission whine—a mild whine at

extreme speeds or high rpm

Transmission whine—a high pitched Transmission gears are worn (high Result of normal gear wear. REPAIR

whine, also described as a squeal mileage vehicle).

Transmission INSPECT the transmission gears for

growling/humming—noise occurs in damage or wear. INSTALL new gears
the forward gears—the noise is more as necessary. REFER to Section
prominent when the gear is
loaded—the problem gear can be
located as the noise occurs in a

specific gear position

Transmission hissing—noise in neutral INSPECT the transmission bearings.

or in forward gears—as bearings wear INSTALL new bearings as necessary.
or break up, the noise changes to a

thumping noise

Transmission Bearings with damaged balls or rollers INSPECT the transmission bearings.

knocking/thudding—noise at low INSTALL new bearings as necessary.
speeds in forward gears REFER to Section 308-03 .

Transmission rumble/growl—noise at CHECK the driveline angle. REPAIR

higher speeds in forward gears, more as necessary. REFER to Section
pronounced in a coast/deceleration

condition

Transmission rumble/growl—noise at Damaged or worn transmission CHECK transmission fluid for

all speeds in forward gears, more bearing or gears (high mileage excessive metal particles. REPAIR as
pronounced in a heavy acceleration

condition

Worn or rough reverse idler gear.

Rough running engine, cylinder misfire.

Excessive backlash in gears

Worn countershaft gears.

Rotating gears/geartrain. Acceptable noise.

Mismatched gear sets.

Damaged or worn transmission INSPECT the transmission bearings.
bearing.

Gear is cracked, chipped or rough.

Damaged or worn bearings.

or with pitted and spalled races.

Incorrect driveline angle.

Driveshaft out of balance or damaged.

vehicles). necessary. REFER to Section 308-03 .

REPAIR as necessary. REFER to
Section 308-03 .

CHECK the ignition system. CARRY

OUT a cylinder power test. REFER to
Section 303-00 .

CHECK the gear backlash. ADJUST

as necessary. REFER to Section
308-03 .

REPAIR as necessary. REFER to

Section 308-03 .

as necessary. REFER to Section
308-03 .

INSPECT the gear sets for an uneven

wear pattern on the face of the gear
teeth. REPAIR as necessary. REFER

to Section 308-03 .

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

308-03 .

REFER to Section 308-03 .

205-00 .

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.

Symptom Chart—Transmission (Automatic) Noise/Vibration

Condition Source Action

Rattle—occurs at idle or at light Damaged engine or transmission CHECK the powertrain/drivetrain

acceleration from a stop mounts.

mounts for damage. INSTALL new
mounts as necessary. REFER to 303.

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100-04-34 Noise, Vibration and Harshness 100-04-34

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

A loose front exhaust pipe heat shield.

Loose inspection plate or dust cover CHECK for loose bolts. TIGHTEN to
plate.

Loose flex plate to converter nuts.

Whine—pitch increases with vehicle Damaged or worn low one-way clutch. INSPECT the transmission for wear or

speed—starts in first and second gear, Damaged or worn intermediate damage. REPAIR or INSTALL new
decreases or goes away at higher one-way clutch. components as necessary. REFER to

gears Section 307-01 .

Whine—the pitch changes with engine A worn or damaged accessory drive CARRY OUT the Engine Accessory

speed component.

Whine—pitch changes with vehicle REPAIR or INSTALL new gears as

speed necessary.

Whine/moan type noise—pitch Damaged engine or transmission CHECK the powertrain/drivetrain

increases or changes with vehicle mounts for damage. CARRY OUT
speed

Whistle—noise is high pitched, INSPECT the main control. REPAIR or

constant—changes in pitch with INSTALL new components as
throttle position necessary. REFER to Section 307-01 .

Friction elements.
Damaged or worn planetary or sun

gear.

Incorrect fluid level.

Partially blocked filter.

Worn or damaged torque converter.

Worn or damaged front pump.

Speedometer gears.

mount.

U-joints worn or damaged.

Damaged or worn differential ring and INSPECT the differential ring and
pinion.

Planetary gears nicked or chipped.

Hydraulic pressure in the main control.

Incorrect band/clutch apply pressure.

REPAIR or INSTALL a new heat shield

as necessary.

specifications. REFER to Section
307-01 .

CHECK for loose nuts. TIGHTEN to

specifications. REFER to Section
307-01 .

Test. REPAIR or INSTALL new
components as necessary. REFER to

Section 303-05 .

CHECK that the transmission is filled

to the correct level. ADD fluid as
necessary. REFER to Section 307-01 .

INSPECT the filter. CLEAN or

INSTALL a new filter as necessary.

CARRY OUT the torque converter

service and replacement check.
REFER to Section 307-01 .

INSPECT the front pump. INSTALL a

new front pump as necessary. REFER
to Section 307-01 .

Powertrain/Drivetrain Mount
Neutralizing in this section.

INSPECT the U-joints for wear or

damage. INSTALL new U-joints as
necessary. REFER to Section 205-01 .

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 .

CHECK the planetary gears for

damage. INSTALL new components
as necessary. REFER to Section

307-01 .

CARRY OUT the line pressure tests.

REPAIR or INSTALL components as
necessary. REFER to Section 307-01 .

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100-04-35 Noise, Vibration and Harshness 100-04-35

DIAGNOSIS AND TESTING (Continued)

Condition Source Action

Worn or damaged torque converter.

Clunk—occurs when shifting from INSPECT the powertrain mounts for

PARK to a drive or reverse position

Bump—occurs when shifting from

PARK to a drive or reverse
position—similar to Clunk but with no

sound

Buzz or hiss Incorrect driveline angles.

Vibration—a high frequency (20–80 Transmission cooler lines grounded CHECK the transmission cooler lines.

Hz) that is felt through the seat or gear
shifter—changes with engine speed

Shutter or chatter—occurs with light to Electrical inputs/outputs. CARRY OUT a Torque Converter

medium acceleration from low speeds Vehicle wiring harness. Clutch Operation Test. RUN on-board
or a stop

Pinpoint Tests

Damaged powertrain mounts.

Damaged or worn pinion bearings.

Worn driveshaft CV joint.

Worn friction elements or excessive INSPECT the transmission for wear.
clutch pack end plate play.

Initial gear engagement. Acceptable condition.

Worn or damaged main control INSTALL new components as
solenoids or valves. necessary. REFER to Section 307-01 .

out. REPAIR as necessary.

Flexplate to torque converter nuts CHECK the flexplate nuts. TIGHTEN
loose.

Fluid filler tube grounded out.

Incorrect inputs/outputs from the diagnostics or self–test. CLEAR the
powertrain control module (PCM), DTCs, ROAD TEST and RERUN
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).

system for normal operation. Sometimes, it is
necessary to remove various vehicle components to

The pinpoint tests are a step-by-step diagnostic
process designed to determine the cause of a
condition. It may not always be necessary to follow a
pinpoint test to its conclusion. Carry out only the steps
necessary to correct the condition. Then, test the

gain access to the component requiring testing. For
additional information, refer to the appropriate section
for removal and installation procedures. Reinstall all
components after verifying system operation is
normal.

CARRY OUT the torque converter

service and replacement check.
REFER to Section 307-01 .

damage. INSTALL new mounts as
necessary. REFER to Section 307-01 .

CHECK for abnormal bearing play or

roughness. INSTALL new bearings as
necessary. REFER to Section 205-02 .

INSPECT the CV joint. INSTALL a

new driveshaft as necessary. REFER
to Section 205-01 .

CHECK that all end play and
clearances are within specification.
REPAIR or INSTALL new components
as necessary. REFER to Section

307-01 .

CHECK for correct driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .

to specification. REFER to Section
307-01 .

CHECK the fluid filler tube. REPAIR as

necessary.

on-board diagnostics or self–test.

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100-04-36 Noise, Vibration and Harshness 100-04-36

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A : BRAKE VIBRATION/SHUDDER

Test Step Result / Action to Take

A1

ROAD TEST THE VEHICLE—LIGHT BRAKING

Check that the wheel and tyres are correct for the vehicle. Inspect the
tyres for abnormal wear patterns. Go to A4.

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.

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),
apply the brake using a moderate to heavy pedal force. For vehicles with ABS, Go to A3.

Is there a vibration/shudder?

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 Go to A5.
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.

Is the vibration/shudder vehicle speed sensitive?

Yes

No

Go to A2.

Yes

For vehicles with standard brakes, Go to A4.

No

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

Yes

No

The brake system is operating correctly.

A4

APPLICATION OF THE PARKING BRAKE

NOTE:

has been isolated to the rear.

A5

CHECK THE FRONT WHEEL BEARINGS

Begin at the front of the vehicle unless the vibration or shudder

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.

Is there a vibration/shudder?

Check the front wheel bearings. Refer to Wheel Bearing Check in this
section. Go to A6.

Are the wheel bearings OK?

Yes

Go to A8.

No

Go to A5.

Yes

No

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

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

A6

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

uneven tyre wear

Are all the suspension components in satisfactory condition?

A7

RESURFACE THE FRONT BRAKE DISCS

CAUTION:

NOTE:

discs. After machining, make sure the brake disc meets the thickness
specification.

A8

CHECK THE REAR SUSPENSION

Follow the manufacturer’s instructions to machine the brake

Refer to Brake Disc Machining in this section. Resurface the front
brake discs. Road test the vehicle.

Is the vibration/shudder present?

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

uneven tyre wear

Are all the suspension components in satisfactory condition?

Do not use a bench lathe to machine brake discs.

Yes

Go to A7.

No

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

Yes

Go to A8.

No

Vehicle is OK.

Yes

Go to A9.

No

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

A9

RESURFACE THE REAR BRAKE DISC OR DRUM

CAUTION:

NOTE:

After machining, make sure the brake disc meets the thickness
specification.

Follow the manufacturers instructions to machine the brake discs.

Refer to Brake Disc Machining in this section. Resurface the rear
brake disc or drums. Road test the vehicle.

Is the vibration/shudder present?

Do not use a bench lathe to machine brake discs.

PINPOINT TEST B : ENGINE TICKING NOISE

Test Step Result / Action to Take

B1

CHECK FOR TICKING NOISE AT THE FUEL RAIL

Disconnect the first fuel line clip.

Is the ticking noise gone?

Yes

CHECK the front suspension for wear or
damage, RESURFACE the front brake discs.
TEST the system for normal operation.

No

Vehicle is OK.

Yes

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

No

Go to B2.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

B2

CHECK FOR TICKING NOISE AT THE FUEL INJECTOR

Using an EngineEAR, listen at the fuel injectors by placing a probe on
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

Is the fuel injector the source of the ticking noise?

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. INSTALL a new belt tensioner. REFER to

Using an EngineEAR, listen at the belt tensioner.

Is the belt tensioner the source of the noise?

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?

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

303-04b for 3.0L (4V) engine. TEST the system
for normal operation.

No

Go to B3.

Yes

Section 303-05 . TEST the system for normal
operation.

No

Go to B4.

Yes

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

No

Go to B5.

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. INSTALL a new oil pump. REFER to Section

Is the oil pump the source of the noise?

B7

CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR
CORRECT OPERATION

Check valve lifter/lash adjuster for correct operation, using
EngineEARs. VERIFY customer concern. CONDUCT a

Are the valve lifters/lash adjusters operating correctly?

Yes

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.

Yes

diagnosis of other suspect components.

No

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

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DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C : FRONT ENGINE ACCESSORY DRIVE BEARING HOOT

Test Step Result / Action to Take

C1

CHECK THE ACCESSORY DRIVE IDLER AND
TENSIONER PULLEY BEARINGS

Carry out the Vehicle Cold Soak Procedure in this section.

Key in START position.

Place an EngineEAR probe directly on the pulley center post or bolt to
verify which bearing is making the noise.

Key in OFF position.

Is either bearing making the noise?

PINPOINT TEST D : POWER STEERING MOAN

Test Step Result / Action to Take

D1

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.

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

INSTALL a new pulley/idler. REFER to Section
303-05 . CARRY OUT the Vehicle Cold Soak
Procedure and TEST the system for normal
operation.

No

CONDUCT a diagnosis on other suspect
accessory drive components.

Yes

Go to D2.

No

CONDUCT a diagnosis on other suspect
accessory drive components.

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.

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100-04-40 Noise, Vibration and Harshness 100-04-40

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E : DRUMMING NOISE

Test Step Result / Action to Take

E1

CHECK THE EXHAUST SYSTEM

Key in START position.

Increase the engine rpm until the noise is the loudest. Note the engine
rpm.

Key in OFF position.

Add approximately 9 kg (20 lb) of weight to the exhaust system. Place
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. Vehicle is OK. TEST the system for normal

Is the noise reduced or eliminated?

Yes

CARRY OUT Exhaust System Neutralizing in
this section. TEST the system for normal
operation.

No

Go to E2.

Yes

operation.

No

CONDUCT diagnosis of other suspect
components.

PINPOINT TEST F : ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE

Test Step Result / Action to Take

F1

CHECK FOR NOISE AT THE VALVE COVERS AND THE
FRONT COVERS (OHC ENGINES)

Carry out the Vehicle Cold Soak Procedure in this section.

Key in START position.

NOTE:

be necessary.

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.

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?

For a short-duration ticking noise, multiple engine starts may

Yes

REMOVE the appropriate cover and INSPECT
for loose, worn/broken components. REPAIR as
necessary. TEST the system for normal
operation.

No

Go to F2.

Yes

REPAIR or INSTALL new components as
necessary.

No

Go to F3.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

F3

CHECK FOR NOISE WHILE DISCONNECTING EACH
FUEL INJECTOR ELECTRICAL CONNECTOR, ONE AT A
TIME

Key in START position.

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

Key in OFF position.

Is the noise reduced or eliminated?

PINPOINT TEST G : FRONT SUSPENSION NOISE

Test Step Result / Action to Take

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

INSPECT THE STEERING SYSTEM

Raise and support the vehicle. For additional information, refer to
Section 100-02 . REPAIR the steering system. INSTALL new

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.

Are the steering components worn or damaged?

Yes

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.

No

INSPECT accessory drive or the transmission as
a possible source.

Yes

Go to G2.

No

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

Yes

components as necessary. TEST the system for
normal operation.

No

Go to G3.

G3

FRONT SHOCK ABSORBER/STRUT CHECK

Check the front shock absorbers/strut mounts for loose bolts or nuts.

Check the front shock absorbers/struts for damage. Carry out a shock
absorber check.

Are the front shock absorbers/struts loose or damaged?

G4

CHECK THE FRONT SPRINGS

Check the front spring and front spring mounts/brackets for wear or
damage. REPAIR or INSTALL new components as

Are the front springs or spring mounts/brackets worn or
damaged?

Yes

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

No

Go to G4.

Yes

necessary. TEST the system for normal
operation.

No

Go to G5.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

G5

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?

G6

CHECK THE STABILIZER BAR/TRACK BAR

Check the stabilizer bar/track bar bushings and links for damage or
wear. REPAIR or INSTALL new components as

Check the stabilizer bar/track bar for damage.

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

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

PINPOINT TEST H : REAR SUSPENSION NOISE

Test Step Result / Action to Take

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?

Yes

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

No

Go to G6.

Yes

necessary. TEST the system for normal
operation.

No

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

Yes

Go to H2.

No

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

H2

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

CHECK THE REAR SPRINGS

Check the rear springs and rear spring mounts/brackets for wear or
damage. REPAIR or INSTALL new components as

Are the rear springs or spring mounts/brackets worn or
damaged?

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. REPAIR or INSTALL new components as

Inspect for twisted or bent control arms/trailing arms.

Are the control arms/trailing arms loose, damaged or worn?

Yes

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

No

Go to H3.

Yes

necessary. TEST the system for normal
operation.

No

Go to H4.

Yes

necessary. TEST the system for normal
operation.

No

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

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DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST I : WHEEL AND TYRE

Test Step Result / Action to Take

I1

ROAD TEST THE VEHICLE

NOTE:

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.

I2

CHECK THE FRONT WHEEL BEARINGS

I3

INSPECT THE TYRES

Wheel or tyre vibrations felt in the steering wheel are most likely

Test drive the vehicle at different speed ranges.

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?

Check the front wheel bearings. Refer to Wheel Bearing Check in this
section. Go to I3.

Are the wheel bearings OK?

Check the tyres for missing weights.

Check the wheels for damage.

Inspect the tyre wear pattern. Refer to the Tyre Wear Patterns chart in
this section.

Do the tyres have an abnormal wear pattern?

Yes

Go to I2.

No

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

Yes

No

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

Yes

CORRECT the condition that caused the
abnormal wear. INSTALL new tyre(s). TEST the
system for normal operation.

No

Go to I4.

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?

Yes

Go to I5.

No

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

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

I5

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). Go to I8.

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). INSTALL a new tyre. TEST the system for

Is the radial runout within specifications?

Yes

No

Go to I6.

Yes

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: INSTALL a new wheel. TEST the system for

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?

Yes

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.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

I8

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). Wheel and tyres are OK. CONDUCT diagnosis

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). INSTALL a new tyre. TEST the system for

Is the lateral runout within specifications?

Yes

on other suspect systems.

No

Go to I9.

Yes

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: INSTALL a new wheel. TEST the system for

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?

PINPOINT TEST J : HIGH SPEED SHAKE OR SHIMMY

Test Step Result / Action to Take

J1

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?

Yes

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.

Yes

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

No

Go to J2.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

J2

CHECK THE END PLAY OF THE FRONT WHEEL
BEARINGS

Check the end play of the front wheel bearings.

Is the end play OK?

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
the vehicle. Go to Pinpoint Test I. Go to J4.

Are the measurements within specifications?

J4

MEASURE THE LATERAL RUNOUT OF THE FRONT
TIRES ON THE VEHICLE

Measure the lateral runout of the front tyres on the vehicle. Go to
Pinpoint Test I. Go to J5.

Is the runout within specifications?

J5

MEASURE THE RADIAL RUNOUT OF THE FRONT
TIRES ON THE VEHICLE

Yes

Go to J3.

No

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

Yes

No

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

Yes

No

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

Measure the radial runout of the front tyres on the vehicle. Go to
Pinpoint Test I. BALANCE the front wheel and tyre assemblies.

Is the runout within specifications?

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 BALANCE the assembly. TEST the system for
around) on the wheel. Inflate the tyre and measure the radial runout. normal operation.

Is the runout within specifications?

Yes

If any tyre cannot be balanced, INSTALL a new
tyre. TEST the system for normal operation.

No

Go to J6.

Yes

No

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

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

J7

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. LOCATE and MARK the low spot on the wheel.

Is the runout within specifications?

J8

CHECK FOR VIBRATION FROM THE FRONT OF THE
VEHICLE

WARNING:

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.

Is the vibration present?

If only one drive wheel is allowed to rotate, speed

Yes

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.

Yes

SUBSTITUTE known good wheel and tyre
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.

J9

CHECK FOR VIBRATION FROM THE REAR OF THE
VEHICLE

WARNING:

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.

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?

If only one drive wheel is allowed to rotate, speed

Yes

Go to

J10

.

No

TEST the system for normal operation.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

J10

CHECK THE DRIVETRAIN

WARNING:

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
.

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?

If only one drive wheel is allowed to rotate, speed

PINPOINT TEST K : CLUTCH VIBRATION

Test Step Result / Action to Take

K1

CHECK ENGINE COMPONENTS FOR GROUNDING

NOTE:

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.

NOTE:

disassembling the clutch system. Refer to Section 205-00 for the correct
driveline angle specifications.

Make sure the clutch is the cause of the vibration concern. The

Check the driveline angles and driveshaft runout before

Yes

CHECK/TEST the drivetrain and driveline
components. TEST the system for normal
operation.

No

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

Yes

REPAIR as necessary. TEST the system for
normal operation.

No

Go to K2.

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?

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 TIGHTEN the bolts to specifications or if
and flywheel. damaged, INSTALL a new clutch pressure plate.

Are there any loose bolts or damage?

K4

CHECK THE CLUTCH DISC SPRINGS

Check for worn, broken or loose clutch disc springs.

Are the clutch springs worn, broken or loose?

Yes

DIAGNOSE the accessory drive components.

No

Go to K3.

Yes

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

No

Go to K4.

Yes

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

No

Go to K5.

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

K5

CHECK THE CLUTCH DISC SPLINES

Inspect the clutch disc splines for damage or wear.

Is there damage or wear?

K6

CHECK THE FLYWHEEL BOLTS

Check for loose flywheel bolts.

Are the bolts loose?

K7

CHECK THE FLYWHEEL SURFACE

Inspect the flywheel surface for wear or damage. Check the flywheel
runout. INSTALL a new flywheel. REFER to Section

Is there any damage or excessive wear?

Component Tests

Steering Gear Grunt/Shudder Test

1. Start and run the vehicle to operating
temperature.

2. Set engine idle speed to 1,200 rpm.

CAUTION: Do not hold the steering wheel
against the stops for more than three to five
seconds at a time. Damage to the power
steering pump will occur.

3. Rotate the steering wheel to the RH stop, then
turn the steering wheel 90 degrees back from that
position. Turn the steering wheel slowly in a 15 to
30 degree arc.

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.

Yes

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

No

Go to K6.

Yes

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

No

Go to K7.

Yes

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
second type of ring and pinion noise pertains to the
mesh pattern of the gear pattern. This gear noise can
be recognized as it produces a cycling pitch or whine.
Ring and pinion noise tends to peak in a narrow
speed range or ranges, and will tend to remain
constant in pitch.

1. Raise and support the vehicle. Refer to Section
100-02.

2. Drain the axle lubricant. Refer to Section 205-02.

3. Remove the carrier assembly or the axle housing
cover depending on the axle type. Refer to
Section 205-02.

4. Inspect the gear set for scoring or damage.

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,

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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 Tooth contact pattern shown on the drive side
gear. of the gear teeth.

Item Description
1 Heel
2Toe

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
obtained. Inspect the contact patterns on the ring
gear teeth.

7. A good contact pattern should be centered on the
tooth. It can also be slightly toward the toe. There
should always be some clearance between the
contact pattern and the top of the tooth.

Tooth contact pattern shown on the drive side
of the gear teeth.

8. A high, thick contact pattern that is worn more
toward the toe.

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.

9. A high, thin contact pattern that is worn toward
the toe.

Tooth contact pattern shown on the drive side
of the gear teeth.

The drive pinion depth is correct. Increase the
differential ring gear backlash.

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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.

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100-04-52 Noise, Vibration and Harshness 100-04-52

DIAGNOSIS AND TESTING (Continued)

Tyre Wear Patterns and Frequency Calculations

Tyre Wear Chart

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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 ÷10 = 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 Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz

mm (inch) @ 16 km/h (10 @ 80 km/h (50 @ 97 km/h (60 @ 113 km/h (70

mph) mph) mph) mph)
483 (19) 182 910/15 1092/18 1274/21
508 (20) 173 865/14 1038/17 1211/20
533 (21) 165 825/14 990/16 1155/19
560 (22) 158 790/13 948/16 1106/18
585 (23) 151 755/13 906/15 1057/18
610 (24) 145 725/12 870/14 1015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13

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DIAGNOSIS AND TESTING (Continued)

Tyre Diameter Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz

785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12

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GENERAL PROCEDURES

Brake Disc Machining

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.

1. Check wheel bearing end-play and correct as

necessary.

2. Remove the tyre and wheel.

NOTE:

vibration has been isolated to the rear.

3. Remove the brake caliper.

4. Inspect the brake linings. Install new brake linings

if below specification. For additional information,
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:

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.

machine brake discs.
NOTE:

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:

Begin at the front of the vehicle unless the

Match-mark before disassembly.
Remove the brake disc.
Using a die grinder with a mild abrasive

(Scotch Brite® 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.

CAUTION: Do not use a bench lathe to

The depth of cut must be between 0.10

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.

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.

Powertrain/Drivetrain Mount
Neutralizing

1. Raise and support the vehicle. For additional
information, refer to Section 100-02.

2. Loosen, but do not remove, the
powertrain/drivetrain mount fasteners.

3. Lower the vehicle.

4. Move the vehicle in forward and reverse 0.6-1.2
meters (2-4 ft).

CAUTION: Do not twist or strain the

powertrain/drivetrain mounts.

5. Raise and support the vehicle.

6. Tighten the powertrain/drivetrain mount fasteners.

7. Lower the vehicle.

8. 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:

on mounts which can be sufficiently bound up to
transmit vibration as if grounded.

1. Raise and support the vehicle. For additional

2. Loosen all exhaust hanger attachments and

3. Loosen all exhaust flange joints.

4. Place a stand to support the muffler parallel to the

5. Tighten the muffler connection.

Neutralize the exhaust system to relieve strain

information, refer to Section 100-02.

CAUTION: Make sure the system is
warmed up to normal operating temperature,
as thermal expansion can be the cause of a
strain problem.

reposition the hangers until they hang free and
straight.

vehicle frame with the muffler pipe bracket free of
stress.

G72682 en 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:

that the brake pads are retraced sufficiently to
allow free movement of the tyre and wheel
assembly.

Make sure the wheel rotates freely and

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.

G72682 en 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. Toe settings are provided in degrees.
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.

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:

NOTE:

adjusted.

NOTE:

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 out is shown as a - (negative) value. It is
preferable to measure vehicles in degrees. Data is for
reference only.

NOTE:

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

See text for XR camber adjustment.

Ute and Wagon rear alignment can not be

Camber and castor figures will vary depending

Toe in is shown as a + (positive) value while

With correct tyre pressures the ride height is

where necessary at kerb height.

NOTE:

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.

When checking ute and wagon front caster it

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 Castor Total Toe at kerb height

Height

350 -1.91 -1.41 -0.91 0.7 7 7.50 8 0.7
360 -1.66 -1.16 -0.66 0.7 6.9 7.40 7.9 0.7
370 -1.44 -0.94 -0.44 0.7 6.8 7.30 7.8 0.7
380 -1.23 -0.73 -0.23 0.7 6.69 7.19 7.69 0.7 -0.02 0.08 0.18
390 -1.07 -0.57 -0.07 0.7 6.59 7.09 7.59 0.7
400 -0.92 -0.42 -0.08 0.7 6.48 6.99 7.48 0.7
410 -0.81 -0.31 -0.19 0.7 6.38 6.88 7.38 0.7
420 -0.72 -0.22 -0.28 0.7 6.27 6.77 7.27 0.7

XR Sedan

Ride Camber Castor Total Toe at kerb height

Height

340 -1.52 -1.02 -0.52 0.7 7.32 7.82 8.32 0.7
350 -1.22 -0.72 -0.22 0.7 7.21 7.71 8.21 0.7
360 -0.95 -0.45 0.05 0.7 7.10 7.60 8.10 0.7
370 -0.71 -0.21 0.29 0.7 6.99 7.49 7.99 0.7 0.06 0.16 0.26
380 -0.50 0.00 0.50 0.7 6.88 7.38 7.88 0.7
390 -0.33 0.17 0.67 0.7 6.77 7.27 7.77 0.7
400 -0.17 0.33 0.83 0.7 6.65 7.15 7.65 0.7

Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °

Variation ° Variation

Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °

Variation ° Variation

Ute

Ride Camber Castor Total Toe at kerb height

Height

370 -1.24 -0.74 -0.24 0.7 6.81 7.31 7.81 0.7
380 -1.05 -0.55 -0.05 0.7 6.7 7.20 7.7 0.7
390 -0.88 -0.38 -0.12 0.7 6.59 7.09 7.59 0.7 -0.02 0.08 0.18
400 -0.73 -0.23 -0.27 0.7 6.48 7.99 7.48 0.7
410 -0.62 -0.12 -0.38 0.7 6.38 7.88 7.38 0.7
420 -0.54 -0.04 -0.46 0.7 6.27 6.77 7.27 0.7

XR Ute, XLS Ute with standard sports suspension

Ride Camber Castor Total Toe at kerb height

Height

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 0.06 0.16 0.26
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

Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °

Variation ° Variation

Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °

Variation ° Variation

01/2003 2003.0 BA FalconG22340 en

204-00-4 Suspension System — General Information 204-00-4

DESCRIPTION AND OPERATION (Continued)

Rear Wheel Alignment

Sedan

Ride Height Camber Total Toe at kerb height

Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °

Variation °

350 -1.96 -1.71 -1.46 0.5
360 -1.76 -1.51 -1.26 0.5
370 -1.57 -1.32 -1.07 0.5
380 -1.38 0.13 -0.88 0.5 0.14 0.24 0.34
390 -1.19 -0.94 -0.69 0.5
400 -1 -0.75 -0.50 0.5
410 -0.81 -0.56 -0.31 0.5
420 -0.61 -0.36 -0.11 0.5

NOTE:

for reference only.

XR Sedan

Sedan camber settings cannot be adjusted,

Ride Height Camber Total Toe at kerb height

Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °

Variation °

340 -1.35 -1.10 -0.85 0.5
350 -1.14 -0.89 -0.64 0.5
360 -0.95 -0.70 -0.45 0.5
370 -0.75 -0.50 -0.25 0.5 0.06 0.16 0.26
380 -0.56 -0.31 -0.06 0.5
390 -0.37 -0.12 0.13 0.5
400 -0.18 0.07 0.32 0.5

01/2003 2003.0 BA FalconG22340 en

204-00-5 Suspension System — General Information 204-00-5

DIAGNOSIS AND TESTING

Suspension System — General
Information

Inspection and Verification

NOTE:

Table 1 lists various steering gear and linkage

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.

trouble symptoms and possible causes. Several of

Symptom Chart

Condition Source Action

Jerky Steering Remove/Repair as required

Loose Steering Remove/Repair as required

Hard Steering and/ or Loss of Power Incorrect Tyre Pressure

Assist

Hard Turning When Stationary Remove/Repair as required

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

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

Adjustment

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

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 Remove/Repair as required

Shimmy or Wheel Tramp Remove/Repair as required

Pull to One Side Remove/Repair as required

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

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

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

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 Remove/Repair as required

Body Sway or Roll Remove/Repair as required

Tyre Squeel on Turns Remove/Repair as required

Binding or Poor Recovery Remove/Repair as required

Abnormal or Irregular Tyre Wear Remove/Repair as required

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

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

Incorrect Steering Gear Adjustment

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

Incorrect Front Wheel Alignment

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

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

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 Remove/Repair as required

Hard or Rough Ride Remove/Repair as required

Rear Suspension Misalignment (Dog- Rear Spring Tie Bolt Off Centre

Tracking)

Shock Absorbers

On Vehicle Tests

1. Grasp the vehicle bumper bar and bounce the
corner of the vehicle up and down. If the shock
absorbers are in serviceable condition the vehicle
will settle to it’s original position within two
bounces after the bumper is released.

2. 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
replaced.

3. 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

4. Inspect the shock absorber for evidence of fluid
leakage. It is important to be sure that any fluid
observed is from the shock absorber and not from
any other source. 3. If the action is smooth, but the shock absorbers

5. If the leakage is severe, replace the shock
absorber if leakage. (Some evidence of fluid
weepage on the shock body is not considered
harmful to the shock provided that the on-vehicle
and hand tests described below are acceptable).

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

Bushings

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

(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

Hand Test

1. With the shock absorber removed from the
vehicle, hold the shock absorber such that it is in
a vertical position, as it would be installed in the
vehicle. Fully compress and extend the shock
absorber unit three times to bleed the shock
absorber. Compress the unit and observe that the
piston rod extends under it’s own internal gas

2. Extend and compress the shock as fast as
possible, using as much travel of the shock as

extension than compression. Faint fluid "swishing"
noises are also normal during extension and
compression of the shock.

are suspected of being weak, repeat Step 2 on a
new shock absorber or on the mating shock
absorber fitted to the opposite side of the vehicle.
Compare the results of both tests.

Remove/Repair as required

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. 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

3. On vehicles with power steering, the steering
wheel must be in the straight-ahead position when
the engine is switched off.

4. If it is necessary to again move the steering wheel
on a power steering vehicle the engine must be
restarted.

5. Measure the angle of each front wheel from the
straight-ahead position and add the angles
together.

Front Wheel Alignment

1. The Caster, Camber and King Pin Inclination
angles are set in production and are not
adjustable.

2. The tie rods, part of the steering rack assembly,
are adjustable for length to permit the setting of
Toe and wheel lock angles.

3. Do not attempt to carry out alignment checks
without first making a preliminary check of the
serviceability of the front end components.

Toe & Steering Wheel Spoke
Adjustments

NOTE:

the front wheels are in the straight-ahead position. If
the spoke is not in its correct position, it can be
corrected while toe is being adjusted.

1. Clean and lubricate the exposed threads on the

2. Hold the tie-rod and loosen the lock nut on each

3. Adjust toe-in. If the steering wheel spokes are in

4. When the toe and steering wheel spoke alignment

5. Position each tie-rod end ball joint at the centre of

Check the steering wheel spoke position when

tie-rods. Loosen the clips on the outer ends of the
rack bellows and ensure that the bellows are free
on the tie-rods.

rod.

NOTE:

their correct position, lengthen or shorten both
rods equally to obtain correct toe. If the steering
wheel spoke is not in its correct position, make
the necessary rod adjustments to obtain correct
toe and steering wheel spoke alignment.

are both correct tighten the lock nut on each rod.

its articulation and tighten the clips on the rack
bellows.

Both rods have right hand threads.

2. If the turning angles are incorrect or uneven when

the tie rods which should be approximately the
same length. It they are appreciably different (i.e.

3.0mm) the turning angles will be adversely
affected. It should be noted that minor differences
in tie rod length are acceptable and, in fact,
sometimes necessary to compensate for
production tolerances in the build up of the
suspension and steering assembly.

3. If the toe and the tie rod lengths are satisfactory
examine the tie rods for distortion. The tie rod ball
joints should also be checked for wear or
looseness.

Upper & Lower Ball Joint Inspection

1. Raise the vehicle.

2. Grasp the tyre at the top and bottom and try to
move it in and out.

3. There should be no perceptible movement in
either joint. If movement is detected in either joint,
that joint should be replaced.

XR Rear Camber Adjustment

1. Measure ride height. Refer to wheel Alignment
charts in this section for ride heights vs. camber.
Select appropriate camber setting.

2. Complete RLCA (Rear Lower Control Arm) to
subframe cam bolt adjustment (set Toe).

3. With toe set and locked in position, adjust left
camber to specification using the cambolt.

4. Adjust the right camber to specification using the
cambolt.

5. Re-adjust left camber if necessary. Tighten both
nuts to the specified torque (126 ± 24 Nm).

6. Take care during the above procedure to ensure
the brake hose bracket is located correctly.

RLCA (Rear Lower Control Arm) to
Subframe Cambolt Adjustment

1. Loosen both bolts and adjust as required to reach
spesified toe.

2. Tighten both nuts to the specified torque
(105 ± 10 Nm).

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 Nm
Upper Arm to Mounting Bracket 50
Upper Arm Mounting Bracket to Body 35
Lower Control Arm to Sub-frame 115
Shock Absorber to Upper Attachment 35
Shock Absorber to Lower Control Arm 80
Spring Seat to Body 35
Ball Joint to Spindle 90
Stabilizer Bar Bracket 35
Stabilizer Bar Link Nuts 55
Wheel Bearing Nut 300
Wheel Nut 125
Brake Caliper to Spindle 115

01/2003 2003.0 BA FalconG48690 en

204-01-3 Front Suspension 204-01-3

DESCRIPTION AND OPERATION

Front Suspension

Suspension

The suspension is so designed that it allows an 6 Shock Absorber Frt
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 Description
4 Bracket Assy
5 Insulator

7 Arm & Shaft Assy Frt Susp Upr
8Bolt Hex M14
9Nut 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.

Item Description
1Nut
2 Washer
3 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

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.

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

Item Description
1 Arm Assy Frt Susp Lower
2 Nut Lock
3 Spindle Assy Frt Wheel

Lower Control Arm Ball Joint

Special Tools

204-236

204-230

Removal
NOTE:

following procedures.

1. Place small end of Installer/Remover tool

2. Place Receiver 204-236-Item 2 above lower

Eye protection must be worn during the

204-236-Item 3 over shaft of ball joint.

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

Item Description Item Description
1 Receiver 204-236-Item 2 1 An appropriate plate to support hydraulic
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.

2 204-230-Item 8
3 Receiver 204-230-Item 3

Upper Control Arm

Removal

1. Raise the vehicle and support it under the body

2. Remove the wheel.

3. Separate the upper ball joint from the upper arm.

4. Remove the four nuts securing the upper arm

5. Remove the two bolts and the bracket assemblies

Installation

1. Position the bracket assemblies on the upper arm

2. Position the control arm on the suspension tower

ram

rails.

Tie the spindle to prevent it from failing away from
the body and straining the brake hose.

brackets to the suspension tower and remove the
assembly from the vehicle.

from the control arm.

and loosely install new prevailing torque nuts.

and install and tighten the attaching nuts.

G48693 en 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 2. Using a hydraulic press with two tonne approx.
clamp joint. Remove the spindle tie. force push out ball joint using tool 204-229-2,

4. Install the wheel and lower the vehicle.

5. With the vehicle at curb attitude tighten the
spindle pivot bolts to specification.

Item Description
1 Arm Assy Frt Susp Upper
2Receiver Bolt
3 Spindle Assy
4Nut

small diameter down.

Upper Control Arm Ball Joint

Special Tools

204-229

Removal
NOTE:

following procedures.

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

Eye protection must be worn during the

facing up, under upper arm casting.

Item Description
1 204-229-Item 2
2 Ball Joint
3 204-229-Item 1 Receiver
4 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.

G48695 en 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 3. Fit the bolt and nut securing the shock absorber
clip. to the lower arm.

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

5. Fit the insulators and brackets supporting the
stabilizer bar to the siderails ensuring that the bar
is cenrally located.

6. Attach the ends of the bar links, ensuring that the
insulators are correctly positioned.

7. Fit the wheel and lower the vehicle.

Item Description
1 204-229-Item 2
2 Upper Control Arm
3 204-229-Item 1 Receiver
4 Ball Joint with Boot Removed

Stabilizer Bar

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.

Stabilizer Bar Centre Bushing (Front
or Rear Bar)

Removal
NOTE:

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

2. Remove the hardware and brackets attaching the

3. Remove the insulators from the bar.

Installation

1. Position the insulators on the front bar. Position

Damage to suspension and/or steering

suspension in the curb load position.

centre section of the stabilizer bar.

the insulator on the rear bar.

G48695 en 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.

Installation

1. Install the bolt, washers, insulators, spacer and
nut as illustrated. Ensure that the insulators are
correctly located in the respective mounting holes.

2. Lower the vehicle.

Lower Arm Bushing

Special Tools

204-230

Removal
NOTE:

lower control arm bushes. They are:

Refer to the applicable scenario numbers.

NOTE:

small bush first.

Three scenarios exist for the replacement of

scenario 1 - replacement of the small bush only,
scenario 2 - replacement of the large bush only,
scenario 3 - replacement of both bushes.

Scenario 1 - Replacement of small bush only

If both bushes are to be removed then remove

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 Description
1 Locating collar 204-230-Item 8
2 204-230-Item 9
3 Forcing screw 204-230-Item 5
4 Holding Nut
5 204-230-Item 10 Orient anvil so stamping

is to top (this positions eccentric hole)

4. Slide large bush anvil 204-230-Item 10 onto the
threaded end of forcing screw.

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

6. Position assembly over the inside end of large
bush.

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.

10. Screw out holding nut to remove slack.

11. With suitable spanners, clamp holding nut and
turn forcing screw using its hexagonal section
until small bush is removed.

NOTE:

is removed.

Removal
Scenario 2-Replacement of large bush only

1. Apply a graphite grease to Forcing Screw thread
before usage.

Beware, the unit will collapse as the bush

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).

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.

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. 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 Description
1 Locating collar 204-230-Item 1
2 204-230-Item 2
3 Forcing screw 204-230-Item 5 Item Description
4 Holding Nut 1 Locating collar 204-230-Item 1
5 204-230-Item 3 Orient anvil so stamping is 2 204-230-Item 2

to top (this positions eccentric hole)

8. Slide Locating Collar over Large Bush Tool to 4 Holding Nut
prevent assembly slipping during use.

9. With suitable spanners, clamp Holding Nut and to top (this positions eccentric hole)
turn Forcing Screw using its hexagonal section
until large bush is removed.

Removal
NOTE:

small bush first.

G48699 en 01/2003 2003.0 BA Falcon

If both bushes are to be removed then remove

3 Forcing screw 204-230-Item 5

5 204-230-Item 3 Orient anvil so stamping is

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
until large bush is removed.