Ford Problems

You can affix insulation material to the inner wheelhouse arches and floor inside the cabin to dull the sound of the stones.

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.

The original fitment Goodyear tyres are no longer made in Australia, Goodyear is now importing its tyres like all other tyre   companies operating here. Once there was no alternative, but to buy the Goodyear tyre, but there are a now dozen or so brands making   tyres of the right size for the Territory and the best advice is to shop around and take the best deal going. They are all much of a muchness so you can buy on price.

It's likely that the converter has collapsed inside and is partially blocking the exhaust. It's not too common, but it does happen, and not just with Fords. The answer is to fit a new converter.

I agree, high transmission fluid temperatures are the fundamental cause of the problem, and once the transmission fluid is burnt it needs to be replaced. Fitting an external cooler is usually enough to keep the temperatures under control.

Ford used a two-pinion set-up in the Borg Warner diff in the BA/BF Falcon and they regularly break, but there is a solution at hand. Trans-Diff in Melbourne regularly rebuilds Falcon diffs and can rebuild your diff with a four-pinion set-up that won’t give you any further problems.

Yes, you can. You should see improved performance and better fuel economy, hopefully enough to offset the higher price of the petrol.

If you talk to suspension specialists like Pedders they will tell you it's a common problem. The springs Ford used are quite long and they're compressed into a small space so they can distort and foul the strut as yours has done. You can replace them with factory originals from Ford or use aftermarket springs from someone like Pedders. They cost about $190 per set of two springs, or about $390 fitted with a wheel alignment. I don't like your chances of getting new springs out of Ford.

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.