Ford

Falcon BA / BF inspection checklist

2002-2008 · 14 things to check before you buy, taken from this car's known problems.

All engines

mediumSunroof drains blocked

Look for: Sunroof drain tubes block with debris, causing water to leak into headliner and footwells.

If you find it: Clear drain tubes with compressed air or flexible wire. Annual preventive clean.

Any age · ~$0-300

2 of 4 engines

highBTR 4-speed auto (BA only) failure

Look for: 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.

If you find it: 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.

From 100-180k km · ~$2000-4500

4.0L Barra 182/190/195 NA I6

highCoil pack failure

Look for: 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.

If you find it: 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.

From 80-150k km · ~$300-600 (set)

mediumPlenum gasket failure (later miles)

Look for: Intake plenum gaskets shrink causing vacuum leaks — rough idle, lean codes, hesitation.

If you find it: Plenum gasket replacement. Upper intake removal — moderate DIY job.

From 180k+ km · ~$200-400

mediumCooling system plastic failure

Look for: Plastic thermostat housing, radiator end tanks, and overflow bottle become brittle and crack causing sudden coolant loss.

If you find it: Aluminium aftermarket thermostat housing is a permanent fix. Replace radiator if end tanks weeping. Always carry coolant if running an unrebuilt cooling system.

From 120k+ km · ~$200-500

4.0L Barra 240T / 245T turbo I6 (XR6 Turbo / F6)

highBTR 4-speed auto failure (BA Turbo)

Look for: 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.

If you find it: 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.

From 80-150k km · ~$2500-5000

highCoil packs (shared with NA Barra)

Look for: Same coil pack failure pattern as NA Barra but turbo's heat accelerates wear.

If you find it: Replace set, use quality coils, inspect plugs every 40k.

From 80-150k km · ~$300-600

mediumBoost solenoid / wastegate actuator wear

Look for: Original Garrett GT3582R wastegate actuator and solenoid develop boost control issues — boost creep, surging, overboost limp mode.

If you find it: Replacement OEM actuator or aftermarket adjustable. Boost solenoid clean or replace. Many fit a manual boost controller for tuneability.

From 100k+ km · ~$200-500

mediumDiff backlash and crown wheel wear

Look for: M86 rear diff develops backlash and noise under load. Tuned/launched examples worst.

If you find it: Diff rebuild with new bearings and shims. Upgraded M86 LSD available. Some upgrade to a 9-inch for tuned applications.

From 150k+ km · ~$1000-2500

5.4L Boss 220/260 V8 (XR8)

highTiming chain tensioner failure

Look for: Boss V8 has dual timing chains with hydraulic tensioners. Tensioners can fail on high-km neglected examples causing chain skip and bent valves.

If you find it: Full chain kit at major service. Listen for rattle on cold start at pre-purchase. Use quality oil at proper intervals.

From 150-250k km · ~$3000-6000

mediumOil consumption (Mk II onward)

Look for: BA Mk II onwards developed reputation for oil consumption — 1L per 2000-4000km. Less common than the Camry 2AZ-FE issue but still notable.

If you find it: Catch can helps reduce blowby. Check oil weekly on examples with this history.

From 100k+ km · ~$0-100/oil

4.0L E-Gas LPG (dedicated)

mediumLPG converter / regulator wear

Look for: LPG vaporiser/regulator wears causing hesitation and rough running on gas.

If you find it: Vaporiser rebuild or replacement. LPG specialist work.

From 150k+ km · ~$400-900

mediumEx-taxi abuse history

Look for: Many BA/BF E-Gas examples were taxis — chassis flex, suspension wear, interior wear, lots of small things tired.

If you find it: Inspect carefully. Taxi examples often well-maintained mechanically but rough cosmetically. Look for proper service log.

Often 400k+ km · Varies

mediumTank certification (LPG)

Look for: LPG tanks require 10-year recertification or replacement. Some older Falcons have expired tanks.

If you find it: Verify tank stamp date. New tank required if expired — no recertification on older designs.

From 10-year interval · ~$200-500 inspection

10 minor things (low severity)

lowLower control arm bush wear

Look for: Front lower control arm bushes wear causing knocking and vague steering.

If you find it: Bush kit (Whiteline, Pedders, Superpro) replacement. Polyurethane for performance use.

From 120k+ km · ~$300-600

lowRear control arm bush wear

Look for: IRS (Independent Rear Suspension) bushes wear causing rear-end vagueness and clunk.

From 120k+ km · ~$300-600

lowBoot lock actuator failure

Look for: Boot lock motor fails — boot won't release with the button.

If you find it: Aftermarket actuator. Boot trim panel off.

Any age · ~$80-200

lowWindow regulator failure

Look for: Plastic window regulator clips break causing window to drop into door.

If you find it: Replacement regulator. Door card off — DIY-friendly with time.

From 100k+ km · ~$150-300

lowClimate control display dead pixels

Look for: Climate control LCD develops dead pixels.

If you find it: Aftermarket ribbon cable or replacement unit.

Any age · ~$50-200

lowValve cover gasket weep

Look for: Valve cover gasket weeps oil onto exhaust manifold causing burning smell, sometimes contaminating spark plug wells.

If you find it: Replace gasket and spark plug tube seals together. Easy DIY job — 2 hours.

From 120k+ km · ~$80-150 DIY

lowPower steering pump whine and leak

Look for: PS pump bearings whine and high-pressure hose seeps. Fluid darkens.

If you find it: PS pump replacement, hose if leaking. Flush system as preventive maintenance.

From 150k+ km · ~$300-600

lowOil pan gasket leak

Look for: Oil pan gasket weeps oil over time.

If you find it: Replacement gasket. Subframe loosen required — not a quick DIY.

From 150k+ km · ~$300-600

lowCam followers / lifters tick

Look for: Hydraulic lifters tick on cold start, sometimes persistent. More common on neglected oil change schedule.

If you find it: Quality oil at proper intervals. Lifter replacement if persistent (head off job).

From 150k+ km · ~$1500-3000

lowLPG mixer carbon buildup

Look for: Vapor injection means LPG passes through a mixer that carbons up over time.

If you find it: Clean mixer at major LPG service.

From 100k+ km · ~$200-400

From FlamingCars' Ford Falcon guide. It's a checklist of known problems, not a replacement for a professional pre-purchase inspection. Your ticks are kept in this browser only.