1998-2002 Ford Falcon AU Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Falcon Generation: AU Model Years Covered: 1998-2002 👋 Introduction Market Position Target Audience: Do-it-yourselfers and experienced mechanics Value Proposition: Inexpensive way to keep your vehicle working properly, comprehensive factory service information Competitive Analysis Advantage: Covers every single detail, easy-to-read format with high-quality diagrams, instant download saves time and postage Key Features Content Richness: Detailed exploded pictures and diagrams, step-by-step instructions, troubleshooting charts Ease Of Use: Designed for both novice and professional technicians 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English File Format: PDF Compatibility: All Versions of Windows & Mac Features: Easy-to-read text, top quality diagrams and instructions, step-by-step instructions, exploded pictures and diagrams, searchable text 📖 Manual Coverage Systems Covered Engine: 4.0L OHC 6 cylinder, 4.0L OHC VCT 6 Cylinder, 5.0L V8 Transmission: BTR 93LE Automatic (6 Cylinder), BTR 97LE Automatic (V8), M57 5 Speed Manual Drivetrain: Tailshaft, Universal Joints, Beamaxle Final Drive, IRS Final Drive Suspension Steering: Front Suspension Axle, Rear Suspension (Standard Beamaxle), Rear Suspension (IRS), Steering Brakes: Brake Systems Exhaust: Exhaust System Fuel System: Fuel Tank, EFI Fuel Pump Electrical Systems: Starting System, Charging System, Cooling System, Fuel Ignition Systems, EECV Engine Management Emission Control, Instruments, Switches, Stereo System, Cruise Control, Horn, Body Electrics Module, Smartlock, Smartshield, SatNav, Lights and Lighting System, Electric Wiring, Fuses Body: Body, Windscreen Wipers Washers Comfort Systems: Heating, AC, Automatic Climate Control Procedures Included General Maintenance: Engine tune-up, maintenance, fluid changes, filter replacements Engine Repair: 6 Cylinder Maintenance and Rebuild, V8 Engine Maintenance and Rebuild, complete disassembly procedures Transmission Repair: BTR 93-97LE Automatic Transmission overhaul, M57 5 Speed Transmission overhaul Chassis Repair: Suspension component replacement, steering system repair, brake system service, axle and driveshaft repair Electrical Diagnostics: Troubleshooting, diagnostic charts, wiring diagrams, fuse identification, component testing Bodywork Trim: Body panel repair and replacement, trim component installation, glass service (implied by windscreen wipers/washers) Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and electrical troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Yes (implied by searchable text mention) Printability: Yes (All pages are printable) Digital Delivery: Instant Download Digital Requirements: Adobe PDF Reader & WinZip Print Quality Diagram Quality: Top Quality Diagrams Binding Type Binding: Digital PDF (printable) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine 4.0L Ohc 6 Cylinder: Displacement: 4.0 Liters (3984cc), Configuration: Inline 6-Cylinder, Overhead Cam (OHC), Fuel Delivery: Multi-point Fuel Injection (MPI) 4.0L Ohc Vct 6 Cylinder: Displacement: 4.0 Liters (3984cc), Configuration: Inline 6-Cylinder, Overhead Cam (OHC), Variable Camshaft Timing (VCT), Fuel Delivery: Multi-point Fuel Injection (MPI) 5.0L V8: Displacement: 5.0 Liters (302 cubic inches / 4942cc), Configuration: V8, Overhead Valve (OHV) pushrod, Fuel Delivery: Multi-point Fuel Injection (MPI) Performance 4.0L Ohc 6 Cylinder Hp: Approx. 190-200 hp (depending on specific variant and tune) 4.0L Ohc Vct 6 Cylinder Hp: Approx. 200-210 hp (depending on specific variant and tune) 5.0L V8 Hp: Approx. 200-230 hp (depending on specific variant and tune) Fuel System Ignition System: EEC-IV (EEC-V on later models) engine management system with distributorless ignition system (DIS) on some 6-cylinder models, traditional distributor on V8. 🔧 Transmission Standard 6 Cylinder Transmission: BTR 93LE 4-speed Automatic V8 Transmission: BTR 97LE 4-speed Automatic Optional Manual Transmission: M57 5-speed Manual Features Automatic Transmission Control: Electronically controlled for optimal shift points and fuel economy. 📐 Dimensions Exterior Body Styles: Sedan, Station Wagon, Utility (Ute) Wheelbase: AU Falcon Sedan/Wagon: 2794 mm (110.0 in); AU Falcon Utility: 3030 mm (119.3 in) Weights Curb Weight Range: Approx. 1500 kg - 1800 kg (depending on body style and engine) 🛡️ Safety Features Ratings Ancap Rating: Refer to specific model year and crash test data. Early AU Falcons had mixed safety ratings; significant improvements were made in later revisions. Active Features ABS: Optional on some models, standard on higher trims and later revisions. Passive Features Airbags: Driver's airbag standard, passenger airbag optional on some early models, standard on later/higher trims. Seatbelts: Pre-tensioned front seatbelts. 💡 Technology Features Infotainment Audio System: Factory fitted radios with AM/FM, cassette and/or CD players. Speaker configurations varied by trim level. Driver Assistance Cruise Control: Available as an option on many models, integrated into steering wheel or column stalk. Connectivity Remote Central Locking: Available on higher trims, often integrated with Ford's 'Smartlock' security system. Comfort And Convenience Climate Control: Manual air conditioning and heating standard, with optional automatic climate control on premium models. 🔧 Maintenance Service Intervals Oil Change: Typically every 10,000 - 15,000 km or 12 months, whichever comes first (refer to manual for exact specifications). Coolant Change: Initial change at 2-3 years, then every 2 years or 40,000-50,000 km (refer to manual for specific coolant type). Fluid Specifications Engine Oil: Refer to manual for specific viscosity grades (e.g., 10W-30, 10W-40, 5W-30 for synthetic) and...
Body panel repair and replacement, trim component installation, glass service (implied by windscreen wipers/washers)
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and electrical troubleshooting.
Approx. 190-200 hp (depending on specific variant and tune)
4.0L Ohc Vct 6 Cylinder Hp:
Approx. 200-210 hp (depending on specific variant and tune)
5.0L V8 Hp:
Approx. 200-230 hp (depending on specific variant and tune)
Fuel System
Ignition System:
EEC-IV (EEC-V on later models) engine management system with distributorless ignition system (DIS) on some 6-cylinder models, traditional distributor on V8.
🔧 Transmission
Standard
6 Cylinder Transmission:
BTR 93LE 4-speed Automatic
V8 Transmission:
BTR 97LE 4-speed Automatic
Optional
Manual Transmission:
M57 5-speed Manual
Features
Automatic Transmission Control:
Electronically controlled for optimal shift points and fuel economy.
📐 Dimensions
Exterior
Body Styles:
Sedan, Station Wagon, Utility (Ute)
Wheelbase:
AU Falcon Sedan/Wagon: 2794 mm (110.0 in); AU Falcon Utility: 3030 mm (119.3 in)
Weights
Curb Weight Range:
Approx. 1500 kg - 1800 kg (depending on body style and engine)
🛡️ Safety Features
Ratings
Ancap Rating:
Refer to specific model year and crash test data. Early AU Falcons had mixed safety ratings; significant improvements were made in later revisions.
Active Features
ABS:
Optional on some models, standard on higher trims and later revisions.
Passive Features
Airbags:
Driver's airbag standard, passenger airbag optional on some early models, standard on later/higher trims.
Seatbelts:
Pre-tensioned front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios with AM/FM, cassette and/or CD players. Speaker configurations varied by trim level.
Driver Assistance
Cruise Control:
Available as an option on many models, integrated into steering wheel or column stalk.
Connectivity
Remote Central Locking:
Available on higher trims, often integrated with Ford's 'Smartlock' security system.
Comfort And Convenience
Climate Control:
Manual air conditioning and heating standard, with optional automatic climate control on premium models.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000 - 15,000 km or 12 months, whichever comes first (refer to manual for exact specifications).
Coolant Change:
Initial change at 2-3 years, then every 2 years or 40,000-50,000 km (refer to manual for specific coolant type).
Fluid Specifications
Engine Oil:
Refer to manual for specific viscosity grades (e.g., 10W-30, 10W-40, 5W-30 for synthetic) and API service classifications depending on engine and climate. Typically around 5-7 liters capacity.
Transmission Fluid Auto:
BTR 93LE/97LE: DEXRON III (or equivalent). Capacity: Approx. 7-9 liters for a service fill.
Transmission Fluid Manual:
M57: Refer to manual for specific manual transmission fluid type (e.g., GL-4 gear oil). Capacity: Approx. 2.5 liters.
Coolant:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Ford specified coolant types should be used.
Known Issues
Common Problems:
Early AU models had criticisms regarding interior materials and some suspension/steering component wear. Coil pack failures on 6-cylinder engines, some transmission issues with the BTR units under heavy load or high mileage, and potential for rear main crankshaft seal leaks on V8s.
Routine Checks:
Regular inspection of coolant hoses, drive belts, brake pads and rotors, and exhaust system for leaks or wear.
📚 Vehicle History
Brand Heritage
Ford Australia:
Ford Australia has a long history of designing and manufacturing vehicles for the Australian market, with the Falcon being a flagship model for decades.
Model Evolution
Au Falcon Introduction:
The AU Falcon, launched in 1998, represented a significant departure from its predecessor (EL Falcon) with a completely new body shell and interior design, influenced by Ford's global 'New Edge' design philosophy. It was a bold but initially controversial design.
Au Facelift:
The AU Falcon underwent facelifts during its production run: Series II (2000) and Series III (2002), which addressed design criticisms and introduced mechanical updates.
Production
Manufacturing Location:
Campbellfield, Victoria, Australia
🏆 Awards & Recognition
Recognitions
Australian Design Awards:
While the AU Falcon was initially polarizing, its design was recognized for its ambition and departure from previous models. Specific awards are not widely documented in this context, but it represented a significant styling evolution for Ford Australia.
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