Motor workshop and repair manuals

• Home
• About
• Privacy

Ford Falcon AU series Workshop Manual

The Ford Falcon is a full-size car that has been from Ford Australian Continent from 1998 to 2002. The AU show ended up being conceived under "Project Eagle" that started in February 1993, and attained the state codename "EA169" in October

The Ford Falcon is a full-size car that has been from Ford Australian Continent from 1998 to 2002. It was the first version for the sixth generation Ford Falcon and also included the Ford Fairmont—the luxury-oriented model number. The AU series replaced the EL Falcon constructed from the previous generation architecture, and is changed because of the updated BA series.

The AU show ended up being conceived under "Project Eagle" that started in February 1993, and attained the state codename "EA169" in October 1994. It was created and taken to market in 1998 only after Ford Australia have considering consideration to a refurbished fifth generation Falcon and a fully brought in substitution for instance the US front-wheel drive Ford Taurus or rear-wheel drive Ford Crown Victoria, the European rear wheel-drive Scorpio and, apparently, even Japanese rear-wheel drive Mazda 929.
Cutaways associated with 1998 Ford Fairmont Ghia

The above options were removed in favour of a substantial redesign of indigenous system, due to concerns about the Australian markets choice for highest towing capacity, large internal size and neighborhood work. Certain issues included, for example: studies at the time indicated that 69percent of Falcons had been fitted with towbars as well as the perception that rear-wheel drive cars were much better at towing; that the import versions have restricted human anatomy design alternatives with no capacity to incorporate a V8 engine.

Stylistically, this latest generation Falcon sported Ford's drastically brand new global design language, branded "unique Edge". The purpose of this design was to entice a young generation of purchasers with avant-garde styles, however, in Australian Continent they polarized public-opinion on benefit of the greater amount of organically designed competitor, the 1997 Holden Commodore. The AU show have a very efficient drag coefficient of Cd=0.29 for sedan and 0.34 when it comes to truck.

The very first time in Falcon's history, Independent back suspension system became readily available as standard on some versions and optional on others. In addition featured Australian manufacturing firsts, like adjustable Cam Timing on some 6-cylinder designs and an adaptive automated transmission regarding high-performance T show with tyre gear moving buttons.

Key modifications from 5th generation Falcon included a 35 kg lowering of pounds for the base vehicles, 17.5 percent stiffer bodyshell, and an eight percent enhancement in gas intake. Peculiarly, Ford Australian Continent chose to make use of the original 1950's font when it comes to newer "Falcon" and "Futura" badges.

As mentioned previously, the AU ended up being the very first Falcon to provide IRS and its own 6-cylinder motors specifically, included advanced features such as VCT on some models and a temperature sensor in cylinder mind, which recognized coolant loss and permitted the automobile to "limp residence" safely by cutting cylinders. The system number made up: the bottom Intech design creating 157 kW; an "HP" version set aside into the XR6 making 164 kW; the VCT variation creating 172 kW for the XR6 VCT; a "Windsor" V8 creating 185 kW.

Transmissions are enhanced for better change feel plus the auto was recalibrated to raised match the upgraded motors. The six and eight cylinder designs had a 4-speed BTR M93LE and M97LE automatic transmissions, correspondingly the six and eight cylinder versions, correspondingly. The automatic XR show systems have an "adaptive move" with five moving tips dependent on travel conditions. The manual transmission, were readily available, was a 5-speed BTR T5 model.

The program cost A$700 million before items establish and key workforce included chief designer, Steve Park, and Marcus Hotblack, Manager of interior decorating.

Design number
Series We

1st a number of the AU Falcon was released in September 1998 and remained for sale until an important improvement in April 2000. It absolutely was marketed underneath the brand-new motto "You've come a long way baby".

The standard AU number included:

Falcon Forté, 4.0L, "Intech" 6-cyl, Sedan/Wagon, 157 kW, 357Nm – to rival the Holden Commodore administrator
Falcon Forté, 5.0L, "Windsor" V8, Sedan, 175 kW, 395Nm – as above
Falcon S, 4.0L, "Intech" 6-cyl, Sedan, 157 kW, 357Nm – to competing Holden Commodore S
Falcon Futura, 4.0L, "Intech" 6-cyl, Sedan/Wagon, 157 kW, 357Nm – to rival the Holden Commodore recognition
Fairmont, 4.0L, "Intech" 6-cyl, Sedan/Wagon, 157 kW, 357Nm – to rival the Holden Berlina
Fairmont Ghia, 4.0L, "Intech VCT" 6-cyl, Sedan, 168 kW, 370Nm – to rival the Holden Calais
Fairmont Ghia, 5.0L, "Windsor" V8, Sedan, 175 kW, 395Nm – as above
Falcon XR6, 4.0L, "HP Intech" 6-cyl, Sedan, 164 kW, 366Nm
Falcon XR6 VCT, 4.0L, "Intech VCT" 6-cyl, Sedan, 172 kW, 374Nm
Falcon XR8, 5.0L, "Windsor" V8, Sedan, 185 kW, 412Nm – to rival the Holden Commodore SS.

Tickford Vehicle manufacturing, had been in charge of the XR brands that held the "Tickford" wings badge. From July 1999, the newly created Ford Tickford skills established the following higher-specification and performance T sets products:

TE50, 5.0L, "Synergy 5000" V8, Sedan, 200 kW, 420Nm
TS50, 5.0L, "Synergy 5000" V8, Sedan, 220 kW, 435Nm, automatic just.

The newest Forté model had been the substitution for the older GLi designation. It had been created and sold to entice to fleet buyers also youthful motorists. When brand new, the car was competitively coming in at A$30,690 with automated transmission and air conditioning installed as standard.

The greater 'up-spec' model ended up being called the Falcon Futura, that was marketed as a family-oriented protection package in the same vogue as the competing Holden Commodore recognition. The Futura differed from Forté in having a body colored grille, standard abdominal muscles, Cruise controls, alloy tires and an electronic digital time clock built in the centre system. The price of the automobile when new had been A$34,990.

The Ford Falcon S sedan was also on the basis of the Forté but created as an entry-level activities version. They accomplished this through further properties such body-coloured grille, alloy tires, S decals regarding back quarters and bootlid, non-IRS sports suspension and a high level spoiler. The colour choices were limited to Hot Chilli Red, Liquid Silver, vibrant White, Galaxy and Silhouette.

The Fairmont is the entry level luxury model of the AU number to face-off its biggest competitor, the Holden Berlina. It have all the accessories of the Futura but included extras such a honeycomb grille, an 80-second headlamp off wait, lumber grain-look dash inserts, unique 15" tires, double horns, Fairmont badging from the boot lid and an analogue clock. The Fairmont was available in sedan and station truck bodystyles. Above the Fairmont was the Fairmont Ghia, that was the best non-performance specs model within the range and sedan just. They had further functions that included special rims and much more lumber grain-look dash inserts. Fairmont & Fairmont Ghia products are not badged as Falcons.

The XR series was the powerful end of range. They initially made up the XR6 HP, XR6 VCT, and XR8 products all sharing a distinctive quad-lamp front bumper club and non-high end bonnet. All show I XR's might have the option of the full Tickford bodykit and special bi-wing rear spoiler.

When it comes to protection gear, the Futura, XR and Fairmont designs all have abdominal muscles brake system besides a driver's part airbag, that has been truly the only primary security function on Falcon S and Forté. The brake system featured 287x24 mm vented front disks and 287x10.5 mm solid back discs.

Exterior model differentiation is accomplished through the utilization of different grilles and bonnets and much more standard fixtures like different alloy wheel design, back light clusters, system colour-coordination and chrome accessories. The wagons featured a unique rear-end in accordance with the prior generation Falcons. Around, the Fairmont and XR model featured complete instrumentation additionally the Fairmont twins in addition used a new dashboard. As opposed to the standard Falcon featuring a big oval pod integrating air-con and stereo, the luxury twin showcased a 2-level shared with the long-wheelbase AU Fairlane/LTD, with a different upper level featuring a woodgrain-like trim across into traveler side that included an analogue clock, trip computer and weather control.

Only the Fairmont Ghia and Falcon XR6 VCT showcased "Intech" motors produced by Tickford automobile manufacturing with variable device time. IRS is installed as traditional from the Falcon XR6 VCT, XR8 and Fairmont Ghia, and recommended on most various other sedan models; the XR models becoming truly the only your might additionally be installed with a limited slip differential.

Despite competitive prices and high traditional equipment relative to their competitors, specifically for the new entry Forté, selling regarding the AU didn't fit those associated with previous model, the EL Falcon. It was partially because of deficiencies in enthusiasm by subscribers for the "brand new Edge" styling, alteration of fleet sale pricing along with the lasting decline searching for huge vehicles.

In May 1999, the AU range received a small change, launching a more impressive braking system booster, forward energy house windows when it comes to Forté and XR6 and decreasing a corner suspension system of non-XR variations by 24 mm. To heighten their interior quality, the Forté is offered with 'medium graphite' internal trim and the patterned seat material is changed through the bolsters on chair centres. Buyers had been also in a position to order the darker 'warm charcoal' colour pallette of other Falcon alternatives.

The actual only real restricted edition launched with this initial series, had been the Falcon Timeless of Summer 1999 marketed till October 1999 to boost product sales. They inherited an egg-crate grille from the non-XR energy number, twin airbags, ABS brake system, cruise control, upgraded speakers, a "warm charcoal" interior, energy aerial, special trim, 15-inch alloys, low profile rear spoiler, bumper inserts and prestige paint. Its best retail price is A$30,690.

The number of AU Falcon Utility vehicles premiered in Summer 1999. It supplied Falcon XL, XLS, XR6 and XR8 style side energy designs, a cab-chassis model and a cab-chassis with factory installed drop-side tray. The latter had been the very first tray energy automobile that Ford Australia have created for several years.

The human body for the AU Falcon utility differed in design through the contending Holden Ute in that the cargo tray was individual through the cab, whereas the tray was an integral part of the body layer in the Holden. As a result, this allowed a corner to just accept various after markets system types, like tray decks, solution body, and camper van shells. Unlike the sedan, the AU Falcon utility cars were remarkably popular.

Show II

A majority of these problems were dealt with because of the AU Series II. They included:

the "high series" increased bonnet from the Fairmont models
a far more standard and common front grille the volume Forté and Futura number
boost level and width for the back bumper
a laminated firewall, enhanced under-carpet asphalting and hydraulic engine supports to reduce NVH
upgraded braking program
16" wheels
decreased floor clearance with brand new shock absorbers and low-friction ball-joints
high quality indoor plastic materials
standard cloth and darker "warm charcoal" interiors
uprated noise techniques
enhanced SmartShield security measures with a transponder located in the secret
standard front side airbags throughout the range.

Human body energy improves, directed at improving occupant safety therefore the Falcon's score inside separate NCAP crash test plan, had been also obtained. Inside stated studies, it gotten a three-star person occupant cover score with a score of 24.2 plus in the offset crash test, it had been unearthed that there was a decreased chance of injury to all system regions. Brand new protection qualities included a passenger airbag and seatbelt pretensioners and load limiters regarding the front chairs across the number. Wagons had been fitted with a three-point lap-sash back centre seatbelt, using the retractor built-into the chair back.

The braking program now featured thicker front side and back disks, twin-piston aluminium-headed front calipers, larger non-asbestos brake pads, larger master cylinder and an increased ability booster. The discs were now ventilated 287x28 mm at the front and solid 287x16 mm at the back. The XR6 VCT and XR8 were in addition available with an optional Tickford advanced braking system setup that brought 329 mm grooved front side brake disks with twin-piston C4 calipers.

Additional functions included the introduction of a 100 watt stereo with single-slot CD athlete, variable periodic wipers and home lock/unlock switch on the tool panel and gear upgrade on the entry Forté design, to shrug down preliminary impressions the low spending plan perception from the earliest AU show. Additionally throughout the range, Ford today offered 3-years or 60,000 kilometer value of planned servicing within the purchase price.

The conventional series II range included:

Falcon Forté, 4.0L, "Intech" 6-cyl, Sedan/Wagon, 157 kW, 357Nm
Falcon Forté, 5.0L, "Windsor" V8, Sedan, 175 kW, 395Nm
Falcon S, 4.0L, "Intech" 6-cyl, Sedan, 157 kW, 357Nm
Falcon Futura, 4.0L, "Intech" 6-cyl, Sedan/Wagon, 157 kW, 357Nm
Fairmont, 4.0L, "Intech" 6-cyl, Sedan/Wagon, 157 kW, 357Nm
Fairmont Ghia, 4.0L, "Intech VCT" 6-cyl, Sedan, 168 kW, 370Nm
Fairmont Ghia, 5.0L, "Windsor" V8, Sedan, 175 kW, 395Nm
Falcon XR6, 4.0L, "Intech" 6-cyl, Sedan, 164 kW, 366Nm
Falcon XR6 VCT, 4.0L, "Intech VCT" 6-cyl, Sedan, 172 kW, 374Nm
Falcon XR8, 5.0L, "Windsor" V8, Sedan, 200 kW, 420Nm
Falcon XR8, 5.0L, "Windsor" V8, Sedan, 220 kW, 435Nm.

As mentioned above, the motor number remained largely in the beginning, except for enhanced result when it comes to XR8 as well as the introduction, from July 2000, of a separate LPG motor, advertised once the "Intech E-Gas". It have a single-point, venturi-style carburetor in place of sequential injections according to the petrol engines. More variations included: various spark plugs, inductive high tension guides and a distinctive engine management processor. The sedans had been fitted with a 92-litre LPG cylinder, while wagons had 115 litre cylinders.

Sedan-based minimal editions included the: X-Pack, SR, Futura Classic, Futura & Fairmont Ghia 75th Anniversary sedans, XR8 Rebel.

Augmenting the X-Pack, in late 2000 Stillwell Ford dealers in Southern Australian Continent launched a Sportryder variant, which included an enhanced and lowered sport suspension utilizing Pedders equipment plus in your area sourced CSA alloy wheels for A$29,990.

The Falcon energy show II number included the XL, XLS, XR and XR8 with minimal editions including: Tradesman; recreations Edition and Marlin; Pursuit.

The FTE T2 range comprised:

TE50, 5.0L, "Synergy 5000" V8, Sedan, 220 kW, 435Nm
TS50, 5.0L, ""Synergy 5000" V8, Sedan, 220 kW, 435Nm.
Show III

This final AU-based Falcon ended up being delivered at the Sydney Motorshow in November 2001, by surprise

The Falcon's Series III number shown that the AU II, with the exception of:

the discontinuance of Falcon S
the beds base Falcon XR6 now additionally installed with VCT version utilising the Fairmont Ghia's exhaust program to separate it from the higher-spec XR6 VCT)
a restricted edition Falcon XR6 VCT Sprint
a Falcon XR8 Pursuit 250 Utility by TFE.

FTE additionally launched more powerful T3 brands the following:

TE50, 5.6L, "Windsor" V8, Sedan, 250 kW, 500Nm
TS50, 5.6L, "Windsor" V8, Sedan, 250 kW, 500Nm.

Externally, the show III, featured body-coloured mirrors and part pieces plus standard part skirts and different wheels on some versions. Headlights became a shade darker, side indicators obvious and a dot matrix windscreen had been added to reduce sunshine glare. Regarding interiors, additional qualities are added as standard: Futura – rear power house windows and velour trim; Fairmont – 6-way power-adjustable driver's chair; Fairmont Ghia – 10-way power-adjustable driver’s chair and leather-based trim. Though abdominal muscles became standard throughout the number, the XR versions missing products: XR6 – limited-slip differential today recommended; all XR's – stereo downgrade to a 4-speaker single-CD device. A bodykit sold as "Havoc" became optional on all Falcons with XR8 purchasers also obtaining the choice of a Tickford bodykit or even the Ford Racing bodykit. Fairmont and XR may also optioned with the "REX" package, allowing rear passenger to relax and play DVD films or connect online game consoles.

The blended creation of Falcon Series II and III to September 2002 totaled 237,701 products.

AU Falcon is a brand new vehicle, so when with earlier latest brands, Ford Aus very first seemed overseas for a replacement. Back in 1989, considering swollen outlay, it was intended regional production could be power down while the future Falcon could be changed with an import.
AU Falcon
However in 1993, John Ogden persuaded Ford United States that axing Falcon and changing it with a front drive automobile would be commercial committing suicide. It was short-lived, but because in 1994, Ford 2000 had been launched, a radical restructuring of Ford’s worldwide procedures, intended to share across the exact same goods platforms and engines across all areas. The 1996 Ford Taurus had been considered, although analysis indicated that 69per cent of Falcons have towbars fitted. There was clearly a perception that rear-wheel drive cars towed much better - the Taurus had been forward drive - together with Taurus could not hold a V8 engine. There would also be no other variations - simply a sedan and truck. The European Ford Scorpio and Mazda 929 had been also considered but they are also narrow and would place the Falcon to the Camry/Magna class. Ford people grudgingly consented to an all-new Falcon, because of the proviso so it would get a handle on the important thing design and development choices.
Work could now began on the many questionable an element of the AU - their styling. Main designer Steve Park’s brief was to make the vehicle look smaller, lighter, tighter and nothing like its rival. “We would not wish reheat the old soup,” playground said. Immediately after the early sketches and clay models, Ford’s stupid “New Edge” international build viewpoint started initially to emerge. Unique Edge means tight, sharp surfaces with sharp angles, supplying a far more athletic stance as opposed to the soft, curved shapes of numerous early-1990s automobiles. The European Ford Ka while focusing become prime samples of this radical styling theme.
Study indicated that the conventional Falcon buyer was male inside the 40s or 50s, therefore the entrepreneurs desired the vehicle to seem slightly small and softer, to interest female purchasers, yet lithe enough to attract young men.
AU Falcon Pictures




Ford AU Falcon
Available For Sale: September 1998 - April 2000
How can I know it's an AU? Edge build with sharp sides, triangualar lighting forward and rear, domed roofing, side crease line. Forte: Silver "waterfall" fan grille. Futura: Body-coloured horizontal bar grille. S: Body-coloured "waterfall lover grille, spoiler, S decals. Fairmont, Fairmont Ghia: Honeycomb grille with chrome surround, body-coloured mirrors, back chrome applique. XR models: Quad headlight build, grille with one horizontal club, human anatomy kit, spoiler. Ute: style side or cab framework build, grey or body-coloured egg-crate grille.



Just what lead is a sleeker, European influenced car, with unique side triangular headlights and tail lighting, a prominent part crease line and a domed roof. The automobile showed up droopy and sad, especially the rear end, and it was criticised since the wheels performedn’t fill the big wheel arches. The AU had been 11mm reduced compared to EL and 20mm greater, as well as the New advantage build in fact led to a more aerodynamic vehicles. “We felt the Falcon must have more daring styling, the front end graphics need to be observed from later on, ergo the greater bold front-end therapy,” said Steve Park. Each model was aesthetically differentiated by various grilles. The strength, replacing the GLi, wore the controversial “waterfall” fan grille. Silver in color, it consisted of 35 straight spokes, while both enjoyed they or disliked they. The Futura featured a much more conservative horizontal treatment. They had alloy wheels, while both automobiles have black colored mirrors and amber back signs. The Forte and Futura, along with the XR designs and utes, showcased the lower show bonnet, which have a sharp blade down the center.
Then up is the Fairmont and Fairmont Ghia. These models provided equivalent grille: strong chrome trim surrounding a honeycomb mesh, with a horizontal chrome or body-coloured bar in the centre. Both Fairmonts have body-coloured mirrors and obvious rear signs, as well as the high show bonnet.
The XR systems kept their trademark four headlight design, only today they took in a more radical, menacing look. They were given showy human body kits with forward spoiler, rocker mouldings, rear door panel flares, rear bumper skirt and decklid spoiler.
With its beginnings dating back on late seventies, the ancient ute is replaced in 1999 by the AU ute. Surprisingly, it had best fortunes compared to the struggling AU sedan, and became a best vendor. There were XR models, with the same front end since the sedans, and the reduced spec versions, due to their very own egg-crate grille. Some Forte proprietors installed their particular vehicles with this newer grille, as did some desperate Ford dealers. Ford caught on, plus late 1999, the minimal edition Falcon Classic sported the egg-crate. Steering away from the traditional ute design, the Falcon ute was readily available as a cab chassis or a method part ute.
As constantly, there clearly was a new wagon. Available as a Forte, Futura and Fairmont, they provided exactly the same aesthetic differentation associated with sedans.
With regards to came to designing the AU’s internal, Marcus Hotblack, Ford’s supervisor of home design, was determined to prevent “the wrap-around cocoon feel” of vehicle interiors, where the controls and tools were angled towards driver. This lead to a large, circular blob in the middle associated with dashboard, which with the “medium graphite” colour pallette, gave a sparse, downmarket sensation. Once the designers had been enthusiastic about differentiating designs, the Fairmonts received a new “high series” dashboard with synthetic woodgrain. Seating had been redesigned and because of an almost modern floorplan, the driver’s seat is noticably reduced. The domed roofline offered much more forward and back headroom, but there was a little less shoulder room and back legroom. All designs featured stereo controls into the tyre, and an optional cellular company kit ended up being readily available.
AU Falcon’s motors made an appearance the same as the EL at first however they are so improved that Ford claimed they were all-new and named them Intech. Substantial adjustment into the standard six lowered noise, vibration and harshness amount and delivered 5per cent best gasoline consumption. The XR6 had been powered by the powerful Intech, the typical V8 attained most energy and torque, whilst the XR8 V8 developed more torque. There were two brand-new Tickford produced machines with adjustable valve time - a primary for an Australian vehicle. One was suited to the Fairmont Ghia, others into latest XR6 VCT. All sixes came with a temperature sensor inside cylinder head, detecting coolant control, and allowing the vehicle to “limp home” by cutting cylinders. Transmissions were enhanced for best change become, while the car had been recalibrated to higher suit the latest machines.

After much debate during developing, separate back suspension became readily available for the 1st time, standard on Fairmont Ghia and some XR products. A world lessons dual wishbone IRS setup had been used, instead of the older trailing arm IRS.
Ford chose to have fun with the value-for-money card because of its $700 million Falcon, and when it had been circulated, the Forte sedan was $29990 with standard automated and air cooling. However the Falcon had dilemma making up shed crushed. The AU range got mostly reviews that are positive because of the media, it was the like it or hate it styling that spoilt an otherwise excellent vehicle. A quiet improvement in middle 1999 led to a larger braking system booster, 24mm decreased suspension system and some various other tweaks.