Recalls: Ford FG 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 FG Falcon
2007-09 Ford FG Falcon E-Gas: reduced braking assistance
In June 2009, a recall was issued for Ford FG Falcon vehicles fitted with the ‘E-Gas’ dedicated LPG system/engine and manufactured from 16 January 2007 to 22 August 2008 (PRA 2009/10855); in February 2010, however, this recall was extended to vehicles manufactured from 20 October 2008 to 4 September 2009 (PRA 2010/11455). For these vehicles, the brake booster check valve may develop a vacuum leak at the check valve – this could result in reduced power assistance to the vehicle’s brakes.
2011-12 Ford FG Falcon EcoLPi: incorrectly sized tyres
In February 2013, a recall was issued for 372 Ford FG and FG.II Falcon XT EcoLPi vehicles that were available for sale from 13 September 2011 to 10 February 2012. These vehicles were fitted with tyres of the incorrect size, which could adversely affect handling and increase the risk of an accident (PRA 2013/13467).
2011-12 Ford FG Falcon EcoLPi: missing O-ring seal
In March 2014, a recall was issued for Ford FG.II Falcon vehicles which had 4.0-litre ‘EcoLPi’ (LPG fuelled) engines and were manufactured between August 4, 2011, and July 18, 2012. In these vehicles, an O-ring seal located between the Fuel Delivery Module and the wiring connector insert of the LPG tank may be missing. If this occurred, gas may leak from the LPG tank to the atmosphere and pose a potential fire hazard (PRA 2014/14024).
2013-14 Ford FG Falcon: engine may stall and not restart
In February 2015, a recall was issued for Ford FG.II Falcon vehicles that were manufactured from 12 November 2013 to 13 October 2014. In these vehicles, the ignition switch electrical connector could disengage. If this occurred while the vehicle was being driven, the engine would stall, electrical functions would be lost and the vehicle could not be restarted – this posed a potential accident hazard to the driver and other road users (PRA 2015/14560).
Problems and faults: Ford FG 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.
BTR transmission
The four-speed BTR automatic transmission had a heat exchanger (or Remote Transmission Oil Cooler, RTOC) under the inlet manifold. However, the lines within the heat exchanger could deteriorate due to age, wear or corrosion, allowing coolant and transmission oil to mix. 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 cooler kit to bypass the heat exchanger.
5R55N/S transmission
For the pre-July 2010 five-speed 5R55N/S automatic transmission, there have been reports of:
- The bands snapping due to a worn servo bore. The servo bore wears because the servo piston is applied via an oil gallery inside the servo piston shaft and this requires a large area of the bore to be open to allow oil in as the shaft moves; and,
- Overdrive planetary gear set failure due to worn shims which cause the gears to wear into the housing.
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 “ZF 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.
Engine
Belt squeal and rattling noises from the engine bay may be due to a faulty accessory belt tensioner which requires replacement. If the tensioner fails, the accessory belt may snap, causing the power steering, alternator and water pump to stop working.
Brakes
Shuddering from the front wheels – which can be felt through the brake pedal – is indicative of warped brake discs.
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 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.
Problems and faults: Ford FG Falcon
- The heater may stop working due to the mixer shaft or flaps breaking.
- The clear plastic on top of the gearshift knob may turn yellow and fall off.
- There have been reports of warped and ill-fitting gloveboxes.
