Ford Falcon 2004 Problems

There's no reason to believe adding a cooler would increase the performance. I wouldn't bother wasting your money on a test.

Ford's claimed fuel consumption for that model was 11.4 L/100 km overall, which means you should get 550 km or so from a tank of fuel. Regular unleaded was Ford's recommended fuel for your car, that's 91-  octane. They also gave the tick of approval for E10.

You could contact Ford's customer assistance service and ask for their help, but I suspect the only way is the get the serial number from the DVD unit and give that to them as the dealer has suggested.

It could be that the brakes are holding on, which was a known fault of the BA. Check the brake master cylinder and the power booster; it's most likely the booster that's causing the problem.

Check the diff mounting bushes, they are a known problem and   produce a "clunk" noise when the throttle is applied.

It’s a design fault in the BA Falcon that has been well documented and I don’t believe you should have to bear the cost of repairing the transmission. Go back to Ford and again ask that they cover the costs. You could well argue that their product was not fit for the purpose for which they sold it to you. If Ford again shuts the door in your face go to the consumer affairs people in your state and enlist their help.

There have been reports of problems with the brake booster, which can cause the brakes to hold on, but as that’s been replaced without success you need to look elsewhere. I would suggest that you check the brake master cylinder.

The range indicated on the trip computer is calculated based on the actual fuel going through the injectors, so it’s generally quite accurate. It has nothing to do with the float in the tank, that’s connected to the fuel gauge, and isn’t necessarily very accurate.

The BA is well out of warranty, so the issue of being fixed under warranty doesn't come up, and it's doubtful that Ford would have automatically changed the head on the basis of a maybe. The best thing to do now is to repair the head.

The control module is the most likely cause; they are known to be troublesome.