Ford

Falcon Ute XD-XF / XG-XH / AU inspection checklist

1979-2002 · 12 things to check before you buy, taken from this car's known problems.

All engines

highBody and chassis rust (especially AU)

Look for: The number-one buying concern across all three eras. Rust attacks door bottoms, cab corners, windscreen and rear-window surrounds, chassis rails, engine-bay seams, tray/tub mounts and panel-van rear quarters. AU clear-coat peeling is also common. Coastal and hard-worked examples can be rusted beyond economic repair.

If you find it: Thorough pre-purchase rust inspection of chassis rails, cab corners and tray mounts; favour dry-state, garaged examples. Treat sound cars with cavity wax.

Any (age) · Varies - often uneconomic

mediumFront suspension and steering wear

Look for: Upper ball joints, front wheel bearings, idler arm and tie-rod ends wear, giving vague, wandering steering and uneven tyre wear. Particularly noted on the AU.

If you find it: Replace ball joints, bearings and steering linkage components; four-wheel alignment.

From 150k+ km · ~$200-800

mediumBTR automatic transmission faults

Look for: The BTR 4-speed auto (XG-XH and AU) can develop shift-solenoid faults and drop into limp mode, especially with neglected fluid; extension-housing bush wear causes a tailshaft clunk.

If you find it: Service the auto on schedule; replace solenoids and extension-housing bush; rebuild if slipping.

From 150k+ km · ~$500-2500

3 of 8 engines

mediumIgnition coil pack / lead misfires

Look for: The coil pack and HT leads degrade, causing misfires, rough idle and a flashing/illuminated engine light, especially when damp.

If you find it: Replace coil pack and quality leads/plugs together. Easy DIY.

From 150k+ km · ~$150-400

2 of 8 engines

mediumValve seat recession on pre-1986 heads (leaded-fuel era)

Look for: 1979-1985 crossflow heads used softer steel valve seats designed for leaded fuel; sustained unleaded use without an additive can recede the exhaust seats, dropping compression and causing rough running.

If you find it: Use a lead-replacement additive, or fit hardened exhaust seats / a post-1986 head during any rebuild.

Any (older heads) · ~$800-1800

mediumOverheating / cooling system age

Look for: The Cleveland needs a healthy cooling system; original radiators, water pumps and timing-cover coolant passages are decades old and a tired system cooks the engine under load.

If you find it: Recore/replace radiator, new water pump and thermostat, fresh coolant; consider an alloy radiator.

Age related · ~$400-1500

mediumHead gasket / cooling o-ring failures

Look for: Water-pump and thermostat-housing o-rings, inlet manifold gaskets and timing-cover seals harden and leak; if cooling is neglected the head gasket can let go.

If you find it: Refresh all coolant o-rings, thermostat housing and water pump proactively; address overheating before it cooks the gasket.

From 150k+ km · ~$500-2000

4.1L 250 crossflow six (carb / EFI)

mediumEFI sensor / wiring faults (EEC-IV 4.1 EFI)

Look for: On the late EFI 4.1, aged sensors, connectors and the ECU loom cause rough idle, stalling and starting issues after decades of heat cycling.

If you find it: Diagnose with EEC-IV codes; refresh sensors, earths and connectors.

Age related · ~$200-700

4.9L / 5.8L Cleveland V8 (XD-XE)

mediumOriginality / rebuild cost

Look for: As a sought-after classic, matching-numbers V8 utes are valuable; a worn engine is expensive to rebuild correctly and non-original swaps hurt value.

If you find it: Verify engine numbers and history pre-purchase; budget for a proper rebuild if tired.

Any · ~$5000-12000 (rebuild)

4.0L SOHC EFI six (XG-XH)

mediumThermostat housing / water pump o-ring leaks

Look for: The 4.0 SOHC uses press-fit o-ring coolant joints at the thermostat housing and water pump that harden and weep with age, risking overheating if ignored.

If you find it: Replace o-rings, thermostat housing and water pump as a set; pressure-test cooling system.

From 150k+ km / age · ~$150-500

4.0L Intech E-Gas dedicated LPG (AU)

mediumLPG converter / mixer wear

Look for: The gas converter (vaporiser) diaphragm and venturi mixer wear with age and high km, causing poor idle, flat-spots and hard hot-starts.

If you find it: Service or rebuild the converter and mixer; replace gas filters and hoses.

From 200k+ km / age · ~$300-900

mediumCooling o-ring / head gasket (shared 4.0)

Look for: Same cooling o-ring weaknesses as the petrol Intech; LPG runs hotter so cooling health is especially important.

If you find it: Refresh coolant o-rings, water pump and thermostat housing; keep cooling system in top order.

From 150k+ km · ~$500-2000

13 minor things (low severity)

lowRear leaf spring sag and worn shackles

Look for: The leaf-sprung live rear axle sags and the shackle bushes wear after years of load-carrying, causing a saggy rear, harsh ride and clunks.

If you find it: Re-arch or replace leaf packs and shackle bushes (Lovells, EFS); add a leaf for load if needed.

Heavy use / age · ~$400-1200

lowFront brake disc warping (XG-XH / AU)

Look for: Front discs are prone to warping (notably AU Series 1), giving a pulsing brake pedal under braking.

If you find it: Machine or replace discs with quality rotors and pads.

Any · ~$250-600

lowAged ancillaries and electrics

Look for: These are old vehicles - expect perished hoses and seals, tired engine mounts, weak window regulators, flaky power windows/central locking and faded interior trim.

If you find it: Budget for a consumables and electrics refresh on purchase; most parts are cheap and plentiful.

Age related · Varies

lowCarburettor and choke wear

Look for: Decades-old carbys suffer worn jets, leaking gaskets, sticking auto-chokes and flat-spots, causing hard starts, hesitation and poor economy.

If you find it: Carby rebuild kit or replacement; many owners refit a manual choke. Cheap DIY work.

Age related · ~$150-500

lowTiming chain rattle at high km

Look for: The single-row timing chain stretches over very high mileage, rattling on start-up and retarding timing.

If you find it: Replace chain and gears (duplex upgrade kits available). Straightforward front-of-engine job.

From 200k+ km · ~$300-700

lowCarburettor wear (carb versions)

Look for: Worn carbys cause flat-spots, hard starts and poor economy; auto-chokes commonly play up.

If you find it: Carby rebuild or swap; many fit a Holley/manual choke. EFI XF examples avoid this entirely.

Age related · ~$150-600

lowCarburettor and ignition wear

Look for: Old four-barrel carbys and points/early electronic ignition drift out of tune, causing flooding, flat-spots and hard starts.

If you find it: Carby rebuild and ignition refresh; electronic distributor conversions are common.

Age related · ~$300-900

lowTiming chain tensioner rattle

Look for: The single-row chain and tensioner wear at very high km, causing a start-up rattle.

If you find it: Replace chain, guides and tensioner during front-cover service.

From 200k+ km · ~$400-900

lowFront main / timing cover oil leaks

Look for: Front crank seal and timing-cover o-rings weep oil with age; power steering pump can also leak onto the alternator.

If you find it: Replace front seal and cover o-rings; reseal/replace power steering pump.

From 150k+ km · ~$200-700

lowVCT phaser cold-start rattle

Look for: The variable cam timing unit can rattle briefly on cold start when oil is old or the engine has been run low on oil.

If you find it: Keep up clean oil with correct grade; replace VCT phaser/cam sprocket if it persists.

From 150k+ km · ~$300-800

lowGas tank certification / age

Look for: LPG tanks have a service life and must be periodically inspected/re-certified; an out-of-date tank fails roadworthy and can't be refilled.

If you find it: Check the tank date and certification; budget for inspection or tank replacement.

Age related · ~$200-600

lowIgnition and EFI sensor faults

Look for: Aged coils, leads and sensors cause misfires and rough running on the high-km Windsor.

If you find it: Refresh ignition components and diagnose EEC-V fault codes.

From 150k+ km · ~$200-700

lowFuel and running cost

Look for: Not a fault, but the V8 ute is meaningfully thirstier; factor higher fuel and tyre costs into ownership.

If you find it: Accept the running cost, or buy the six if economy matters.

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.