Ford Falcon headliner replacement cost will be somewhere between about $300 and $500, depending on a few details. Those prices are based on a modern Falcon, say, a BA Falcon or FG Falcon from this century, after Ford had switched to the one-piece, cardboard-backed headliner. However, the cost could be more if the vehicle is a station wagon or has a sunroof fitted, as both these things alter the amount of material used and the degree of difficulty in removing and refitting the headliner.
Other variables include whether you take the vehicle to a motor trimmer to have the existing headliner recovered, or you call an onsite repairer to remove your old headliner and fit a reconditioned unit in your driveway or car-park at work.
You might be able to find a second-hand replacement headliner at an auto parts recycler, but the danger is that the headliner you buy might also fail in the not-too distant future. That’s because the modern one-piece headliner – including late-model Falcon headlining - is made from a structural backing board with a layer of foam sandwiched between the board and the vinyl or cloth that you see above your head. Over time and with heat, the foam layer breaks down into dusty fragments and the adhesion between the backing board and cloth or vinyl is lost. That’s when the cloth starts to hang down inside the car.
Overall, Falcon roof lining replacement is not a difficult job for an experienced trimmer, but it is a bit fiddly and will take some time. Many owners put up with a saggy headliner, but a fresh roof lining repair will make the car look and feel brand new again.
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