AU Ford Falcon - SPUD Project



12V Accessory Power Source (Cigarette Lighter) information on the 12V accessory plug (cigarette lighter socket). Applies to EA/EB/ED/EF/EL/AU/BA/BF Falcons and SX/SY Territory models Antilock Braking System (ABS) Antilock Braking System (ABS) information Air Conditioner Controls - Series 1 air Conditioner controls repair information (Series 1 only) Accessory plug Information on the Mobile Office pack accessory plug. Also relevant to the BA/BF/FG Falcons and SX/SY/SZ Territorys Alternator alternator information Body Control Module (BCM) Body Control Model (BCM) information Digital Clock Information on the basic clock available on all low models Brake Switch brake switch replacement Reading Vehicle Identification Plate (Build Plate) Codes - How to read Vehicle Identification Plate A.K.A. build plate codes Crankshaft Angle Sensor basic information on the Crankshaft Angle Sensor, or CAS. Cabin Fuse Panel in-depth information on the continuity and functionality of the interior cabin fuse box PCM Catch Codes Centre Console Buttons accessory buttons (e.g. TCS, ABS, ANT.) information and pinouts Manufacturer Specific Instructions - CodeEzy Keyfob cloning instructions using a CodeEzy branded universal keyfob (Smartlock only) Common Faults common faults Credits Credits DTCs DTC (A.K.A Diagnostic Trouble Codes), and other relevant ECU/PCM Information Door Lock Actuators repair and replacement information for the door lock actuators. Also relevant for BA/BF Falcons and SX/SY Territorys Interior Driver Buttons information on driver-side console buttons (Lock/Boot/Fuel) Engine Number engine number information and location Exterior Door Handles Information on the replacement of the exterior door handles. Also relevant to the BA/BF Falcons and SX/SY Territorys Factory Specifications Factory Specifications fuel filter replacement Fuel Injectors fuel injector diagnosis and replacement Fuel Pressure Regulator Fuel Pressure Regulator replacement steps. applicable to BA/BF/FG/FGX Falcons and SX/SY/SZ Territory models (I6 only) Fuses & Relays fuse information and minimum viable fuses, including diagrams and parts tables Headlight Switches headlight switch controls information and pinouts Head Unit Head Unit information Idle Speed Controller (ISC) Idle Speed Controller Information Ignition Coil Pack ignition coil pack information, including replacement and testing information Instrument Cluster instrument cluster information and special functions Interior Mirror information and removal and replacement information for the interior mirror. Also relevant to the BA/BF/FG Falcons and SX/SY/SZ Territorys Manufacturer Specific Instructions - KEYDIY keyfob cloning instructions using a KEYDIY branded keyfob and programmer Central Locking Keyfobs central locking and Central Locking keyfob information Component lifespans - Educated guess lifespans for common maintenance components. Likely partially useful for various models of vehicle Miscellaneous Notes - Uncategorized notes not requiring a dedicated page PCM PCM (ECU equivalent) location and general information PCV PCV information and replacement instructions Parts Sharing - (partial) list of shared parts from Ford Falcons XA/XB/XC/XD/XE/XF/XG/XH/EA/EB/EF/EL/AU/BA/BF/FG/FGX, and Ford Territory SX/SY/SZ Premium Audio System Premium Audio Information Rear Lights Connector tail light/rear light assembly plug information Relays - General Information types of relays (general information) Manufacturer Specific Instructions - Remocon Keyfob cloning instructions using a Remocon branded keyfob and programmer (Smartlock only) Roof Racks roof rack installation methods and information Seatbelts replacement and repair instructions for seatbelts and B-Pillar Seatbelt trims. Partially useful for the BA/BF Falcons and SX/SY Territory models Series Information Series specifics information Sparkplugs spark plugs information and replacement instructions Speakers Speaker installation and wiring information. Partially applies to BA-BF Falcons and SX-SY Territory models Speedometer Reading Calculator interactive calculator for changing of speedometer reading based on transmission driven gear, diff ratio, and wheel size. Changing Differential Ratios and Tyre Sizes calculations required for changing of speedometer reading based on transmission driven gear, diff ratio, and wheel size. Steering Wheel Controls steering wheel Cruise Control and Media Control assembly information, pinout, and 3D printable model Thermo Fan Thermo fan removal instructions Thermostat thermostat replacement instructions PCM Relearn PCM Relearn procedure Reading the Tickford Vehicle Engineering (TVE) Plates - How to read the Tickford Vehicle Engineering (TVE) Plates Trailer Auxiliary plug towbar trailer connector information, including instructions on how to wire a custom trailer plug (if required). Partially applicable to BA-BF Falcons and SX-SZ Territorys Tyre Size Calculator Generic Tyre Size Calculator Reading the Vehicle Identification Number (VIN) Plate how to read and decode the VIN number and engine number Ford Falcon AU VIN Decoder Ford Falcon AU Interactive VIN Decoder Verification Letters how to get an official Ford Verification Letter. Will work with other similar models Wheels & Tyres information on the tyre sizes and brake dust covers. also includes general information on calculating tyre size from a tyre size Sedan audio upgrade - 6x9” Speakers

Common Faults

Common Faults

While the AU Falcon is generally regarded as a quite reliable vehicle, there are common faults with this model that cannot be ignored. Below is a non-exhaustive list of common issues these vehicles are likely to have over the course of ownership.

Fault Series Configurations Notes
Antilock Braking System (ABS) All All Sensor and module failure can cause ABS to become “hyperactive”, sending excess pressure to the brake master cylinder and causing premature failure and stripped paint in area below brake master cylinder
Air Conditioner Controls S1 All issues known of solder joints cracking behind AC/AC Max buttons and easily broken plastic dials
Alternator All I6 motor models Prone to oil and power steering fluid ingress
Ball Joints All All prone to wearing out, however simple to replace using a bearing tool
Brake Master Cylinder All All tends to leak from behind, stripping the paint on the Brake Booster and surrounding painted area. Less common on S1 vehicles due to different Brake Master Cylinder used
Climate Control All High Models (Fairmont/Fairlane/LTD/TL50) Ribbon cable separation and display failure common due to time
Exhaust Rear Resonator All Wagon Rust common around entry and exit welds of rear resonator. Known reliable repair is to replace with straight pipe section
Front Brake Calipers S1 All single piston design does not allow for hard braking on regular basis. regular maintenance is essential on these models
Front Brake Rotors All All front rotors prone to warping due to brake design, Wagon and Utility body types most affected due to front brake bias
Fuel Pump All All Standard fuel pump known to starve engine if driven hard consistently, and fail prematurely
Fuel Sender Circuit All All Various causes known with wiring, cluster, and sender unit, but consistent factor appears to be failure of the fuel reader in the Instrument Cluster
Power Steering High Pressure Line All I6 motor models failure allows power steering fluid to leak onto the alternator. This then causes the alternator to fail as well
Rear Shelf Speakers All Sedan Mesh cover prone to separation from speaker cone assembly due to UV exposure, causing increased vibration. Can be fixed by removing the mesh carefully, replacing the speakers or using the opportunity to upgrade the speakers to another size
Rust All All Exhaust, Middle muffler and rear section most affected
Rust All Sedan bottom of boot lid and strut mount areas. exasperated on models fitted with a spoiler due to mount holes
Rust All Utility section between cab and tub affected
Smartlock Central Locking Remote S1 All rubber buttons prone to splitting and grime ingress. Once failed, expensive to replace with OEM remote due to low supply and relatively high demand, however aftermarket cloning remotes are available to copy OEM remotes
Suspension Ball Joints (Front) All All upper and lower ball joints prone to failure. Recommended to use heavy duty or quality replacements, or to replace control arm if bushes also worn
Suspension Bushes (Front) All All upper and lower control arm bushes not necessarily prone to failure, but makes excessive noise when failed. Recommended to replace with heavy duty or polyurethane bushes, or to replace control arm if ball joints also worn
Suspension Bushes (Rear) All IRS Optioned models IRS bushes are likely to fail over time, similar to the B-series counterparts which came with IRS as standard
Thermostat Housing All I6 motor models likely to leak through gap between top pipe end and housing end. Various causes known, most common being uneven mounting surfaces on thermostat installation (usually grime)
VCT Solenoid All VCT motor models Solenoids fail due to wearing and will no longer actuate, replacements hard to find
Water Pump All All While OEM water pump is known good for an average of 200,000kms, aftermarket water pumps from reputable manufacturers have been known to have issues with bearing fitment and a weak plastic pulley wheel

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