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Top issues
24 known problems · 5 high
high
BTR 4-speed auto (BA only) failure
2 of 4 engines
high
Coil pack failure
4.0L Barra 182/190/195 NA I6
high
BTR 4-speed auto failure (BA Turbo)
4.0L Barra 240T / 245T turbo I6 (XR6 Turbo / F6)
Recalls
1 on recordREC-002473
2002-10-09
Defect: The inner CV joints of the IRS half shafts fitted to certain BA I6 sedan models may have been assembled without a retaining circlip.
Hazard: This may allow the half shaft to move away from the inner CV joint and become disengaged.
Remedy: Contact your nearest Ford dealer for inspection and repair, free of charge.
Affected: 3,224 units
Official notice: www.vehiclerecalls.gov.au · details checked 2026-09-29
Check a specific car by VIN at vehiclerecalls.gov.au.
At this odometer
See which of this car's known problems are due at that mileage, which should already have been dealt with, and what's coming up.
Generations
Best and worst years for the Ford Falcon →
Before: Ford Falcon AU (1998-2002)
After: Ford Falcon FG (2008-2014) →
Price (AUD)
$3k–$18k (Sedan), $4k–$25k (Ute), more for clean XR6 Turbo & V8
Body styles
Sedan, Wagon, Ute (BA / BF / FG Ute)
Drivetrain
RWD
Origin
Australia
Built in
Broadmeadows, Victoria
Overview
The BA Falcon (2002) introduced the now-legendary Barra inline-6 — a DOHC VCT 4.0L petrol that, in turbo form, became the most modifiable engine ever built in Australia. The BA was a substantial overhaul of the AU. BF (2005) brought ZF 6-speed auto on most models plus the powerful XR6 Turbo (245kW). Sold as XT, Futura, Fairmont, Fairmont Ghia, XR6, XR6 Turbo, XR8 trims. The BA/BF is the bargain era — values have been climbing since manufacturing ended but you can still find good examples cheap.
Engines & variants
4.0L Barra 182/190/195 NA I6
Engine
DOHC VCT inline-6 NA
Engine code
Config
I6 NA
Displacement
3984cc
Power
182kW (BA) → 190kW (BA Mk II) → 195kW (BF)
Torque
380Nm @ 2500rpm
Drivetrain
RWD
0–100
~8.0s
Economy
10.5-11.5 L/100km combined
Tow (braked)
2300kg
Tow (unbraked)
750kg
Transmission
5MT, 6MT, 4AT (BTR), 6AT (ZF 6HP26)
Timing chain / belt / gear
Chain-driven, inspect from 200,000km+
Pros
- Barra I6 is one of the toughest engines ever made in Australia
- Chain-driven timing — no belt service
- Massive parts supply via aftermarket and wreckers
- ZF 6-speed (BF Mk II+) is exceptional — silky and durable
- Plenty of space, big boot, family-friendly
- Cheapest entry into a proper RWD Aussie sedan
Cons
- BA 4-speed auto (BTR) is a known weak point
- Thirsty — 13-15L/100km real-world urban
- Interior plastics dated
- Suspension bushes wear fast
- Coil packs failure common (one of THE Falcon issues)
Known problems
high
Coil pack failure
Individual coil-on-plug failures are the most common Falcon I6 fault. Causes misfires, rough idle, check engine light. Symptoms: lumpy idle, hesitation under load, intermittent miss. Worse in damp weather.
Fix: Replace failed coil immediately. Many owners replace the full set proactively. Use quality coils (Bosch, Delphi, Tridon) — avoid eBay generics. Inspect spark plug wells for oil contamination from valve cover seals at the same time.
high
BTR 4-speed auto (BA only) failure
BA 4-speed auto (BTR M97) develops harsh shifts, slipping, then total failure. Most BAs need a rebuild or upgrade by 200k. Heat is the killer — towing or city driving accelerates wear.
Fix: Upgrade to ZF 6-speed conversion if budget allows ($3000+). Otherwise fluid + filter every 60k, external trans cooler mandatory. Pre-purchase, check trans oil for burnt smell.
low
Valve cover gasket weep
Valve cover gasket weeps oil onto exhaust manifold causing burning smell, sometimes contaminating spark plug wells.
Fix: Replace gasket and spark plug tube seals together. Easy DIY job — 2 hours.
medium
Plenum gasket failure (later miles)
Intake plenum gaskets shrink causing vacuum leaks — rough idle, lean codes, hesitation.
Fix: Plenum gasket replacement. Upper intake removal — moderate DIY job.
medium
Cooling system plastic failure
Plastic thermostat housing, radiator end tanks, and overflow bottle become brittle and crack causing sudden coolant loss.
Fix: Aluminium aftermarket thermostat housing is a permanent fix. Replace radiator if end tanks weeping. Always carry coolant if running an unrebuilt cooling system.
low
Power steering pump whine and leak
PS pump bearings whine and high-pressure hose seeps. Fluid darkens.
Fix: PS pump replacement, hose if leaking. Flush system as preventive maintenance.
4.0L Barra 240T / 245T turbo I6 (XR6 Turbo / F6)
Engine
DOHC VCT inline-6 turbo
Engine code
Config
I6 turbo
Displacement
3984cc
Power
240kW (BA) → 245kW (BF)
Torque
450Nm @ 2000-4250rpm
Drivetrain
RWD
0–100
~6.0s (BA) → ~5.8s (BF)
Economy
12.5 L/100km combined (real-world 14-18)
Tow (braked)
2300kg
Tow (unbraked)
750kg
Transmission
6MT, 4AT (BTR), 6AT (ZF 6HP26)
Timing chain / belt / gear
Chain-driven, inspect from 200,000km+
Pros
- Legendary Barra Turbo — 400-500kW achievable on stock internals
- Forged crank, sodium-filled exhaust valves from factory
- Massive aftermarket — ECU tunes, larger turbos, fuel system parts everywhere
- Iconic Aussie performance value — sub-$15k for 245kW
- ZF 6-speed in BF Mk II is one of the best autos ever fitted to an Aussie car
- Genuine cult following
Cons
- BA 4AT cannot handle the torque long-term — many fail by 150k
- Tuned examples hammer the rear diff
- Many have been thrashed or modified poorly
- Heat soak limits sustained performance
- Premium fuel mandatory
Known problems
high
BTR 4-speed auto failure (BA Turbo)
The 4-speed cannot handle 450Nm long-term. Slipping under boost, harsh shifts, total failure. Almost every BA XR6 Turbo on 4AT has been rebuilt or converted by now.
Fix: ZF 6-speed swap ($4000+) is the popular fix. Heavy-duty rebuild with upgraded valve body and clutches another option. Pre-purchase: any sign of harsh shifting = walk away or budget for trans work.
medium
Boost solenoid / wastegate actuator wear
Original Garrett GT3582R wastegate actuator and solenoid develop boost control issues — boost creep, surging, overboost limp mode.
Fix: Replacement OEM actuator or aftermarket adjustable. Boost solenoid clean or replace. Many fit a manual boost controller for tuneability.
medium
Diff backlash and crown wheel wear
M86 rear diff develops backlash and noise under load. Tuned/launched examples worst.
Fix: Diff rebuild with new bearings and shims. Upgraded M86 LSD available. Some upgrade to a 9-inch for tuned applications.
high
Coil packs (shared with NA Barra)
Same coil pack failure pattern as NA Barra but turbo's heat accelerates wear.
Fix: Replace set, use quality coils, inspect plugs every 40k.
low
Oil pan gasket leak
Oil pan gasket weeps oil over time.
Fix: Replacement gasket. Subframe loosen required — not a quick DIY.
5.4L Boss 220/260 V8 (XR8)
Engine
DOHC 32V Modular V8
Engine code
Config
V8 NA
Displacement
5408cc
Power
220kW (BA) → 230kW (BA Mk II) → 260kW (BF)
Torque
470-500Nm
Drivetrain
RWD
0–100
~6.5s
Economy
13.5 L/100km combined (real-world 15-18)
Tow (braked)
2300kg
Tow (unbraked)
750kg
Transmission
6MT (Tremec), 4AT (BTR), 6AT (ZF 6HP26)
Timing chain / belt / gear
Chain-driven, inspect from 200,000km+
Pros
- Australian-developed quad-cam V8 (based on Ford Modular)
- Smooth, characterful sound
- Strong torque across the range
- Cheaper to buy than Holden LS1/LS2 equivalents
- FPV variants based on this engine command big money
Cons
- Thirsty — 15-18L/100km real world
- Complex DOHC layout vs Holden LS pushrod
- Less aftermarket support than LS engines
- Heavy front end affects handling
- Premium fuel preferred
Known problems
high
Timing chain tensioner failure
Boss V8 has dual timing chains with hydraulic tensioners. Tensioners can fail on high-km neglected examples causing chain skip and bent valves.
Fix: Full chain kit at major service. Listen for rattle on cold start at pre-purchase. Use quality oil at proper intervals.
medium
Oil consumption (Mk II onward)
BA Mk II onwards developed reputation for oil consumption — 1L per 2000-4000km. Less common than the Camry 2AZ-FE issue but still notable.
Fix: Catch can helps reduce blowby. Check oil weekly on examples with this history.
high
BTR 4-speed auto failure
Same BTR issues as the Barra — handles V8 torque worse than the 6-speed ZF.
Fix: ZF 6-speed conversion or BTR rebuild. Pre-purchase, harsh shifts = walk away or negotiate hard.
low
Cam followers / lifters tick
Hydraulic lifters tick on cold start, sometimes persistent. More common on neglected oil change schedule.
Fix: Quality oil at proper intervals. Lifter replacement if persistent (head off job).
4.0L E-Gas LPG (dedicated)
Engine
Dedicated LPG inline-6 (vapor injection)
Config
I6 NA
Displacement
3984cc
Power
156kW
Torque
371Nm
Drivetrain
RWD
0–100
~9.5s
Economy
13.5 L/100km LPG
Tow (braked)
2300kg
Tow (unbraked)
750kg
Transmission
5MT, 6MT, 4AT (BTR), 6AT (ZF 6HP26)
Timing chain / belt / gear
Chain-driven, inspect from 200,000km+
Pros
- Dedicated LPG factory tune — far better than aftermarket conversions
- Cheap to run when LPG infrastructure works
- Most were ex-taxi or fleet — well maintained, big km
- Bargain entry to a Falcon — often under $5k
- Same chain-driven Barra reliability
Cons
- LPG infrastructure shrinking — limited in regional NSW
- Lower power than petrol variants
- Reduced boot space due to tank
- Resale lower than petrol equivalents
- Many ex-taxi examples have abuse history
Known problems
medium
LPG converter / regulator wear
LPG vaporiser/regulator wears causing hesitation and rough running on gas.
Fix: Vaporiser rebuild or replacement. LPG specialist work.
low
LPG mixer carbon buildup
Vapor injection means LPG passes through a mixer that carbons up over time.
Fix: Clean mixer at major LPG service.
medium
Ex-taxi abuse history
Many BA/BF E-Gas examples were taxis — chassis flex, suspension wear, interior wear, lots of small things tired.
Fix: Inspect carefully. Taxi examples often well-maintained mechanically but rough cosmetically. Look for proper service log.
medium
Tank certification (LPG)
LPG tanks require 10-year recertification or replacement. Some older Falcons have expired tanks.
Fix: Verify tank stamp date. New tank required if expired — no recertification on older designs.