🏷️ Basic Information

Make:

Ford

Model:

Falcon AU Series

Model Variants:

Fairmont, Fairlane, XR6, XR8

Body Styles:

Sedan, Ute, Wagon

Production Years:

1998-2002

Series Coverage:

Series 1, Series 2, Series 3

Chassis Code:

AU

👋 Introduction

Positioning:

The Ford Falcon AU series represented Ford's Australian flagship large car, competing in a segment with strong local and import rivals. This manual caters to owners and mechanics of this significant Australian-made vehicle.

Competitors:

Primarily competed against Holden Commodore (VT, VX series), Toyota Camry (later generations), and various imported sedans.

Distinctive Features:

The AU Falcon introduced a significant styling and engineering update over its predecessor (AU). Known for its robust Australian-designed and manufactured platform, powerful inline-six and V8 engines, and the performance-oriented XR variants.

📋 Manual Details

Primary Focus:

Comprehensive repair, maintenance, and diagnostics

Body Styles Covered:

Sedan, Station Wagon, Utility (Ute)

Trim Levels Covered:

All trims including XR6, XR8, Fairmont, Fairlane, and standard Falcon models

Estimated Page Count:

Detailed information suggests a substantial volume, likely exceeding 1000 pages in print equivalent.

Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

Download Link (likely PDF)

📖 Manual Coverage

Engine Systems:

Engine tune-up, maintenance, rebuild procedures for 6-cylinder and V8 engines, cooling system, fuel system, ignition system, EECV engine management and emission control.

Drivetrain Systems:

Clutch, BTR 93LE and 97LE automatic transmissions, M57 5-speed manual transmission, tailshaft, universal joints, beam axle final drive, Independent Rear Suspension (IRS).

Chassis Systems:

Steering, front suspension, rear suspension (standard beam axle and IRS), brake systems, exhaust system, fuel tank and EFI fuel pump.

Electrical Systems:

Starting system, charging system, instruments, switches, stereo system, cruise control, horn, body electrics module, Smartlock, Smartshield, SatNav, lights and lighting system, electric wiring diagrams, fuses.

Body Systems:

Bodywork, interior trim, exterior panels, windscreen wipers and washers, heating, air conditioning, automatic climate control.

Maintenance Procedures:

Routine servicing, oil changes, filter replacements, fluid checks and top-ups, belt inspections and replacements, spark plug replacement, diagnostic checks.

Repair Procedures:

Engine rebuilds (6-cyl and V8), transmission overhauls and repairs, brake system repairs, suspension component replacement, steering system repairs, electrical component troubleshooting and replacement, body panel repair.

Diagnostic Procedures:

Troubleshooting charts, fault finding for engine management, electrical systems, and mechanical components.

Depth:

Comprehensive, covering from basic maintenance to advanced repair and rebuild procedures. Includes detailed technical specifications, torque values, and diagnostic flowcharts.

Diagnostics:

Detailed diagnostics for EECV engine management, electrical faults, and mechanical issues.

Schematics:

Includes detailed electric wiring diagrams for all systems.

📊 Manual Specifications

Format Details:

Downloadable digital format, likely PDF. Assumed to be searchable and printable.

Quality:

Digital format quality (PDF) is generally high, ensuring clarity of diagrams and text.

Binding:

Not applicable for digital download, but a physical equivalent would be professionally bound.

Paper:

Not applicable for digital download, but a physical equivalent would use durable paper for workshop environments.

⚙️ Engine Specifications

Engine Family 1:

OHC 6 Cylinder

Engine Family 2:

OHC VCT 6 Cylinder

Engine Family 3:

OHV V8 (Windsor-based)

Displacement 6 Cyl:

4.0 Litres (3984 cc)

Displacement V8:

5.0 Litres (302 ci)

Horsepower 6 Cyl:

Varies by variant, typically 172 kW to 190 kW for naturally aspirated OHC 6, and up to 200 kW for VCT variants.

Torque 6 Cyl:

Varies by variant, typically 375 Nm to 400 Nm for naturally aspirated OHC 6, and up to 405 Nm for VCT variants.

Horsepower V8:

Typically 175 kW to 200 kW for standard V8, up to 220 kW for XR8 variants (depending on Series).

Torque V8:

Typically 420 Nm to 460 Nm for standard V8, up to 475 Nm for XR8 variants (depending on Series).

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection (MPI) for all engines.

Fuel Type:

Unleaded Petrol (ULP)

🔧 Transmission

Manual Transmission:

M57 5-Speed Manual

Automatic Transmission 6Cyl:

BTR 93LE 4-Speed Automatic

Automatic Transmission V8:

BTR 97LE 4-Speed Automatic

Transmission Features:

Rear-wheel drive (RWD) configuration for all transmissions. V8 automatic may feature a slightly more robust torque converter or cooler depending on the specific XR8 tune.

📐 Dimensions

Wheelbase Sedan:

Approximately 2800 mm

Wheelbase Wagon Ute:

Approximately 2900 mm

Length:

Varies by body style (Sedan: ~4950mm, Wagon: ~5000mm, Ute: ~5030mm)

Tare Weight Range:

Approximately 1600 kg to 1850 kg depending on body style and engine.

Gvm Range:

Approximately 2100 kg to 2400 kg depending on model and application (e.g., Ute).

🛡️ Safety Features

Ancap Rating:

AU Falcon series received mixed results. Early models (Series 1) had lower ratings. Later series and specific models improved, but detailed ANCAP reports for each specific AU variant would need verification.

Active Safety Features:

Anti-lock Braking System (ABS) available on higher trims and as an option. Traction Control System (TCS) also available on certain higher-spec models, particularly XR variants.

Passive Safety Features:

Driver and front passenger airbags. Some later models may have side airbags as an option. Three-point seatbelts with pretensioners. Crumple zones in the body structure.

💡 Technology Features

Infotainment Features:

Factory-fitted stereo systems with radio, cassette, and CD player options. Higher trims may include premium sound systems. Later models (Series 3) saw improvements in head unit design and features.

Driver Assistance Features:

Cruise control standard on many models. ABS and Traction Control available as optional or standard on higher trims.

Connectivity Features:

Limited by the era; no integrated Bluetooth or USB connectivity in early models. Later models may have had provision for aftermarket systems. Smartlock and Smartshield systems relate to security and immobilisation.

🔧 Maintenance

General Service Interval:

Typically 10,000 km or 6 months, whichever comes first, for oil and filter changes. More comprehensive services at 20,000 km, 40,000 km, etc., including checks on other fluids, brakes, and suspension.

Engine Oil 6Cyl:

API SG/SH/SJ or higher. Viscosity typically SAE 10W-30 or 10W-40, depending on ambient temperature. Check owner's manual for exact recommendation.

Engine Oil V8:

API SG/SH/SJ or higher. Viscosity typically SAE 10W-30 or 10W-40. May require a higher performance oil due to higher operating temperatures of the Windsor V8. Check owner's manual for exact recommendation.

Coolant:

Ethylene glycol-based coolant (e.g., Ford Genuine or equivalent). Typically a 50/50 mix with distilled water. Specification should be verified in the manual for correct colour and additive package.

Transmission Fluid Auto:

BTR specification fluid, often referred to as Dexron-II/III compatible or a specific BTR fluid. Crucial to use the correct type to avoid transmission damage.

Transmission Fluid Manual:

GL-5 rated gear oil, typically 75W-90 or 80W-90 viscosity. Capacity around 2.5-3.0 litres. Check manual for precise specification.

Brake Fluid:

DOT 3 or DOT 4 brake fluid. Must be kept dry as it is hygroscopic.

Common Issues 6Cyl:

Cracked exhaust manifolds (especially Series 1), intake manifold gasket leaks, idle control valve issues, potential for spark plug 'tipping' (later models with 2-piece plug). VCT variants can develop timing chain noise if maintenance is neglected.

Common Issues V8:

Internal engine component wear with high mileage, coolant leaks from intake manifold crossover, potential for rocker arm wear, transmission cooler line leaks, exhaust leaks.

Common Issues General:

Interior trim creaks and rattles, air conditioning system issues (compressor, evaporator), power window regulator failures, tailshaft centre bearing wear, suspension component wear (ball joints, bushes), rust in common areas (wheel arches, sills).

Oil Filter 6Cyl:

Example part number: Ford genuine FA166 / Ryco Z405 / WIX 57712

Air Filter 6Cyl:

Example part number: Ford genuine FA110 / Ryco A1163 / WIX 42010

Oil Filter V8:

Example part number: Ford genuine FA167 / Ryco Z406 / WIX 57707

Air Filter V8:

Example part number: Ford genuine FA113 / Ryco A1579 / WIX 42031

📚 Vehicle History

Heritage:

Ford Australia has a long history of producing large, rear-wheel-drive sedans and utilities, with the Falcon being its iconic nameplate for decades. The AU generation was a significant step in this lineage.

Evolution:

The AU Falcon was a radical departure in styling from the previous AU. It underwent incremental updates through Series 1, 2, and 3, addressing feedback and refining features, particularly in interior materials and drivetrain refinements.

Manufacturing Location:

Broadmeadows, Victoria, Australia

🏆 Awards & Recognition

Awards:

The AU Falcon, despite its polarizing initial styling, was recognized for its Australian engineering and capability. Specific awards would vary by year and trim, often related to local motoring publications' 'car of the year' categories or specific performance accolades for XR models.

Safety Ratings Context:

As mentioned, safety ratings were a point of evolution for the AU series, with later iterations generally showing improvements.

Certifications:

Ford's manufacturing processes would adhere to Australian automotive manufacturing standards of the time.