Target Audience:
DIY enthusiasts, independent repair shops, professional mechanics seeking detailed service information for the Ford Falcon AU/early BA series.
Value Proposition:
Provides extensive technical data, repair procedures, and diagnostic information at a fraction of the cost of dealership-provided manuals or professional labor for repairs.
Features:
Detailed illustrations, clear diagrams, comprehensive wiring schematics, step-by-step instructions, printable format for practical workshop use.
Covered Years:
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Estimated Pages:
Thousands (typical for comprehensive workshop manuals covering multiple years and variants)
Type:
Workshop Service and Repair Manual (Factory Service Manual equivalent)
Powertrain:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, manual transmission, automatic transmission, driveline.
Chassis:
Suspension (front and rear), steering, brakes (front and rear, ABS), wheels, tires.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, body controls, comfort and convenience, engine control module (ECM) diagnostics, power distribution, audio systems.
Body:
Body construction, interior trim, exterior trim, doors, windows, seats, roof, bumpers, glass, HVAC system (heating, ventilation, air conditioning).
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication, inspection points.
Repair:
Detailed step-by-step repair procedures for all major components and systems, including engine overhaul, transmission repair, brake caliper replacement, suspension arm replacement, electrical component diagnosis and repair.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), wiring diagrams for electrical system diagnosis.
Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical specifications, diagnostic data.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring schematics.
Readability:
Optimized for PDF Reader, allowing for zooming in/out for clarity of diagrams and text.
Printability:
Fully printable, allowing users to print specific sections or the entire manual for workshop use.
Binding:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Software:
Adobe PDF Reader, WinZip (for extraction if compressed)
Operating Systems:
Compatible with all versions of Windows and Mac operating systems.
Engine Options Au:
4.0L I6 Barra (OHC, naturally aspirated and supercharged variants), 5.6L V8 Windsor (OHV).
Engine Options Early Ba:
4.0L I6 Barra (OHC, naturally aspirated and Barra Turbo variants), 5.4L V8 Barra 32V (SOHC).
4.0L I6 Barra Na (Au):
Approx. 157kW (210 hp) @ 5000 rpm, 370Nm (273 lb-ft) @ 3000 rpm
4.0L I6 Barra Supercharged (Au Xr8/Xr6 Variants):
Approx. 172kW (230 hp) @ 4750 rpm, 420Nm (310 lb-ft) @ 3250 rpm
5.6L V8 Windsor (Au):
Approx. 185kW (248 hp) @ 4800 rpm, 418Nm (308 lb-ft) @ 3200 rpm
4.0L I6 Barra Na (Ba):
Approx. 182kW (245 hp) @ 5350 rpm, 380Nm (280 lb-ft) @ 3250 rpm
4.0L I6 Barra Turbo (Ba Xr6 Turbo):
Approx. 245kW (329 hp) @ 5250 rpm, 480Nm (354 lb-ft) @ 2000 rpm
5.4L V8 Barra 32V (Ba Xr8):
Approx. 220kW (295 hp) @ 5350 rpm, 470Nm (347 lb-ft) @ 3500 rpm
Injection Type:
Multi-point fuel injection (MPI) or Sequential Electronic Fuel Injection (SEFI).
Fuel Type:
Unleaded Petrol (RON 91 recommended for naturally aspirated, higher octane for performance variants).
Manual Options:
Various 4-speed and 5-speed manual transmissions (e.g., T5 for V8s, Getrag for I6s).
Automatic Options:
4-speed automatic (e.g., BTR D5/D7), 5-speed automatic (e.g., 5R50W for BA models).
Adaptive Shifting:
Present on later automatic transmissions, adjusting shift patterns based on driving style.
Body Styles:
Sedan, Station Wagon, Utility (Ute).
Wheelbase Au Sedan:
Approx. 2790 mm (109.8 in)
Wheelbase Au Wagon:
Approx. 2896 mm (114.0 in)
Wheelbase Ba Sedan:
Approx. 2789 mm (109.8 in)
Curb Weight Range:
Approximately 1550 kg to 1850 kg (3417 lbs to 4079 lbs) depending on body style and engine.
Ancap Rating Au:
Not rated or limited (early models lacked standardized testing, later AU models improved).
Ancap Rating Ba:
Achieved 4-star ANCAP rating for sedan variants.
ABS:
Available as an option on many models, standard on higher trims and later years.
Traction Control:
Available on select higher-performance or luxury variants.
Airbags:
Driver and passenger front airbags standard on most models from mid-AU onwards, side airbags available on some higher trims.
Seatbelts:
All seating positions equipped with three-point seatbelts (lap-sash).
Audio Systems:
Factory fitted AM/FM radio with CD player (single or in-dash 6-CD stacker), cassette player on early AU models. Higher trims featured premium audio systems.
Cruise Control:
Available on most models, standard on higher trim levels.
Early Bluetooth:
Not available in this generation of vehicles. Aftermarket solutions are typically used for Bluetooth integration.
HVAC System:
Manual air conditioning and heating systems were standard. Automatic climate control was an option on higher-spec models.
Oil Change Interval:
Typically every 10,000 km (6,200 miles) or 6 months, whichever comes first. Check manual for specific engine and oil type.
Timing Belt Replacement:
Not applicable for Barra I6 engines (timing chain). V8 Windsor models typically have a timing chain, generally considered maintenance-free unless issues arise.
Coolant Flush:
Recommended every 30,000 km (18,600 miles) or 2 years. Use genuine Ford coolant (e.g., genuine Ford Super Long Life Coolant).
Engine Oil Spec I6:
API SG/SH or later, SAE 10W-30 or 10W-40 (check manual for exact grade and capacity).
Engine Oil Spec V8:
API SG/SH or later, SAE 10W-30 or 10W-40 (check manual for exact grade and capacity).
Transmission Fluid Auto:
Mercon V or equivalent for BTR 4-speed and 5-speed automatics (check manual for specific transmission).
Transmission Fluid Manual:
Refer to manual for specific fluid type (e.g., SAE 75W-90 GL-4 or GL-5).
Brake Fluid:
DOT 3 or DOT 4 (check manual, DOT 4 recommended for improved performance).
Au Series Common Issues:
Gearbox control module failures (4-speed auto), minor electrical gremlins, potential for paint fade/peel on certain colours, interior trim creaks.
Ba Series Common Issues:
Territory-specific ECU issues (less common), minor suspension component wear, potential for coil pack failure on Barra engines (though generally robust).
Ford Australia Legacy:
The Ford Falcon is an iconic Australian-made vehicle with a long history of performance, reliability, and utility, deeply ingrained in Australian automotive culture.
Au Series Introduction:
Launched in 1998, the AU Falcon represented a significant departure in styling and engineering from its predecessors, featuring a distinctive 'New Edge' design language and shared platform elements with European Fords.
Ba Series Introduction:
Introduced in 2002, the BA Falcon was a major redesign, offering improved styling, enhanced safety, and significant mechanical updates, including the introduction of the powerful Barra engines and a more sophisticated independent rear suspension on sedans.
Manufacturing Location:
Broadmeadows, Victoria, Australia.
Production Years Covered:
1998-2005, spanning the majority of the AU series and the initial years of the BA series.
Australian Car Of The Year:
The BA Falcon won the prestigious Wheels Magazine Car of the Year award in 2002.
Engine Performance Acclaim:
The Barra engine family, particularly the turbocharged variants, received significant praise for its power, torque, and aftermarket tuning potential.
