Recalls: Ford AU Falcon
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: Ford AU Falcon
- In April 1999, a recall was issued for Ford AU Falcon models manufactured from 19 March 1999 to 22 March 1999 due to the bolts which secured the upper suspension arm to the upper bushes potentially having been affected by hydrogen embrittlement – this could result in suspension noise and, in extreme cases, the upper arms may separate from the bushes (PRA 1999/3907).
- In June 1999, a recall was issued for Ford AU models manufactured prior to 24 March 1999 due to incorrectly torqued front spindle upper ball joint retaining bolts (PRA 1999/3967).
- In June 1999, a recall was issued for Ford AU models manufactured prior to 15 March 1999 due to the front centre seat belts having a passenger airbag warning label attached to the belt which prevented the belt from being shortened to a length which complied with the Australian Design Rules (PRA 1999/3968).
- In February 2001, a recall was issued for Ford AU Series I and Series II models fitted with six cylinder engines (including LPG engines) and manufactured from 2 October 1999 to 31 January 2001. For these vehicles, the throttle cable grommet was susceptible to failure – if damaged and not replaced, the accelerator may be rendered inoperative, resulting in a sudden loss of power (PRA 2001/4640).
- In August 2001, a recall was issued for Ford AU Series I and Series II models fitted with accessory-fitted heavy duty (1600kg and 1800kg) towbar goosenecks; factory-fitted goosenecks were not affected. The accessory-fitted goosenecks were susceptible to becoming brittle, which may result in the gooseneck fracturing in service and the trailer separating (PRA 2001/4856).
- In April 2002, a recall was issued for AU Series III models fitted with ABS and manufactured on 5 December 2001, 6 December 2001, 13 December 2001 and 14 December 2001. In these vehicles, the ABS modules may lose all brake fluid from the front braking circuit (PRA 2002/5303).
- In June 2004, a recall was issued for Ford AU Series I and Series II models manufactured from 1 June 1998 to 22 May 2001 (inclusive). For these vehicles, inappropriate servicing of the steering rack retaining hardware may affect the integrity of the steering rack mounting stud. Furthermore, over-tightening of the steering rack mounting hardware may degrade the thread-locking compound (PRA 2004/7066).
Problems and faults: Ford AU Falcon
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.
Engines
- Head gasket failures were less common than previous generations, but coolant loss still posed a risk of overheating the engine.
- Belt squeal and rattling noises from the engine bay may be due to a faulty accessory belt tensioner that requires replacement. If the tensioner fails, the accessory belt may snap, causing the power steering, alternator and water pump to stop working.
- A rough idle may be due to a loose inlet manifold which requires tightening or the spark plug leads may need to be replaced.
- AU.II and AU.III models were fitted with aluminium radiator cores with resin header tanks that were susceptible to failure.
- An extremely low oil pressure reading when the engine is hot and idling may actually be due to an electrical earthing problem.
- A ticking noise from behind the left headlight may be due to a failed purge valve solenoid.
- The O-ring seal at the back of the water pump was susceptible to leaking.
- Variable build quality for the V8 engines could result in rattling lifters, dropped valves, bore distortion and oil-burning.
Transmissions
- Oil may leak from the rear transmission seal.
Suspension
- Knocking noises from front suspension may be due to worn lower ball joints.
- Knocking noises from the front of the vehicle, vague steering and squeaking noises when turning are indicative of steering rack failure.
- For models with independent rear suspension, knocking or banging noises from the rear suspension may require the top shock absorbers mounts to be replaced.
Brakes
- Shuddering from the front wheels – which can be felt through the brake pedal – is indicative of warped brake discs.
- The level of power braking assistance may decrease due to the brake booster deteriorating – this was primarily a problem for AU.I models.
Problems and faults: Ford AU Falcon
- For manual models, the firewall and pedal box could crack, enabling water to leak into the driver’s footwell. Reinforced brackets may help prevent further cracking in the firewall.
- The horn may stick when depressed or not sound at all, requiring the horn pad and airbag module (a single unit) to be replaced.
- The six-stack CD changers were susceptible to failure.
- Water could accumulate in the boot gutters, flow over the rubber seals and leak into the boot due to a poor seal between the boot and rubber seals.
- Problems with the door locks are usually due to the actuators failing.Inaccurate fuel gauge readings may require the fuel sender unit to be replaced.
- The front power windows may stop working due to dust within the switch blocking the contact points. Dissembling the switches and cleaning the contacts may fix the problem; alternatively, an aerosol contact cleaner could be sprayed into the switch via a nozzle. However, pressing the window switch up and down thirty-one (31) times may reset the window motor/regulator and restore operation.
- The front power windows may be slow to raise or may do so on an angle due to the glass sticking against the rubber seals – this can be fixed by lubricating the inside of the door frames with silicon spray or graphite powder.
- The fuel gauge may provide inaccurate readings due to faulty fuel senders.
