Ford Falcon Problems

Have the brake rotors checked; they could be warped. It’s a common problem and they can be machined if they’re not worn out, or replaced if they are too badly worn.

I would suggest that you replace the transmission fluid. That might be enough to fix your problem, but it sounds like the transmission needs a full service.

We understand that the valve body was revised to soften the selection of sixth gear, so that should help, but it could also be that you have a problem with the diff mounting bushes and bolts, and perhaps even the diff itself. These are all problem areas on the Falcon and could be contributing to your problem. But I would expect that if there was a problem with the bushes, bolts or diff that you would also hear or feel it at other times, not just when it's going into sixth gear.

You would have to think there is a problem with the control module, one that’s more widespread than we so far know about. Perhaps other readers could tell us about their experience.

Anyone with a brake shudder they can't cure would be well advised to check the brake master cylinder to see if it is sticking.

Tyres are tricky because they are not normally covered by the warranty. They’re considered as fair wear and tear items. But scrubbing front tyres as you report would appear to be above and beyond “fair” wear and tear and I would certainly have a crack at Ford for compensation. Get as much information as you can from other owners to support your claim.

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.

You've done the logical things in replacing and/or machining the discs, and replaced the wheel bearings. Make sure there are no problems in those areas now. You could also check the brake master cylinder to make sure it is fully retracting when you take your foot off the pedal. Another Falcon owner has told us they found the master cylinder was holding the brakes on slightly and it was causing the discs to warp.

It's very difficult now that Ford has made an assessment and carried out the repairs it considers necessary. I would keep thorough records of the communications you have, or have had, with the dealer and Ford, retain any correspondence you have received from them, and perhaps have it inspected by an acknowledged paint expert like Graeme Cuthbert (0422 444 335). You need to have as much documentation as   possible if it comes to a dispute at a later date.

If it's driving well and the only thing that bothers you is the door rattle I wouldn't be too concerned about checking for anything else. The dealer should check the car over in the service and I would expect him to bring any problems to your attention, but it doesn't sound like it has any issues needing attention other than the door.