Target Audience:
Owners, mechanics, and enthusiasts of Ford Falcon AU Series vehicles seeking comprehensive repair and maintenance information.
Value Proposition:
Provides factory-level diagnostic and repair procedures, essential for maintaining complex systems and ensuring longevity of Australian-built Fords.
Coverage Scope:
Encompasses all major mechanical, electrical, and body systems across a wide range of luxury and performance variants within the AU Falcon lineage.
Covered Models:
Falcon, Futura, Fairmont, Fairmont Ghia, XR6, XR8, Fairlane, LTD
Covered Engines:
All 6-cylinder (including Barra variants), All V8 (including Windsor variants)
Type:
Factory Service Manual / Repair Manual
Format:
Digital (likely PDF)
Powertrain:
Engine tune-up, cooling system, ignition system, fuel system, emission system, clutch, automatic transmission, manual transmission, drive/tail shaft, universal joints, final drive, exhaust system, fuel tank, EFI fuel pump
Chassis:
Steering, front suspension & axle, rear suspension (beam axle), brake system, wheels & tires
Body And Electrical:
Body, heating & air conditioning, automatic climate control, instruments, stereo systems, horn, body electronics, Smart Lock system, lights & switches
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication
Diagnostics And Troubleshooting:
Diagnostic charts, troubleshooting electrical systems, identifying common faults and their remedies
Repair And Rebuild:
Detailed step-by-step repair procedures for all major systems, component removal and installation, major component overhauls
Depth:
Comprehensive. Covers everything from basic servicing to major component rebuilds and complex electrical diagnostics. Suitable for professional technicians and advanced DIY mechanics.
Engine Codes Common:
OHC inline-6, Barra (various displacements, e.g., 4.0L)
Engine Codes Common:
Windsor V8 (e.g., 4.9L/5.0L, 5.6L/5.6L Windsor)
Hp Range Typical:
172-255 kW (depending on variant and year)
Hp Range Typical:
200-255 kW (depending on variant and year)
Type:
Electronic Fuel Injection (EFI)
Type:
Distributorless Ignition System (DIS) or Coil-on-Plug (COP) for later models
Type:
Pressurized liquid cooling system with thermostat and fan
System:
Catalytic converter, EGR (Exhaust Gas Recirculation), O2 sensors
Common Units:
4-speed automatic (e.g., BTR D3000, 4HP24)
Common Units:
5-speed manual (e.g., T5)
Shift Modes:
Some variants may offer 'Sports' or 'Economy' modes on automatic transmissions.
Automatic Transmission Fluid:
Mercon V or equivalent (refer to manual for specific model year)
Manual Transmission Fluid:
Dexron III or equivalent manual transmission fluid (refer to manual for specific model year)
Ancap Rating Era:
Likely 3-4 stars for later models based on contemporary ratings for large sedans of that era (specific ratings vary by year/trim).
Braking Systems:
ABS (Anti-lock Braking System) standard on most models, EBD (Electronic Brakeforce Distribution) on later models.
Traction Control:
Optional on some models, particularly higher performance variants.
Airbags:
Driver and front passenger airbags standard. Side airbags optional on some premium variants.
Seatbelts:
Pre-tensioning front seatbelts.
Body Construction:
Reinforced safety cell, crumple zones.
Stereo Systems:
Factory radio/cassette/CD players, often with upgraded premium sound systems on Fairmont Ghia and Fairlane/LTD models. Aux input often limited or absent on early models.
Cruise Control:
Standard on most models, optional on base variants.
Keyless Entry:
Available on higher trims, often integrated with Smart Lock system.
Smart Lock:
Ford's proprietary immobiliser and central locking system, coverage includes troubleshooting and repair.
Oil Change Interval:
Typically 10,000 - 15,000 km or 12 months (refer to manual for specific engine/oil type)
Coolant Change Interval:
Every 2-3 years or 40,000 - 60,000 km (using correct coolant)
Spark Plug Replacement:
Varies significantly by plug type (copper, platinum, iridium) and engine. Check manual, typically 40,000 km for copper, 80,000-100,000 km for platinum/iridium.
Engine Oil Spec 6Cyl:
SAE 5W-30 or 10W-30 API SG/SH/SJ or higher (refer to manual for specific viscosity and API rating)
Engine Oil Spec V8:
SAE 10W-30 or 10W-40 API SG/SH/SJ or higher (refer to manual for specific viscosity and API rating)
Coolant Type:
Ford Super Plus 2000 or equivalent long-life coolant (typically orange/red)
Brake Fluid:
DOT 3 or DOT 4
Common Wear Items:
Suspension bushes, ball joints, tie rod ends, engine mounts, tailshaft universal joints, radiator and hoses.
Electrical Common Faults:
Sensor failures (e.g., TPS, MAF), BCM (Body Control Module) issues, instrument cluster problems, power window regulators.
Engine Common Faults:
Cracked exhaust manifolds (V8), coolant leaks (especially intake manifold gaskets on V8), occasional ignition coil failures.
Ford Australia:
Continuation of Ford Australia's long-standing tradition of producing large, rear-wheel-drive sedans and wagons tailored for Australian conditions.
Au Series Introduction:
The AU Falcon represented a significant styling and engineering departure from the previous AU Falcon, introducing a more contemporary European-influenced design.
Series Progression:
Series I (1998-2000), Series II (2000-2002), Series III (2002-2003). Each series introduced revisions to styling, features, and powertrains, notably the introduction of the Barra engine family.
Manufacturing Location:
Broadmeadows, Victoria, Australia
Production End Year:
2003 (replaced by BA Falcon)
Market Perception:
The AU Falcon was critically divisive upon release due to its styling, but later series and the Barra engine are highly regarded for performance and reliability. XR variants are recognized as capable performance sedans.
Industry Reviews Era:
Received mixed reviews initially, with praise for refinement and ride quality but criticism for exterior styling. Powertrain and chassis upgrades in later series improved reception.
