Ford

Falcon Ute BA-FG inspection checklist

2002-2016 · 13 things to check before you buy, taken from this car's known problems.

All engines

highRear differential / subframe bush failure (ute IRS)

Look for: A signature Falcon ute/wagon fault - the rubber diff and subframe bushes are under-built and fail, giving a heavy 'clunk' or thump under acceleration and braking. The rear subframe usually has to come out to replace them.

If you find it: Replace with upgraded polyurethane or solid bushes; heavily worked utes sometimes get a 9-inch diff conversion.

From 100k+ km · ~$600-2000

highZF / BTR automatic transmission faults

Look for: The 6-speed ZF auto (BF/FG) can suffer from neglected/contaminated fluid and the radiator-mounted trans cooler mixing coolant into the transmission fluid; the older 4-speed BTR autos wear at high km too.

If you find it: Regular ZF fluid/filter service, check for coolant contamination, fit an external trans cooler; rebuild if damaged.

From 120k+ km · ~$1500-4500

mediumSelector / shift cable bush failure

Look for: The automatic gear-selector cable's plastic/rubber end bush cracks and falls apart, leaving the car unable to select gears - can strand the vehicle.

If you find it: Replace the selector cable bush (cheap part); a common roadside failure.

From 100k+ km · ~$50-300

mediumSpare-wheel well, tray and cab-chassis rust

Look for: The spare-wheel well rusts badly with trapped water, and work-hardened utes/cab chassis rust in the tray mounts, tub floor and rear cab seam, especially coastal or beach-used examples.

If you find it: Inspect the spare well, tray floor and cab seam closely; favour dry-climate, well-kept cars; repair/rustproof.

Any (age/coastal/work use) · ~$300-2500

mediumAlternator failure (six-cylinder)

Look for: The six-cylinder alternator sits low under the power-steering pump and is killed by leaking PAS/coolant fluid getting into it, causing charging faults.

If you find it: Replace alternator and fix the leaking hose/pump above it so it doesn't recur.

From 120k+ km · ~$300-700

4.0L Barra Turbo petrol I6 (XR6 Turbo, 240T/245T/270T)

highTurbo oil-feed line starvation / turbo failure

Look for: The factory turbo oil-feed banjo bolt contains a small mesh filter and restrictor that clogs with oil sludge, starving the turbo of oil and destroying it - it can happen even on cars with a good service history.

If you find it: Remove/clean or delete the banjo filter and fit an upgraded oil-feed line; use quality oil and change it on time. Many owners do this preventively.

Any (often 100k-200k km) · ~$1500-3500

highAbused / over-tuned engine wear

Look for: Hard-tuned or launched XR6 Turbos can suffer cracked pistons, spun bearings or stretched chains. The bottom end is strong but not bulletproof against big boost and abuse.

If you find it: Compression/leak-down test pre-purchase, scan for past tunes, prefer a documented stock or conservatively-tuned car.

Varies · ~$5000-12000 (rebuild)

mediumBoost-control solenoid and intercooler piping leaks

Look for: The boost-control solenoid and intercooler hoses/clamps perish, causing boost faults, limp mode or whistling leaks.

If you find it: Replace solenoid and intercooler piping/clamps; upgraded silicone hoses are common.

From 120k+ km · ~$150-600

4.0L Barra NA petrol I6 (182/190/195)

mediumPlastic intake manifold runner / coolant pipe failures

Look for: The Barra uses plastic intake components and a plastic coolant crossover pipe at the rear of the head that get brittle with age and heat, cracking and causing coolant loss or vacuum leaks.

If you find it: Replace with updated parts; the alloy aftermarket coolant pipe is a common preventive fix.

From 150k+ km · ~$200-700

4.0L Barra LPG I6 (E-Gas / EcoLPi)

mediumValve seat / valve recession (LPG running)

Look for: Long-term LPG running with poor valve lubrication can accelerate exhaust valve seat wear and recession, causing tappet noise and lost compression.

If you find it: Confirm valve lube/upper-cylinder additive history; compression test pre-purchase; head recondition if worn.

From 200k+ km · ~$1500-3000

mediumEcoLPi liquid-injection pump and injector faults

Look for: The EcoLPi system's in-tank LPG pump and liquid injectors can fail, causing hard starting, hesitation and fault codes.

If you find it: Diagnose and replace the pump/injectors; specialist LPG workshop.

From 100k+ km · ~$800-2500

5.4L Boss V8 petrol (XR8)

mediumCam phaser rattle and timing-chain wear (3-valve)

Look for: The 3-valve 5.4 (BA/BF) suffers cam phaser rattle on cold start and timing-chain/guide wear, with a distinctive top-end noise.

If you find it: Replace phasers, chains, guides and tensioners; use correct oil and change on time.

From 120k+ km · ~$1500-4000

mediumSpark plug seizing / thread blow-out (3-valve)

Look for: The modular 3-valve head is notorious for spark plugs seizing or stripping the alloy threads on removal, sometimes requiring thread inserts.

If you find it: Careful removal technique, anti-seize, and thread repair (Time-Sert) if damaged.

Any (at plug change) · ~$300-1500

5 minor things (low severity)

lowFront suspension and ball-joint wear

Look for: Front lower control-arm bushes, ball joints and sway-bar links wear with age and load, causing clunks and uneven tyre wear.

If you find it: Standard front-end refresh; do bushes, ball joints and links together.

From 120k+ km · ~$300-900

lowCam cover and rocker cover oil leaks

Look for: The cam/rocker cover gaskets weep oil over time, sometimes onto the exhaust manifold causing a burning smell.

If you find it: Reseal the cam cover; cheap DIY job.

From 120k+ km · ~$150-500

lowIgnition coil and coil-pack misfires

Look for: Coil-on-plug units fail with age causing misfire, rough idle and a check-engine light.

If you find it: Replace coils (often as a set) and spark plugs.

From 100k+ km · ~$200-600 (set)

lowLPG tank certification / lifespan

Look for: Australian LPG tanks have a service life (typically ~10 years from manufacture) after which they must be recertified or replaced.

If you find it: Check the tank date; budget for replacement on older cars.

Any (10-15 year tank life) · ~$800-1800

lowFuel thirst and harder-worked driveline

Look for: Real-world 14-18+ L/100km and extra torque load on the diff/bushes; not a fault but a cost.

If you find it: Accept fuel cost; keep an eye on diff bushes (see shared problems).

Any · Running cost

From FlamingCars' Ford Falcon Ute 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.