Target Audience:
Owners, professional mechanics, and automotive technicians specializing in Ford Falcon AU models. Essential for those performing in-depth repairs and maintenance.
Value Proposition:
Provides comprehensive, model-specific technical data that generic repair guides lack. Crucial for accurate diagnosis, repair, and maintenance of a complex vehicle like the AU Falcon.
Key Features Of Manual:
Engine-specific rebuild procedures, detailed electrical schematics, troubleshooting guides, and coverage for all body styles and performance variants (XR6, XR8).
Manual Coverage Scope:
Comprehensive workshop manual covering all AU Falcon and Fairmount models, including XR6 and XR8 variants, across Sedan, Utility, and Wagon body styles.
Estimated Page Count:
Over 1000 pages (estimated based on typical workshop manual depth for this era and range).
Manual Type:
Workshop Manual / Service Manual / Repair Manual
Format:
Digital Download (Link provided)
Engine Systems:
Engine tune-up, maintenance, rebuild procedures for 4.0L OHC 6-cylinder, 4.0L OHC VCT 6-cylinder, and 5.0L V8 engines. Includes fuel, ignition, cooling, starting, charging, EECV engine management, and emission controls.
Transmission Systems:
Detailed coverage of BTR 93LE 4-speed Automatic Transmission (6-cylinder), BTR 97LE 4-speed Automatic Transmission (V8), and M57 5-speed Manual Transmission. Includes maintenance, overhaul, and troubleshooting.
Drivetrain Systems:
Covers tailshaft, universal joints, Beamaxle final drive, and Independent Rear Suspension (IRS) final drive.
Suspension Steering:
Front suspension and axle, rear suspension (standard beamaxle and IRS), steering systems.
Braking Exhaust:
Comprehensive brake systems coverage, including hydraulic and mechanical components. Exhaust system servicing and replacement.
Fuel System:
Fuel tank, EFI fuel pump, lines, and injectors.
Wheels Tires:
Wheel and tire specifications, replacement procedures, and alignment considerations.
Body Exterior:
Body panel repair, door mechanisms, glass, windshield wipers and washers.
Body Interior Comfort:
Heating, Air Conditioning (AC), and Automatic Climate Control systems. Instruments, switches, stereo system, cruise control, horn.
Electrical Electronics:
Body electronics module, Smartlock, Smartshield, SatNav system, lights and lighting system, electric wiring diagrams, fuse layouts, and diagnostic charts.
Maintenance Procedures:
Scheduled maintenance, fluid checks and changes, filter replacements, spark plug replacement, belt inspection and replacement.
Repair Procedures:
Engine rebuilds, transmission overhaul, brake caliper and rotor replacement, suspension component replacement, electrical component diagnosis and replacement, body panel repair.
Troubleshooting:
Diagnostic charts and procedures for common and complex issues across all major vehicle systems.
Diagnostics:
EECV engine management diagnostics, electrical system troubleshooting, emission control system analysis.
Depth Of Coverage:
Detailed, step-by-step instructions for both routine maintenance and complex mechanical and electrical repairs, suitable for professional mechanics and advanced DIY enthusiasts.
Engine Options:
4.0L OHC 6-cylinder, 4.0L OHC VCT 6-cylinder, 5.0L V8 (likely Windsor variant).
Xr6 Engine Performance:
4.0L OHC 6-cylinder: Approx. 172 kW (170-180 hp), 361 Nm (266 lb-ft). VCT variant offered slight improvements.
Xr8 Engine Performance:
5.0L V8: Approx. 185 kW (248 hp), 408 Nm (301 lb-ft).
Engine Management System:
EEC-V (Electronic Engine Control - Version V) with EFI (Electronic Fuel Injection).
Engine Oil Spec:
Typically SAE 15W-40 or 10W-30 API SG or SH for 6-cylinder; SAE 10W-30 or 10W-40 API SG or SH for V8. Refer to specific manual chapter for exact OEM specifications and capacities.
Transmission Types:
5-Speed Manual (M57), 4-Speed Automatic (BTR 93LE for 6-cyl, BTR 97LE for V8).
Automatic Transmission Variants:
BTR 93LE (6-cylinder), BTR 97LE (V8).
Manual Transmission Features:
M57: 5-speed manual, known for durability in performance applications.
Automatic Transmission Fluid Spec:
BTR transmissions typically used Dexron III (or equivalent). Capacity varies by model, approximately 8-10 liters for a complete fluid change. Refer to manual for exact fill procedure and capacity.
Manual Transmission Fluid Spec:
Typically GL-4 or GL-5 gear oil, viscosity 75W-90 or 80W-90. Capacity around 2.5 liters. Refer to manual for exact specification.
Sedan Dimensions:
Length: approx. 4920 mm, Width: approx. 1795 mm, Height: approx. 1455 mm (varies slightly by trim).
Ute Dimensions:
Length: approx. 4940 mm, Width: approx. 1795 mm, Height: approx. 1495 mm (varies by payload).
Wagon Dimensions:
Length: approx. 4960 mm, Width: approx. 1795 mm, Height: approx. 1485 mm (varies by trim).
Kerb Weight Range:
Approx. 1550 kg (Sedan 6-cyl) to 1750 kg (XR8 Sedan/Wagon). Utes typically lighter.
Gvm Ute:
Gross Vehicle Mass for Ute variants typically around 2600-2700 kg.
Audio System:
Factory fitted stereo systems with AM/FM radio and CD player. Higher trims may have premium sound systems. Manual covers instrument cluster, switches, and stereo system integration.
Cruise Control:
Cruise control was an available option and is covered in the manual's instrumentation and switchgear sections.
Body Electronics:
Features like Smartlock (immobiliser) and Smartshield (security system) are covered, indicating early integration of vehicle security and control modules.
Oil Filter Change Interval:
Every 10,000 km or 6 months, whichever comes first. Use of synthetic oil may extend intervals per manual recommendation.
Air Filter Replacement:
Every 20,000 km or 12 months, or more frequently in dusty conditions.
Spark Plug Replacement:
6-cylinder: Typically every 40,000 km (standard plugs) or 80,000-100,000 km (platinum/iridium). V8: Similar intervals depending on plug type. Refer to manual for specific engine and plug type.
Transmission Fluid Change:
Automatic: Every 40,000-60,000 km. Manual: Every 60,000-80,000 km. Crucial for longevity. Check manual for specific intervals and fluid types.
Coolant Spec:
Ethylene glycol based antifreeze. Typically a 50/50 mix with distilled water. Ford recommends specific coolant types; consult manual for OEM specification (e.g., Motorcraft Premium Engine Coolant).
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid. Should be flushed and replaced every 2-3 years due to moisture absorption.
Common Au Falcon Issues:
Ignition coil pack failure (particularly on 6-cylinders), thermostat housing leaks, air conditioning system leaks (especially compressor and hoses), rear main crankshaft seal leaks (V8), differential pinion seal leaks, minor body rust (wheel arches, sills), electrical gremlins related to body control modules and wiring harness issues.
Ford Australia Legacy:
The Falcon nameplate has been a cornerstone of Ford Australia's manufacturing and sales for decades, representing a locally developed, large Australian car.
Au Falcon Development:
The AU Falcon, launched in 1998, represented a significant departure in styling and engineering from its predecessors (EL Falcon). It was designed to be more globally competitive, though initial reception was mixed. It underwent facelifts in Series 2 (2000) and Series 3 (2001) to address criticisms and improve features.
Manufacturing Location:
Broadmeadows, Victoria, Australia
Production Period:
1998-2002
