Ford Falcon 2004 Problems

Unfortunately it is a common problem and your experience is in line with that of other Falcon owners. For a time there Ford was replacing diffs on cars that were out of warranty, but that seems to have stopped. If you had a dealer replace the second diff I would suggest you go back to Ford and ask for some compensation.

Have the rotors checked to see how much they have worn. It could be that they only need a skim, but if they are heavily worn they might need replacing.

I ASSUME it's a three-valve V8, and if so it is a common problem. I know one case where the heads had to be removed from the engine so the bits of plug jammed in the threads could be removed safely. It took two weeks and cost a small fortune. It's a problem when the plugs are left unchecked for so long; if they were more regularly removed and cleaned etc, it probably wouldn't happen. I agree it shouldn't happen, and you shouldn't be responsible if the plugs do break. You can fight Ford in the event they do, or maybe you could just leave the plugs alone.

From your description it appears it only happens when the brakes are applied so I'd be looking for a vacuum leak associated with the brakes, such as a split or cracked hose or fitting on the brake booster or manifold.

I agree it's a common problem, one that is expensive to fix because it affects the transmission, but I doubt you'll ever get any compensation. The best way to get satisfaction is to buy another brand
next time.

You certainly won't do it any harm by servicing it more often, if anything you're doing the best thing for it. Extra servicing will help ward off those major problems you're concerned about, but it's impossible to say when you might strike trouble.  The engine is generally robust and not likely to need any major work for some time yet. If it's an auto I would anticipate a rebuild in the next 50,000-100,000 km. Apart from that it's the usual things -- brakes, shocks, suspension bushes.

Front-end vibrations are an annoying part of BA ownership and there are a number of possible causes. Check the wheel bearings to make sure they are adjusted correctly, and make sure the wheel nuts are not over-tightened as that can warp the wheels. Other owners, and brake mechanics, have reported problems with the brake master cylinder/booster holding the brakes on slightly, which can be enough to warp the discs quite quickly.

I'M NOT sure what your experience has been with the Falcon, but before you dump it and spend money on a replacement, I'd try to fix the issues that concern you. The main problem with the Falcon when towing is the automatic transmission. I'd install an external transmission oil cooler, which will ensure the auto doesn't overheat and will remove the chance of having a problem with the factory oil cooler in the radiator.

Thanks for the tip about the brake master cylinder; it's something worth considering by anyone with a vibration they can't fix.

THE radiators have been a problem for some time, and most owners only find out they have a problem when the transmission starts acting up. That's usually too late and they end up having to pay for an expensive transmission rebuild. The problem is with the cooler in the radiator, which fails, letting coolant into the transmission. At least Ford came to the party and helped with the cost of repairs, even though you might have liked more.