Review: Ford AU Falcon Ute (1999-02)

Review: Ford AU.I Falcon Ute (1999-00)

Overview

Released in June 1999, the Ford AU Series I (AU.I) Falcon Ute was available in three bodies: cab chassis, cab chassis with an optional factory-fitted drop-side tray and with an integrated style side box. Manufactured in Campbellfield, Victoria, the rear-wheel drive AU Falcon Ute was available with 4.0-litre six-cylinder petrol, 4.0-litre six-cylinder LPG and 4.9-litre V8 petrol engines. As per the table below, the AU.I Falcon Ute range consisted of XL, XLS, XR6 and XR8 variants.

Engines: Intech, E-Gas LPG and Windsor V8

Of the engines,

• The 4.0-litre Intech six-cylinder petrol engine had cast iron block, an alloy cylinder head, sequential electronic fuel injection, a single overhead camshaft (SOHC, chain-driven), two valves per cylinder, an EEC V control unit and a compression ratio of 9.65:1. Compared to its predecessors, the Intech engine had a more rigid block, a new cylinder head, triple-layered steel head gasket, more rigid crankshaft with larger bearings, lighter Teflon-coated pistons, lighter connecting rods, single conical valve springs, a cast aluminium sump (cross-bolted through the main bearing caps), electronic distributorless ignition system (EDIS) and a ‘limp home’ mode which enabled the engine to keep running without coolant fluid. Furthermore, a flexible decoupler between the exhaust manifold and new catalytic converter enabled a lower idle speed of 550 rpm;
• For the XR6, the 4.0-litre Intech HP (High Performance) engine had a unique cylinder head, reshaped inlet port, redesigned exhaust port, ‘open’ combustion chamber (shaped to restrict pre-detonation from hot spot areas), a unique camshaft, higher fuel pressure and recalibrated engine management system;
• The 4.0-litre Intech E-Gas dedicated LPG engine which had a single-point, venturi-style carburetion (rather than sequential injection as per the petrol engines). Compared to the 4.0-litre Intech petrol engine, the E-Gas engine had different spark plugs, inductive high tension leads and a unique engine management processor;
• The 4.9-litre pushrod Windsor V8 engine had a cast iron block and cylinder head, two valves per cylinder, EEC V engine management and a compression ratio of 9.1:1. For the AU range, the V8 engines were based on a later generation small block developed for the Ford UT Explorer. Compared to its predecessor, this V8 engine had GT 40 P cylinder heads with centralised platinum spark plugs, a ‘high flow’ fuel intake system, new inlet manifold and distributorless ignition; and,
• For the Falcon XR8, the 4.9-litre Windsor V8 engine had a unique camshaft profile, an aluminium trumpet device in the air filter to increase cold air flow, Tickford 4-into-1 headers, a ceramic coated exhaust manifold and a low back pressure exhaust system.

For models with petrol engines, the AU Falcon Ute had an 82 litre fuel tank. For dedicated LPG engines, however, two 55 litre gas cylinders were fitted.

Transmissions

The Falcon Ute was available with four-speed BTR M93LE and M97LE automatic transmissions for the six and eight cylinder models, respectively. Alternatively, both six and eight cylinder models were available with five-speed BTR T5 manual transmissions.

For the AU range,

• the automatic transmissions were upgraded with multi-groove C1 (clutch #1) plate friction elements for smoother gear engagements; and,
• the T5 manual transmissions had a new gearset with increased gear tooth contact ratios for reduced gear noise, while an isolator was added to the gearshift offset lever.

Development and dimensions

Developed in conjunction with the AU Falcon sedan and wagon, the AU Falcon Ute had a new, stiffer body structure with straightened side rails that were welded together to a beam behind the front bumper. As per the sedan and wagon range, innovations for the AU Falcon Ute included new headlights for a 30 per cent increase in light projection, triple weather-strip sealing for the doors (previously double weather-strips) and new sound proofing materials – sourced from OrbSeal Australia – which expanded during the paint baking process to fill gaps and cavities more effectively.

The AU Falcon Ute cab chassis was 4938 mm long, 1871 mm wide, 1437 mm tall and had a 3096 mm long wheelbase; for models with the integrated style side box, length increased by 139 mm to 5077 mm. Furthermore, the style side box had an integrated polyethylene bedliner, was wide enough to fit a pallet between the wheel arches and could fit 1.2m x 1.8m building sheets in the specially designed slots in the bedliner.

Inside, the AU Falcon Ute was available with two bucket seats or, for models with column shift automatic transmissions, a three seat split bench. Behind the seats, there was a 400 mm deep storage area.

Suspension

The AU Falcon Ute introduced double-wishbone front suspension and Ford’s ‘Wide Trac’ rear suspension which consisted of a live rear axle with shock absorbers located outboard of the leaf springs and angled towards the front of the vehicle. This rear suspension was based on the AU Falcon wagon, but with adjustments to shock valving and dual rate springs to cater for the extra load-bearing capacity.

Safety equipment and brakes

Standard safety equipment for the AU.I Falcon Ute included a driver’s airbag, while the XR6 and XR8 were also fitted with ABS.

The AU.I Falcon Ute had 287 mm by 24 mm vented front brake discs and 287 mm by 10.5 mm solid rear discs.

Features

Standard features for the Falcon Ute XL included a two speaker sound system, steering wheel audio controls, remote central locking, rake and reach steering wheel adjustment, power mirrors and ‘Smartshield’ immobiliser; a split bench seat was standard with the automatic column shift models. Inside, the XL had a ‘dark graphite’ colour scheme with speckled blue and grey ‘Chelsea’ trim for the seat cushions and plain ‘Vincent’ fabric on the bolsters.

The Falcon Ute XLS was further equipped with 16-inch alloy wheels with sports suspension, a four speaker 100 watt stereo, cruise control, variable intermittent wipers and power front windows; utility models were also equipped with a soft tonneau cover. Inside, the XLS had a ‘warm charcoal’ colour scheme and Jacquard trim with a darker pattern than the XL.

The Falcon Ute XR6 and XR8 featured 17-inch alloy wheels, ‘Sanderson’ patterned trim with ebony seat bolsters, a leather-wrapped steering wheel and a power antenna. The XR6 and XR8 were also fitted with a limited slip differential.

Review: Ford AU.II Falcon Ute (2000-02)

Overview

Released in April 2000, the AU Series II (AU.II) Falcon Ute introduced upgraded brakes, greater refinement, variable cam timing (VCT) for the XR6 variants and, from March 2001, more powerful XR8 engines.

Developments

The AU.II Falcon Ute introduced the following developments:

• Upgraded brakes: thicker front and rear discs (see ‘Safety equipment’, below), twin-piston aluminium-headed front calipers, bigger non-asbestos brake pads, changes to the master cylinder and a higher capacity booster;
• Structural upgrades to enhance offset front and side impact performance, including a laminated impact protection panel in the driver’s floor area for improved lower leg protection;
• A laminated firewall for greater refinement; and,
• Service intervals were also extended from 10,000 km to 15,000 km.

Engine: XR6 Intech VCT

For the AU.II Falcon Ute, the XR6 was available with Ford’s Intech VCT engine which, relative to the HP Intech engine, added variable cam timing (VCT) and a low back pressure exhaust system. Mounted on the front of the engine, the VCT module adjusted camshaft profiles via an oil pressure-driven helix. At engine speeds from 1000-3700 rpm, the camshaft profile would increase torque, while the camshaft profile beyond 3700 rpm provided greater power.

Engine: 200 kW XR8

Available from March 2001, the XR8 engine produced 200 kW due to the fitment of Ford Motorsport (FMS) 1.6:1 roller rockers (produced by Crane).

Safety equipment and brakes

Safety equipment for the AU.II Falcon Ute was enhanced as front seatbelts with pretensioners and load limiters were made standard across the range.

The AU.II Falcon Ute had 287 mm by 28 mm front brake discs with twin-piston calipers and 287 mm by 16 mm solid rear discs.

ANCAP crash testing

In ANCAP crash testing , the AU.II Falcon Ute received a four star adult occupant protection rating with a score of 25.18. In the offset and side impact tests, there was a moderate risk of serious chest injury for the driver.

Features

Standard features for the AU.II Falcon Ute were extended to include a 100 watt sound system with four speakers and a CD player, speed alert with steering wheel controls, variable intermittent wipers and an overhead sunglasses holder. There were also revised heater/ventilation controls, new cloth interior trim (with full cloth trim seats replacing the vinyl-backed seats of the AU.I Falcon Ute) and a dash-mounted digital clock. The immobiliser was also upgraded to allow entry via the driver’s door only or both doors and included a panic alarm.

The Falcon Ute XR6 and XR8 were further equipped with a six speaker sound system with a six-stack CD player, while the XR8 could be identified by its more aggressive front bumper and grille.

Limited Editions: Pursuit, XL Tradesman, XL Sports Edition and XLS Marlin

The AU.II Falcon Ute range included several limited edition models:

• Released in February 2001, Pursuit editions of the XR6 VCT and XR8 variants featured a more aggressive body kit and polished aluminium sports bar;
• Released in May 2001, the XL Tradesman was fitted with 16-inch alloy wheels and a factory aluminium tray (or $1000 towards a custom tray);
• Released in May 2001, the XL Sports Edition added 16-inch alloy wheels, air conditioning and SE decals; and,
• Also released in May 2001, the XLS Marlin featured a six-stack CD player, polished alloy ‘sports bar’, tonneau cover and ‘Marlin’ decals.

Review: Ford AU.III Falcon Ute (2002)

Overview

Released in February 2002, the AU Series III (AU.III) was a minor update for the Falcon Ute range. As part of the update, the XL variant was fitted with 16-inch one-tonne rated steel wheels, while the XLS was fitted with the more powerful 4.0-litre inline six cylinder engine previously used in the XR6.

Visually, the AU.III Falcon Ute could be identified by its smoked headlight surrounds, darker-tint dot matrix windscreen (for reduced sung glare) contrast colour headlight bezel and clear side indicator lenses. The XL was also fitted with a body-coloured grille, while the XLS added body-coloured mirrors and a chrome exhaust tip.

XR8 Pursuit 250 engine

Compared to the 200 kW 4.9-litre V8 engine, the stroked 5.6-litre Tickford V8 engine had CNC ported and machined GT40-p heads, bigger inlet (11.9 mm) and exhaust (12.0 mm) valves, Yella Terra 1.72:1 roller rockers, an 82 mm throttle body, increased fuel pressure (4.3 bar), three-piece tuned intake manifolds, a Mustang Cobra conical air intake, floating gudgeon lightweight pistons, shotpeened billet connecting rods, an engine oil cooler and a compression ratio of 9.6:1

The engine was available with four-speed BTR M97LE automatic and five-speed Tremec TR3650 manual transmissions (with a heavy duty Valeo clutch).

XR8 Pursuit 250

The newly-introduced XR8 Pursuit 250 featured a 5.6-litre Tickford V8 engine , 18-inch alloy wheels with high performance Dunlop SP9000 tyres, grooved front and rear disc brakes, unique bodykit (including front airdam spoiler, side skirts and rear bumpers), leather seats, and a Momo steering wheel and gearshift.

Limited editions: XL Tradesman, XL Sports Edition, XLS Marlin

The AU.III Falcon Ute range included several limited edition models:

• Released in March 2002, the XL Tradesman cab chassis could be identified by its 16-inchalloy wheels and factory aluminium tray (or $1000 towards a custom tray);
• Released in March 2002, the XL Sports Edition added 16-inch alloy wheels, air conditioning and ‘SE’ decals; and;
• Also released in March 2002, the XLS Marlin was equipped with a six-stack CD player, air conditioning, a polished alloy sports bar, tonneau cover and ‘Marlin’ decals.

Related links

• Wikipedia.org: Ford AU Falcon