Review: FPV BF.I Pursuit (2005-06)

Overview

Released in October 2005, the FPV BF Mk.I (BF.I) Pursuit was a rear-wheel drive, performance utility. Manufactured in Campbellfield, Victoria, the BF Pursuit was powered by a 5.4-litre ‘Boss 290’ V8 petrol engine that was mated to either six-speed manual or automatic transmissions.

Boss 290 engine

Assembled by hand in Campbellfield, the 5.4-litre Boss 290 V8 engine had a cast iron block, cast aluminium cylinder head (shared with the Mustang Cobra R), forged steel crankshaft, cross-bolted main bearing caps, sintered connecting rods, double overhead camshafts (DOHC) per cylinder bank, roller finger followers, four valves per cylinder, an alloy inlet manifold, coil on plug ignition and a compression ratio of 10.5:1.

To comply with Euro III emissions standards and new drive-by noise rules (ADR 83/00), changes for the BF Boss 290 engine – relative to its BA predecessor – included:

• A dual ram-entry airbox (first introduced in the BA F6 Typhoon and BA F6 Tornado ) for more efficient induction;
• Twin knock sensors;
• Camshaft timing improvements for a lower idle speed and better idle stability;
• Repositioning the front oxygen sensor from the manifold to the catalyst downpipe for greater accuracy in measuring the air/fuel ratio; and,
• A new exhaust system which consisted of four-into-one extractors from each cylinder bank joining into twin 2 ¹/₄-inch exhaust with an intermediate silencer box. Exhaust gases would then pass through new tri-flow silencers before exiting via the six-inch twin-outlets which featured a trapezoidal design.

Compared to the Boss 260 V8 engine in the Ford BA Falcon XR8 , the Boss 290 engine had:

• High performance pistons with domed tops, larger internal pillars and a special ring pack. As a result of the higher compression ratio (10.5:1), the Boss 290 engine required 95 RON premium unleaded petrol;
• Re-engineered connecting rods to accommodate the larger gudgeon pin of each piston;
• Specially balanced crankshafts to match the new piston and conrod combination;
• High performance tri-metal main and big-end bearings for extra durability;
• Cobra R inlet and exhaust camshaft profiles (for 13 mm inlet and 12 mm exhaust valve lift);
• Longer valve stems and springs to match the high lift camshafts;
• A modified camshaft cradle for the longer finger followers;
• A high-compression ‘Terminator’ head gasket;
• High-tensile head bolts that were stretched under tension for greater strength; and,
• A unique Boss 290 engine management system.

For the BF range, ‘transient rpm’ limits were introduced which enabled the engine to momentarily exceed the prescribed rev limit of 6000 rpm during upshifting by 250 rpm (i.e. to 6250 rpm). This enabled wide open throttle upshifting of gears to be scheduled at an engine speed closer to the rev limiter than would otherwise be possible.

Transmissions

The BF Pursuit was available with either:

• A six-speed Tremec T56 manual transmission; or,
• Newly-introduced six-speed ZF 6HP26 automatic transmissions. The Pursuit was fitted with the high-performance version of this transmission – which had upgraded clutches with extra plates in the clutch packs – and a torque capacity of 600 Nm.

The close-ratio six-speed Tremec T56 manual transmission had double synchromesh on all forward gears and single synchromesh on reverse, linear bearings in the shift rail, direct linkage shifters, an electronic reverse gear lockout and a final drive ratio of 3.463:1.

The ZF 6HP26 transmission featured adaptive ‘Driver Recognition’ behaviour, including brake support downshifts, gear holding when cornering, gear holding for uphill and downhill driving and gear holding for fast-off throttle driving situations. Furthermore, the ZF 6HP26 transmission had a remote transmission oil cooler (RTOC) – with a three-way coolant thermostat – that was mounted to the engine block. Acting as a heat exchanger, coolant lines (or tubes) passed through the radiator to warm-up the transmission fluid on start-up and provide cooling under high load/high temperature operating conditions.

Development and dimensions

Like the BF Falcon Ute range, changes for the BF Pursuit included:

• The introduction of a two-piece, lofted outer dashboard;
• The addition of bitumastic pads to the body for damping of low- and mid-frequency noises;
• The introduction of an absorptive roof-liner;
• Improved static sealing;
• Body structure improvements through the fitment of a reinforcing box section to the transmission cross member and centre bearing body reinforcement;
• New engine and transmission mounts; and,
• Redesigned exhaust hangers to isolate muffler vibration from the body.

Other developments for the BF range included:

• The introduction of Bosch ABS 8.0 (previously 5.3) which included electronic brake force distribution;
• An upgraded traction control system and the introduction of electronic stability control and cornering brake control;
• A revised pedal map for the electronic throttle control; and,
• A higher-output alternator for improved fuel economy, lower rotational speeds and lower fan speeds.

The BF Pursuit was 5077 mm long, 1870 mm wide, 1515 mm tall and had a 3096 mm long wheelbase; kerb weight was approximately 1780 kg. Compared to the BA Pursuit , the BF Pursuit could be identified by its deeper front bumper and fog lights.

Suspension

The BF Pursuit had double wishbone front suspension and a live rear axle suspended by leaf springs (both with gas-filled dampers and anti-roll bars).

Safety equipment

Standard safety equipment for the FPV BF Pursuit included dual front airbags, ABS, electronic brake force distribution, traction control, front seatbelt pretensioners and driver’s seatbelt load limiter.

Brakes

The FPV BF Pursuit was fitted with a ‘Performance’ braking package which consisted of 355 mm by 32 mm cross-drilled and slotted front brake discs with four-piston Brembo calipers and 328 mm by 26 mm cross-drilled rear discs with single piston calipers.

As an extra-cost option, the Pursuit was available with a ‘Premium’ braking package which had six-piston Brembo front calipers and 328 mm by 26 mm cross-drilled rear discs with single-piston calipers.

Features

Standard features for the FPV BF Pursuit included 19-inch alloy wheels, a 100 watt sound system with six speakers and a six-disc CD player, air conditioning, cruise control, a power adjustable driver’s seat, automatic headlights, front fog lamps, a leather-wrapped steering wheel, remote central locking, power windows and mirrors, a tilt and reach adjustable steering wheel, trip computer, a soft tonneau cover and an immobiliser.

The Pursuit was also fitted with a limited slip rear differential.

Related links

• Specifications: FPV BF.I GT, GT-P and Pursuit (November 2005)

Review: FPV BF.II Pursuit (2006-08)

Overview

Released in October 2006, the BF Mk.II (BF.II) Pursuit introduced minor changes with an FPV performance steering wheel and chrome highlights for the air conditioning vents.

Boss 302 engine – November 2007

In November 2007, the Boss 302 V8 engine was introduced. Compared to the Boss 290 , changes for the Boss 302 engine included:

• New inlet and exhaust camshaft profile to increase inlet valve lift and duration (necessitating new valves and valve springs);
• A higher compression of 10.8:1 (previously 10.5:1);
• Stainless steel fabricated exhaust manifolds;
• High-flow dual exhaust system; and,
• A revised engine calibration.

Related links

• Specifications: FPV BF.II GT, GT-P, Pursuit and Super Pursuit (November 2006)
• Wikipedia.org: FPV BF Range

Review: FPV FG.I Pursuit (2008-10)

Overview

Released in May 2008, the FPV FG Mk.I (FG.I) Pursuit was a rear-wheel drive, performance utility. Manufactured in Campbellfield, Victoria, the FG Pursuit was powered by a 5.4-litre V8 petrol engine that was mated to either a six-speed automatic or manual transmission. The FG.I Pursuit was discontinued in 2010 when the 5.4-litre V8 engine was phased out of production due to Euro IV emissions standards.

5.4-litre Boss 315 V8 engine

The 5.4-litre Boss 315 V8 petrol engine had a cast iron block, cast aluminium cylinder head, forged steel crankshaft, cross-bolted main bearing caps, sintered connecting rods, double overhead camshafts (DOHC) per cylinder bank, roller finger followers, four valves per cylinder, twin knock sensors, coil on plug ignition and a compression ratio of 11.0:1. Compared to the Boss 302 V8 engine , the Boss 315 engine had:

• New camshaft timing and profile for higher lift and extended duration;
• Stronger pistons;
• An increased compression ratio (to 11.0:1, previously 10.5:1);
• A twin-plate throttle body to reduce pressure loss through the induction system;
• A new upper intake manifold plenum chamber for improved air flow;
• A new exhaust manifold;
• A new high flow, ‘straight-through’ twin exhaust system with new stainless steel exhaust manifolds;
• Higher peak engine speed of 6500 rpm (previously 6000 rpm);
• A new windage tray which reduced crankshaft windage losses; and,
• A new oil pan.

Transmissions

The FPV Pursuit was available with six-speed Tremec TR6060 manual or six-speed ZF 6HP26 automatic transmissions.

Replacing the Tremec T56 manual transmission, the Tremec TR6060 had triple synchromesh on first and second gears and double synchromesh on all other gears (including revrese) which reduced gear shift efforts and shift travel. The reduced shift travel also provided increased space for the use of larger, stronger gears for greater durability.

The FPV Pursuit was fitted with the high-performance ZF 6HP26 transmission which was rated for 600 Nm applications and had upgraded clutches with extra plates in the clutch packs. For the FG range, the 6HP26 transmission had a cylinder cut function whereby the fuel injectors would be deactivated during gearshifts to reduce shift times.

Development

Developed in conjunction with the FG Falcon Ute , the FPV Pursuit had:

• A stronger body structure which made increased use of high-strength steels and ultra high-strength Boron steel and included a new front subframe, additional reinforcement inside the front rails, new high strength floor cross members, transmission tunnel reinforcement and a larger, stronger B-pillar;
• New Virtual Pivot Control Link front suspension (described below);
• A forward-mounted, Y-shaped steering rack with variable-ratio steering gear;
• Upgraded static sealing and triple-sealed doors;
• Larger, 81 litre fuel tanks; and,
• A self-adjusting park brake.

Dimensions

Compared to the BF Pursuit , the FG Pursuit was 19 mm longer (at 5096 mm), 63 mm wider (1933 mm), 34 mm lower (1481 mm) and had a 4 mm longer wheelbase (3100 mm); kerb weight was approximately 1790 kg.

Suspension

The FG Pursuit had ‘Virtual Pivot Control Link’ front suspension which consisted of double wishbone front suspension (with two lower ball joints, an upper A-arm and virtual pivot lower control links) and a live rear axle suspended by leaf springs (both with gas-filled dampers and anti-roll bars).

The FG Pursuit’s double wishbone front suspension had two lower ball joints that connected the separate lower arms to the suspension knuckle. These two lower links created a virtual pivot of the lower arm – hence the ‘Virtual Pivot Control Link’ name – and allowed the suspension to behave as though the lower pivot point was at the intersection of the two arms. Due to the use of aluminium and high strength steels, the Virtual Pivot Control Link suspension was 22 kg lighter than that in the BF Pursuit .

At the rear, the Hotchkiss rear suspension consisted of a live rear axle with leaf springs. For the FG utility range, the rear suspension was revised with stiffened three-pin leaf spring shackles.

Safety equipment

Standard safety equipment for the FPV FG Pursuit included dual front airbags, seat-mounted head/thorax-protecting side airbags, ABS, brake assist, electronic brake force distribution, electronic stability control, traction control and front seatbelts with pretensioners and load limiters.

Brakes

The FPV FG Pursuit had 355 mm by 32 mm cross-drilled and ventilated front brake discs with four-piston Brembo calipers and 328 mm by 26 mm cross-drilled and ventilated rear discs with single-piston calipers.

As an extra-cost option, the Pursuit was available with a premium braking package which added six-piston Brembo front calipers.

ANCAP crash testing

In ANCAP crash testing , a similarly equipped FG Falcon Ute – with dual front airbags and seat-mounted head/thorax side airbags – received a five star adult occupant protection rating with a score of 33.58 out of 37. In the offset crash test, there was a slight risk of serious chest injury for the front occupants and a slight risk of serious lower leg injury for the passenger. In the side impact test, there was a slight risk of serious chest injury.

Features

Standard features for the FPV FG Pursuit included 19-inch alloy wheels with 245/35 ZR19 Dunlop Sport Maxx tyres, a four speaker sound system with a six-disc CD player and auxiliary inputs (MP3/iPod), climate control air conditioning, a seven-inch colour display, four-way power adjustable cloth seats, cruise control with speed alert, Bluetooth connectivity, automatic headlights, a leather-wrapped steering wheel, remote central locking, power mirrors and windows, a tilt and reach adjustable steering wheel, 12 volt power outlet, trip computer, a soft tonneau cover and an immobiliser.

Brochure

• Brochure: FPV FG.I GT Series, Pursuit and Super Pursuit (January 2009)

Related links

• Specifications: FPV FG.I Pursuit and Super Pursuit (May 2008)

Review: FPV FG.II Pursuit (2012, 2014)

Overview

In August 2012, the FG.II Pursuit returned for a limited production run of seventy-five (75) R-Spec variants. Despite its name, however, the FG.II Pursuit R-Spec was based on the FG.II GS Ute . Visually, the Pursuit R-Spec could be identified by its five-spoke alloy wheels with ‘Vixen’ accents, GT colour-coded bumper, ‘Vixen’ upper and lower grille surrounds, fog lamp bezels, door mirror caps, decals and black-painted exhaust tips.

5.0-litre Boss 315 V8 engine

Developed in Australia by Prodrive at a cost of $36 million, the 5.0-litre V8 ‘Boss 315’ Miami V8 engine was based on Ford’s naturally aspirated Coyote V8 engine that was introduced in the 2010 Ford Mustang GT. The hand-built ‘Boss 315’ Miami V8 engine had an aluminium block and cylinder head, an HTV 1900 supercharger (developed by Harrop Engineering and using Eaton Twin Vortices Series technology) providing maximum boost pressure of 0.34 bar (4.93 psi), a forged steel crankshaft, powder sintered forged connecting rods, double overhead camshafts, variable intake camshaft timing, roller finger followers, four valves per cylinder, and a compression ratio of 9.25:1. Due to its aluminium construction, the supercharged Miami V8 engine was 47kg lighter than its Boss 315 predecessor.

Transmissions

For the supercharged Boss 315 engine,

• The TR6060 transmission was fitted with a new bell-housing to suit a new twin-plate clutch system (shared with the Mustang GT500) and revised second gear synchros were implemented; and,
• The 6HP26 transmission was upgraded with a new 7-plate clutch pack and 4-planet planetary gearset for improved torque capacity.

Features: Pursuit R-Spec

Compared to the FG.II GS Ute , the R-Spec featured eight-inch wide rear tyres, a premium sound system, ‘Shadow’ leather sports seats and piano black interior finishes.

2014 FPV Pursuit Ute

In June 2014, the Pursuit was released in a limited production run of 120 units. Compared to the FG.II GS Ute , the Pursuit Ute was distinguished by its eight-inch GT wheels with five-spoke alloy wheel design, premium sound system, satellite navigation system, climate control, partial leather seats, ‘Pursuit’ badging and build number badge.

Visual cues for the Pursuit included a GT front bumper, F6 side skirts, GT wheels and a ‘stealth’ stripe design package which, according to Ford, was ‘evocative of the blacked-out headlights from Ford muscle cars of the 70s’. Available in Winter White, Kinetic (blue), Silhouette (black), Octane (orange) and Smoke (dark grey) paint finishes, the Pursuit Ute featured standard matte black stripes for all colours, with a ‘performance white’ option for the Kinetic finish and metallic gold for Silhouette; silver strip options were also available for the Smoke and Silhouette finishes.

Brochures

• Brochure: FPV FG.II GT R-Spec and Pursuit R-Spec (August 2012)
• Brochure: FPV FG.II Pursuit (July 2014)

Related links

• Wikipedia.org: FPV FG Range

Review: FPV BA.I Pursuit (2003-04)

Overview

Released in February 2003, the FPV BA Mk.I (BA.I) Pursuit was a rear-wheel drive, performance utility. Manufactured in Campbellfield, Victoria, the Pursuit was powered by the 5.4-litre Boss 290 V8 petrol engine which was mated to either a four-speed automatic or five-speed manual transmission.

Boss 290 engine

Assembled by hand in Campbellfield, the 5.4-litre Boss 290 V8 engine had a cast iron block, cast aluminium cylinder head (shared with the Mustang Cobra R), forged steel crankshaft, cross-bolted main bearing caps, sintered connecting rods, double overhead camshafts (DOHC) per cylinder bank, roller finger followers, four valves per cylinder, an alloy inlet manifold, coil on plug ignition and a compression ratio of 10.5:1.

Compared to the Boss 260 V8 engine in the Ford BA Falcon XR8 , the Boss 290 engine had:

• High performance pistons with domed tops, larger internal pillars and a special ring pack. As a result of the higher compression ratio (10.5:1), the Boss 290 engine required 95 RON premium unleaded petrol;
• Re-engineered connecting rods to accommodate the larger gudgeon pin of each piston;
• Specially balanced crankshafts to match the new piston and conrod combination;
• High performance tri-metal main and big-end bearings for extra durability;
• Cobra R inlet and exhaust camshaft profiles (for 13 mm inlet and 12 mm exhaust valve lift);
• Longer valve stems and springs to match the high lift camshafts;
• A modified camshaft cradle for the longer finger followers;
• A high-compression ‘Terminator’ head gasket;
• High-tensile head bolts that were stretched under tension for greater strength; and,
• A unique Boss 290 engine management system

Transmissions

The FPV Pursuit was available with either the:

• Four-speed BTR M97-019 automatic transmission which had a special high torque gear set and low-stall speed torque converter. With this transmission, the driver could perform console-mounted sequential shifts with full manual override; or,
• Five-speed Tremec TR3650 manual transmission which, for the Boss 260 and 290 engines, had a unique input shaft, clutch housing, extension housing, shift rail and 31-spline output shaft.

Development and dimensions

The driveline of the BA Pursuit was based on the AU Falcon Ute XR8 Pursuit 250 , but incorporated elements from the BA GT sedan. Specifically,

• Like the BA GT, the Pursuit had a 105 BCD Flex coupling behind the transmission to absorb driveline shocks. However, the BA GT’s centre universal joint was replaced by a plunging CV joint from the XR8 Pursuit 250;
• Compared to the Pursuit 250, the double cardan joint at the differential end of the was replaced by a fixed CV joint and, for greater refinement, the front shaft was lengthened and the rear shaft shortened.

Furthermore, the Pursuit was fitted with a Dana M86 limited slip differential which featured a wet design heavy-duty multi-plate clutch.

The BA Pursuit was 5077 mm long, 1870 mm wide, 1515 mm tall and had a 3096 mm long wheelbase; kerb weight was approximately 1780 kg.

Suspension

The FPV BA Pursuit had double wishbone front suspension and a live rear axle suspended by leaf springs (both with gas-filled dampers and anti-roll bars). Like the Pursuit 250, the BA Pursuit had Delphi dampers front and rear.

Safety equipment

Standard safety equipment for the FPV BA Pursuit included dual front airbags, ABS, electronic brake force distribution, front seatbelts with pretensioners and a load limiting seatbelt for the driver.

Brakes

The FPV BA Pursuit had 325 mm by 32 mm grooved and vented Rossini front brake discs with two-piston C6 calipers and 303 mm by 16 mm grooved rear discs with single piston calipers.

Features

Standard features for the FPV BA Pursuit included 18-inch alloy wheels with 245/40 ZR18 Dunlop SP9000 tyres, a 100 watt sound system with four speakers and a CD player, air conditioning, cruise control, contoured sports seats with suede-feel bolsters, a four-way power adjustable driver’s seat, adjustable front seat lumbar support, remote central locking, power mirrors and windows, a tilt and reach adjustable steering wheel, a trip computer and an immobiliser.

Review: FPV BA.II Pursuit (2004-05)

Overview

Released in October 2004, the BA Mk.II (BA.II) Pursuit introduced a six-speed Tremec T56 manual transmission and revised suspension settings with increased spring rates. Inside, there were ‘Sports Instrument’ gauges on top of the upgraded interior command centre (ICC) with a large TFT colour screen and illuminated window switches.

Tremec T56 manual transmission

The close-ratio six-speed Tremec T56 manual transmission had double synchromesh on all forward gears and single synchromesh on reverse, linear bearings in the shift rail, direct linkage shifters and an electronic reverse gear lockout.

Features

Standard features for the FPV BA.II Pursuit were extended to include a 100 watt sound system with six speakers and a six-disc CD player, dual-zone climate control air conditioning and automatic headlights.

Related links

• Wikipedia.org: FPV BA Range

Recalls: FPV BF Pursuit

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls: FPV BF Pursuit

No recall information is available for the FPV BF Pursuit. To search for recalls of Ford models, please visit Product Safety Recalls Australia: Ford.

Problems and faults: FPV BF Pursuit

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

ZF transmission

The six-speed ZF automatic transmissions used an external heat exchanger to cool the transmission. However, the lines within the heat exchanger could deteriorate over time, allowing coolant and transmission oil to mix. If this occurred, the fluid in the coolant reservoir would appear milky (hence the term ‘milkshake’) and, within the transmission, the friction linings would be pulled from their steel backings and the mechatronic control unit would be damaged. To fix, the transmission would have to be rebuilt and the mechatronic control unit replaced.

To prevent contamination of the transmission fluid with coolant, a common modification was to fit an external air/oil cooler kit to bypass the heat exchanger. In fitting these, however, it was important that the transmission fluid be filled to the correct level as the ZF transmission was sensitive to fluid levels and would enter ‘limp home’ mode if not within tolerances. Another modification was to replace the OEM heat exchanger and hoses/lines to the transmission with a more robust after-market product. Please note, however, that Ford Australia considered any modifications to the heat exchanger to void the warranty.

Engines

• The O-ring seal at the back of the water pump was susceptible to leaking.
• A rattling noise at idle may be due to a loose exhaust heat shield.
• The radiator was susceptible to leaking.
• Low idle, stall or variable idle: for Ford’s BA/BF vehicles, engine speed may drop below the normal idle speed – the engine may then either stall or the ECU may intervene to raise engine speed, causing a variable idle. Ford Australia issued a service bulletin (TSB 20/05) regarding this problem recommending that the throttle body be cleaned and the ECU re-flashed.
• Knocking noises from the engine bay which are loudest near the glovebox may be due to the vacuum hoses vibrating against the body or other components – this can be fixed with a cable-tie.

Rear brake hose service campaign

In May 2007, Ford Australia initiated a ‘service campaign’ to replace the rear brake hoses of 200,000 Ford BA/BF vehicles that were produced from September 2002 to March 2007. In these vehicles, the rear brake hoses were susceptible to excessive wear and could leak. At worst, however, the hoses could rupture. According to Ford, the driver would generally experience reduced braking effectiveness and a warning light would illuminate in the instrument cluster to warn the driver. As part of the service campaign, the brake hoses were replaced during regular servicing performed by Ford dealers.

Brakes

• The ABS light may illuminate intermittently due to problems with the ABS sensors – this may be fixed by cleaning or replacing the sensors.

Handbrake

For Ford BA/BF sedans, the handbrake shoe may not centre correctly when the handbrake is released due to the fixed end not holding the show in position – this may cause a ‘cyclic swish type noise’ from the driver’s side rear wheel when driving. Ford Australia issued a technical service bulletin (TSB 09/06) regarding this problem and developed a kit (BA2 2K068 AKIT) to fix whereby a revised park brake shoe centering spring would be fitted and the contact points lubricated.

Suspension

• Knocking noises from front suspension may be due to worn lower ball joints.
• Clunking noises from the rear of the vehicle – particularly at low speeds – may indicate that the differential bushes require replacement.
• Knocking noises from the rear suspension when driving over bumps may indicate that the upper shock bushes require replacement.

Problems and faults: FPV BF Pursuit

• A malfunctioning body computer may turn on the interior lights and drain the battery; if so, the computer needs to be reset.
• Problems with the door locks are usually due to the actuators failing.
• Low battery voltage can make the gearshift indicators flash and the transmission enter ‘limp home’ mode, requiring the battery to be replaced.
• The combination switch for the headlights may only work in the ‘auto’ position or may stop working due to the wires for the manual and automatic operation snapping.

Recalls: FPV FG Pursuit

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls: FPV FG Pursuit

No recall information is available for the FPV FG Pursuit. To search for recalls of Ford models, please visit Product Safety Recalls Australia: Ford.

Problems and faults: FPV FG Pursuit

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

ZF Transmission

The six-speed ZF automatic transmissions used an external heat exchanger to cool the transmission. However, the lines within the heat exchanger could deteriorate over time, allowing coolant and transmission oil to mix. If this occurred, the fluid in the coolant reservoir would appear milky (hence the term ‘milkshake’) and, within the transmission, the friction linings would be pulled from their steel backings and the mechatronic control unit would be damaged. To fix, the transmission would have to be rebuilt and the mechatronic control unit replaced.

To prevent contamination of the transmission fluid with coolant, a common modification was to fit an external air/oil cooler kit to bypass the heat exchanger. In fitting these, however, it was important that the transmission fluid be filled to the correct level as the ZF transmission was sensitive to fluid levels and would enter ‘limp home’ mode if not within tolerances. Another modification was to replace the OEM heat exchanger and hoses/lines to the transmission with a more robust after-market product. Please note, however, that Ford Australia considered any modifications to the heat exchanger to void the warranty.

Suspension

• Knocking noises from the rear suspension when driving over bumps may indicate that the upper shock bushes require replacement.

Battery voltage

Ford’s FG range introduced a new CAN Bus which can result in error messages and faults (such as the air conditioning not working, see below) if battery voltage drops below 9.6 volts during start up. While the original battery fitted by Ford was rated as 520 CCA, it is recommended that higher rated batteries be fitted.

Air conditioning not working

• The FG Falcon range had a different air conditioning than its BA/BF predecessors and poor performance could be due to a defective HIM module (most common for late 2009 to early 2010 models). For models with climate control, a faulty ambient temperature sensor – positioned on the left wing mirror – could also be the cause. A software upgrade was subsequently introduced which kept the compressor engaged for longer.
• In March 2011, the conditioning system was revised with a new HIM module, evaporator, condensor, compressor and pipework, though it cannot be retrofitted to earlier models.
• If the battery voltage drops below 9.6 volts during start up, the air conditioning compressor won’t operate (such that air conditioning will not work). If the battery has recently been disconnected or gone flat, the air conditioning must be reset by letting the motor idle with the air conditioning switched on for at least a minute.

Miami V8 engine: oil consumption

For Ford’s 5.0-litre supercharged Miami V8 engine, owners are recommended to check the oil level every 1,000 kilometres when running in and every 2,000 kilometres thereafter since the engine does consume some oil when new. In the USA, Ford considers oil consumption for the supercharged V8 engine of one quart per 1000 miles (around 600 ml per 1000 kilometres) to be acceptable.

Recalls: FPV BA Pursuit

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls:

No recall information is available for the FPV BA Pursuit. To search for recalls of Ford models, please visit Product Safety Recalls Australia: Ford.

Problems and faults: FPV BA Pursuit

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

Boss 290 V8 engine: chain tensioners and rattling on start-up

The Boss 290 V8 engine was initially fitted with plastic chain tensioners. Over time, the plastic chain tensioners would wear out and lose tension, causing a rattling noise on start-up (see video below) and oil to drain out. It is understood that metal chain tensioners were introduced late in the production of the FPV BA Mk II.

Boss 290 V8 engine: oil consumption

For the FPV BA.I GT, the Boss 290 V8 engine had excessively hard piston rings which, combined with a ‘light run-in process’, resulted in cylinder bore glazing (whereby the piston rings did not develop effective seals) and high oil consumption which persisted for the life of the engine. In part, however, the high oil consumption was also due to the Boss 290 V8 engine being filled with synthetic engine oil from the factory; for the BA.II GT, the engine was filled with Castrol 15W-40 Protec mineral oil (also marketed as Castrol GTX3).

Engines

• A rattling noise at idle may be due to a loose exhaust heat shield.
• The radiator was susceptible to leaking.
• The O-ring seal at the back of the water pump was susceptible to leaking.
• Low idle, stall or variable idle: for Ford’s BA/BF vehicles, engine speed may drop below the normal idle speed – the engine may then either stall or the ECU may intervene to raise engine speed, causing a variable idle. Ford Australia issued a service bulletin (TSB 20/05) regarding this problem recommending that the throttle body be cleaned and the ECU re-flashed.
• Knocking noises from the engine bay which are loudest near the glovebox may be due to the vacuum hoses vibrating against the body or other components – this can be fixed with a cable-tie.

Transmissions

• Four-speed BTR automatic transmission: the transmission cooler was located in the radiator and the cooling lines were susceptible to failure due to age, wear or corrosion. If this occurred, the fluid in the coolant reservoir would appear milky (hence the term ‘milkshake’) and damage to the transmission would require it to be rebuilt or replaced. To prevent contamination of the transmission fluid with coolant, a common modification was to fit an external air/oil transmission cooling kit which bypassed (and sealed) the cooler in the radiator.
• Difficulty selecting gears may be due to a loose gear selector linkage/mechanism.

Steering shudder

In December 2004, Ford Australia issued a technical service bulletin (TSB 98R/04) for Ford BA vehicles with six-cylinder engines due to fluid pulsations in the power steering system causing the steering wheel to shudder – this generally occurred during low speed manoeuvres like parking. To fix, the power steering system was to be bled; if that did not fix the problem, a new high-pressure power steering hose was to be fitted and the system bled.

Rear brake hose service campaign

In May 2007, Ford Australia initiated a ‘service campaign’ to replace the rear brake hoses of 200,000 Ford BA/BF vehicles that were produced from September 2002 to March 2007. In these vehicles, the rear brake hoses were susceptible to excessive wear and could leak. At worst, however, the hoses could rupture. According to Ford, the driver would generally experience reduced braking effectiveness and a warning light would illuminate in the instrument cluster to warn the driver. As part of the service campaign, the brake hoses were replaced during regular servicing performed by Ford dealers.

Brakes

• The ABS light may illuminate intermittently due to problems with the ABS sensors – this may be fixed by cleaning or replacing the sensors.

Suspension

• Knocking noises from front suspension may be due to worn lower ball joints.
• Clunking noises from the rear of the vehicle – particularly at low speeds – may indicate that the differential bushes require replacement.
• Knocking noises from the rear suspension when driving over bumps may indicate that the upper shock bushes require replacement.

Problems and faults:

• A malfunctioning body computer may turn on the interior lights and drain the battery; if so, the computer needs to be reset.
• Problems with the door locks are usually due to the actuators failing.
• Low battery voltage can make the gearshift indicators flash and the transmission enter ‘limp home’ mode, requiring the battery to be replaced.

Released in October 2005, the FPV BF Mk.I (BF.I) Pursuit was a rear-wheel drive, performance utility. Manufactured in Campbellfield, Victoria, the BF Pursuit was powered by a 5.4-litre ‘Boss 290’ V8 petrol engine that was mated to either six-speed manual or automatic transmissions… Read full FPV BF Pursuit review

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Released in May 2008, the FPV FG Mk.I (FG.I) Pursuit was a rear-wheel drive, performance utility. Manufactured in Campbellfield, Victoria, the FG Pursuit was powered by a 5.4-litre V8 petrol engine that was mated to either a six-speed automatic or manual transmission. The FG.I Pursuit was discontinued in 2010 when the 5.4-litre V8 engine was Phased out of production due to Euro IV emissions standards... Read full FPV FG Pursuit review

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Images: FPV FG.II Pursuit (2012, 2014)

The FPV FG.II Pursuit returned in August 2015 for a limited production run of seventy-five (75) R-Spec variants. Despite its name, however, the FG.II Pursuit R-Spec was based on the FG.II GS Ute. The FPV Pursuit R-Spec could be identified by its five-spoke alloy wheels with ‘Vixen’ accents, GT colour-coded bumper, ‘Vixen’ upper and lower grille surrounds, fog lamp bezels, door mirror caps, decals and black-painted exhaust tips.

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Released in February 2003, the FPV BA Mk.I (BA.I) Pursuit was a rear-wheel drive, performance utility. Manufactured in Campbellfield, Victoria, the Pursuit was powered by the 5.4-litre ‘Boss 290’ V8 petrol engine which was mated to either a four-speed automatic or five-speed manual transmission… Read full FPV BA Pursuit review

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ANCAP: Ford FG.I Falcon Ute crash testing

In ANCAP crash testing, an FG Falcon Ute – with dual front airbags and seat-mounted head/thorax side airbags – received a five star adult occupant protection rating with a score of 33.58 out of 37. For more information about this test, please go to the ANCAP website.