1998-2002 Ford AU Falcon Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Falcon Generation Code: AU Series 1, 2, 3 Model Years Covered: 1998, 1999, 2000, 2001, 2002 👋 Introduction Market Position Target Audience: Owners of 1998-2002 Ford AU Falcon seeking to perform their own maintenance and repairs, or professional workshops requiring factory service information. Competitive Analysis Value Proposition: Provides factory-accurate, comprehensive repair information at a fraction of the cost of official dealership manuals, empowering owners with the knowledge to maintain and repair their vehicles effectively. Key Features Comprehensiveness: Highly detailed, factory-level information with step-by-step instructions and hundreds of illustrations. Usability: Designed for both experienced mechanics and the do-it-yourself enthusiast. Accessibility: Digital PDF format compatible with all PC-based Windows operating systems and Mac, easily printable. 📋 Manual Details Coverage Areas Market Focus: Australia Regions Supported: Primarily Australian market, with technical data applicable to vehicles sold in other RHD markets where the Falcon was offered. Page Count Estimated Pages: Varies by specific edition, but typically extensive, encompassing thousands of pages for full factory documentation. For sales purposes, digital versions are often condensed or specific to repair categories. Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel, ignition, cooling, exhaust, lubrication, emissions control, drivetrain (transmission, driveshaft, differential, axles). Chassis: Suspension (front and rear), steering, brakes (front and rear, ABS), wheels and tires. Electrical: Wiring diagrams, charging system, starting system, lighting, instrumentation, body control modules, audio systems, climate control electronics, power accessories. Body And Trim: Exterior body panels, interior trim, seats, glass, doors, hood, trunk, bumpers, seals. HVAC: Air conditioning system, heater core, blower motor, controls, refrigerant handling. Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, tire rotation, brake pad inspection. Troubleshooting: Diagnostic procedures for engine performance issues, electrical faults, HVAC problems, brake system malfunctions, and transmission operation. Repair And Rebuild: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation, including engine overhauls, transmission rebuilds, brake caliper replacement, and suspension component replacement. Specifications And Data: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic trouble codes (DTCs) and their meaning. Technical Depth Level Of Detail: Factory-level detail, suitable for both DIY enthusiasts and professional mechanics. Includes detailed illustrations, diagrams, and exploded views. Scope: Comprehensive, covering complete disassembly and reassembly of major vehicle systems. 📊 Manual Specifications File Format Format: PDF Searchability: Text-searchable within the PDF document for quick access to specific information. Print Quality Printability: All pages are printable, allowing users to create hard copies of specific sections or the entire manual. Binding Type Binding: Digital (N/A for PDF download) Paper Type Paper Type: Digital (N/A for PDF download) ⚙️ Engine Specifications Primary Engine Engine Family: Ford Barra / Windsor V8 Common Engines Covered: 4.0L I6 (OHC and DOHC variants), 4.9L V8 Windsor, 5.6L V8 Windsor (less common). Performance 4.0L I6 Horsepower: Approx. 175-200 kW (depending on specific engine variant and tune) 4.9L V8 Horsepower: Approx. 200-220 kW (depending on specific engine variant) Fuel System Induction Type: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (RON 91 recommended for standard tune, higher octanes for performance variants) 🔧 Transmission Standard Transmission Options: 4-speed Automatic (BTR DSY/DSG), 5-speed Manual (Getrag). Optional Optional Transmissions: Later AU models and performance variants may have offered different automatic transmission options. Features Automatic Features: Electronically controlled, with torque converter lock-up for improved fuel efficiency. 📐 Dimensions Exterior Body Styles: Sedan, Station Wagon (also referred to as 'Fairmont/Fairlane' variants for luxury trims). Wheelbase: Approx. 2794 mm (Sedan), 2944 mm (Wagon) Weights Kerb Weight: Varies significantly by model and engine, typically ranging from 1500 kg to 1800 kg. 🛡️ Safety Features Ratings Ancap Rating: No official ANCAP rating available for the AU Falcon range. Safety features varied by trim level. Active Features ABS: Anti-lock Braking System (ABS) was optional or standard on higher trim levels and later models. Traction Control: Traction control (TC) was available on select models, particularly those with V8 engines or premium packages. Passive Features Airbags: Driver and front passenger airbags were available, with availability increasing in later AU series. Seatbelts: Three-point seatbelts for all occupants. 💡 Technology Features Infotainment Audio Systems: Factory fitted radio/cassette players, with CD players becoming more common in later models and higher trims. Basic speaker systems. Driver Assistance Cruise Control: Standard on most models, or optional on base trims. Connectivity Auxiliary Input: Not typically equipped with factory auxiliary inputs; aftermarket solutions required for modern device connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 km or 6 months, whichever comes first. Consult manual for specific engine types and driving conditions. Spark Plug Replacement Interval: Varies by spark plug type (copper, platinum, iridium). Intervals typically range from 30,000 km to 100,000 km. Coolant Change Interval: Initial change at 240,000 km...
Owners of 1998-2002 Ford AU Falcon seeking to perform their own maintenance and repairs, or professional workshops requiring factory service information.
Competitive Analysis
Value Proposition:
Provides factory-accurate, comprehensive repair information at a fraction of the cost of official dealership manuals, empowering owners with the knowledge to maintain and repair their vehicles effectively.
Key Features
Comprehensiveness:
Highly detailed, factory-level information with step-by-step instructions and hundreds of illustrations.
Usability:
Designed for both experienced mechanics and the do-it-yourself enthusiast.
Accessibility:
Digital PDF format compatible with all PC-based Windows operating systems and Mac, easily printable.
📋 Manual Details
Coverage Areas
Market Focus:
Australia
Regions Supported:
Primarily Australian market, with technical data applicable to vehicles sold in other RHD markets where the Falcon was offered.
Page Count
Estimated Pages:
Varies by specific edition, but typically extensive, encompassing thousands of pages for full factory documentation. For sales purposes, digital versions are often condensed or specific to repair categories.
Suspension (front and rear), steering, brakes (front and rear, ABS), wheels and tires.
Electrical:
Wiring diagrams, charging system, starting system, lighting, instrumentation, body control modules, audio systems, climate control electronics, power accessories.
Later AU models and performance variants may have offered different automatic transmission options.
Features
Automatic Features:
Electronically controlled, with torque converter lock-up for improved fuel efficiency.
📐 Dimensions
Exterior
Body Styles:
Sedan, Station Wagon (also referred to as 'Fairmont/Fairlane' variants for luxury trims).
Wheelbase:
Approx. 2794 mm (Sedan), 2944 mm (Wagon)
Weights
Kerb Weight:
Varies significantly by model and engine, typically ranging from 1500 kg to 1800 kg.
🛡️ Safety Features
Ratings
Ancap Rating:
No official ANCAP rating available for the AU Falcon range. Safety features varied by trim level.
Active Features
ABS:
Anti-lock Braking System (ABS) was optional or standard on higher trim levels and later models.
Traction Control:
Traction control (TC) was available on select models, particularly those with V8 engines or premium packages.
Passive Features
Airbags:
Driver and front passenger airbags were available, with availability increasing in later AU series.
Seatbelts:
Three-point seatbelts for all occupants.
💡 Technology Features
Infotainment
Audio Systems:
Factory fitted radio/cassette players, with CD players becoming more common in later models and higher trims. Basic speaker systems.
Driver Assistance
Cruise Control:
Standard on most models, or optional on base trims.
Connectivity
Auxiliary Input:
Not typically equipped with factory auxiliary inputs; aftermarket solutions required for modern device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km or 6 months, whichever comes first. Consult manual for specific engine types and driving conditions.
Spark Plug Replacement Interval:
Varies by spark plug type (copper, platinum, iridium). Intervals typically range from 30,000 km to 100,000 km.
Coolant Change Interval:
Initial change at 240,000 km or 5 years, subsequent changes every 120,000 km or 5 years, whichever comes first. Use specified coolant.
Fluid Specifications
Engine Oil:
API SG/SH or ACEA A2/A3 rated. Viscosity: 5W-30, 10W-30, or 10W-40 depending on ambient temperature. Check manual for specific recommendations. Capacity approx. 4.5-5.5 Litres.
Transmission Fluid Auto:
Mercon V or equivalent. Capacity approx. 7.5-9.5 Litres (drain and fill).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90. Capacity approx. 2.0-2.5 Litres.
Brake Fluid:
DOT 3 or DOT 4.
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with demineralised water. Specify Ford-approved coolant for long-life protection.
Known Issues
Lsd Bushings:
wear in the Limited Slip Differential (LSD) bushings can lead to clunking noises and handling issues.
Ignition Coils:
Failure of ignition coils, particularly on the 4.0L inline-six engines, can cause misfires and rough running.
Window Regulators:
Failure of power window regulators and motors is a common electrical/mechanical issue.
Radiator Leaks:
Cracking and leaks from the plastic end tanks of the radiator can occur over time.
Heater Core:
Leaking heater cores can lead to coolant loss and fogging of the interior windshield.
📚 Vehicle History
Brand Heritage
Ford Australia:
Ford Australia has a long and significant history of designing and manufacturing vehicles specifically for the Australian market. The Falcon is a cornerstone of this heritage, evolving through numerous generations.
Model Evolution
Au Falcon Introduction:
The AU Falcon replaced the AU Falcon in September 1998. It represented a significant departure from previous Falcon generations in terms of styling and engineering, featuring a more international 'global' design language.
Au Series Updates:
The AU Falcon underwent several updates: AU Series I (1998-2000), AU Series II (2000-2001), and AU Series III (2001-2002), each introducing styling revisions, feature upgrades, and mechanical improvements.
Production
Manufacturing Location:
Campbellfield, Victoria, Australia
Production Years:
1998-2002
🏆 Awards & Recognition
Recognitions
Market Reception:
The AU Falcon was a sales success in Australia, continuing the Falcon's dominance in the large Australian sedan market, despite initial mixed reviews on its styling.
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