Target Audience:
Do-it-yourselfers and experienced mechanics
Value Proposition:
Inexpensive way to keep your vehicle working properly, comprehensive factory service information
Advantage:
Covers every single detail, easy-to-read format with high-quality diagrams, instant download saves time and postage
Content Richness:
Detailed exploded pictures and diagrams, step-by-step instructions, troubleshooting charts
Ease Of Use:
Designed for both novice and professional technicians
Manual Type:
Factory Service Repair Workshop Manual
Compatibility:
All Versions of Windows & Mac
Features:
Easy-to-read text, top quality diagrams and instructions, step-by-step instructions, exploded pictures and diagrams, searchable text
Engine:
4.0L OHC 6 cylinder, 4.0L OHC VCT 6 Cylinder, 5.0L V8
Transmission:
BTR 93LE Automatic (6 Cylinder), BTR 97LE Automatic (V8), M57 5 Speed Manual
Drivetrain:
Tailshaft, Universal Joints, Beamaxle Final Drive, IRS Final Drive
Suspension Steering:
Front Suspension Axle, Rear Suspension (Standard Beamaxle), Rear Suspension (IRS), Steering
Fuel System:
Fuel Tank, EFI Fuel Pump
Electrical Systems:
Starting System, Charging System, Cooling System, Fuel Ignition Systems, EECV Engine Management Emission Control, Instruments, Switches, Stereo System, Cruise Control, Horn, Body Electrics Module, Smartlock, Smartshield, SatNav, Lights and Lighting System, Electric Wiring, Fuses
Body:
Body, Windscreen Wipers Washers
Comfort Systems:
Heating, AC, Automatic Climate Control
General Maintenance:
Engine tune-up, maintenance, fluid changes, filter replacements
Engine Repair:
6 Cylinder Maintenance and Rebuild, V8 Engine Maintenance and Rebuild, complete disassembly procedures
Transmission Repair:
BTR 93-97LE Automatic Transmission overhaul, M57 5 Speed Transmission overhaul
Chassis Repair:
Suspension component replacement, steering system repair, brake system service, axle and driveshaft repair
Electrical Diagnostics:
Troubleshooting, diagnostic charts, wiring diagrams, fuse identification, component testing
Bodywork Trim:
Body panel repair and replacement, trim component installation, glass service (implied by windscreen wipers/washers)
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and electrical troubleshooting.
4.0L Ohc 6 Cylinder:
Displacement: 4.0 Liters (3984cc), Configuration: Inline 6-Cylinder, Overhead Cam (OHC), Fuel Delivery: Multi-point Fuel Injection (MPI)
4.0L Ohc Vct 6 Cylinder:
Displacement: 4.0 Liters (3984cc), Configuration: Inline 6-Cylinder, Overhead Cam (OHC), Variable Camshaft Timing (VCT), Fuel Delivery: Multi-point Fuel Injection (MPI)
5.0L V8:
Displacement: 5.0 Liters (302 cubic inches / 4942cc), Configuration: V8, Overhead Valve (OHV) pushrod, Fuel Delivery: Multi-point Fuel Injection (MPI)
4.0L Ohc 6 Cylinder Hp:
Approx. 190-200 hp (depending on specific variant and tune)
4.0L Ohc Vct 6 Cylinder Hp:
Approx. 200-210 hp (depending on specific variant and tune)
5.0L V8 Hp:
Approx. 200-230 hp (depending on specific variant and tune)
Ignition System:
EEC-IV (EEC-V on later models) engine management system with distributorless ignition system (DIS) on some 6-cylinder models, traditional distributor on V8.
Ancap Rating:
Refer to specific model year and crash test data. Early AU Falcons had mixed safety ratings; significant improvements were made in later revisions.
ABS:
Optional on some models, standard on higher trims and later revisions.
Airbags:
Driver's airbag standard, passenger airbag optional on some early models, standard on later/higher trims.
Seatbelts:
Pre-tensioned front seatbelts.
Audio System:
Factory fitted radios with AM/FM, cassette and/or CD players. Speaker configurations varied by trim level.
Cruise Control:
Available as an option on many models, integrated into steering wheel or column stalk.
Remote Central Locking:
Available on higher trims, often integrated with Ford's 'Smartlock' security system.
Climate Control:
Manual air conditioning and heating standard, with optional automatic climate control on premium models.
Oil Change:
Typically every 10,000 - 15,000 km or 12 months, whichever comes first (refer to manual for exact specifications).
Coolant Change:
Initial change at 2-3 years, then every 2 years or 40,000-50,000 km (refer to manual for specific coolant type).
Engine Oil:
Refer to manual for specific viscosity grades (e.g., 10W-30, 10W-40, 5W-30 for synthetic) and API service classifications depending on engine and climate. Typically around 5-7 liters capacity.
Transmission Fluid Auto:
BTR 93LE/97LE: DEXRON III (or equivalent). Capacity: Approx. 7-9 liters for a service fill.
Transmission Fluid Manual:
M57: Refer to manual for specific manual transmission fluid type (e.g., GL-4 gear oil). Capacity: Approx. 2.5 liters.
Coolant:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Ford specified coolant types should be used.
Common Problems:
Early AU models had criticisms regarding interior materials and some suspension/steering component wear. Coil pack failures on 6-cylinder engines, some transmission issues with the BTR units under heavy load or high mileage, and potential for rear main crankshaft seal leaks on V8s.
Routine Checks:
Regular inspection of coolant hoses, drive belts, brake pads and rotors, and exhaust system for leaks or wear.
Ford Australia:
Ford Australia has a long history of designing and manufacturing vehicles for the Australian market, with the Falcon being a flagship model for decades.
Au Falcon Introduction:
The AU Falcon, launched in 1998, represented a significant departure from its predecessor (EL Falcon) with a completely new body shell and interior design, influenced by Ford's global 'New Edge' design philosophy. It was a bold but initially controversial design.
Au Facelift:
The AU Falcon underwent facelifts during its production run: Series II (2000) and Series III (2002), which addressed design criticisms and introduced mechanical updates.
Manufacturing Location:
Campbellfield, Victoria, Australia
