Thinking about buying a used Ford Falcon (1988–2017) in New Zealand? We've documented 30 known faults for this model spanning engine, transmission, cooling, and suspension. Each researched and verified before it's published. The most serious issues here are rated critical. Two are set out in full below — the rest, with the symptoms, repair costs and checks for each, are free with an account.
30
Documented faults
Critical
Most serious
$600–$2,200
Typical repair
6
Systems covered
Known Ford Falcon faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
01Boss 5.4 V8 secondary timing chain stretch and guide failure
CriticalOccasionalEngine $2,500–$8,000 to fix
The 5.4L V8 Barra used in the GT and XR8 models (BF onwards) has a secondary timing chain between the two cam sprockets. These secondary chains and their plastic guides deteriorate over time and mileage. A stretched or broken guide allows the chain to jump, causing timing errors, rough running, and potential valve-to-piston contact on higher-revving examples. Failure often begins with rattling on cold start. Timing chain replacement is labour-intensive on the DOHC V8.
Symptoms to notice
Rattling or clattering noise from engine on cold start
Check engine light with camshaft timing codes
Rough running or hesitation at all engine speeds
Engine misfire that worsens under load
What to check
Listen on cold start for chain rattle from the front and top of the engine. Scan for P0016/P0017 or cam correlation codes. Ask if the car has had any timing work done. High-mileage V8 Falcons should have documented chain inspection.
Where to look: Front of engine – secondary timing chain and upper plastic guides
Ask the seller
“Has the timing chain been replaced or inspected?”
“Has there ever been a rattling noise on cold start?”
“Are there any engine warning lights or fault codes present?”
02Rear Differential Carrier Bushing Wear (IRS)
MinorCommonSuspension $300–$900 to fix
The FG/FGX Falcon's independent rear suspension mounts the differential carrier to the subframe via large rubber bushings that deteriorate with age, heat cycling, and aggressive use. When the bushings degrade, the differential can shift under load, causing clunking on throttle application and lift-off, imprecise rear-end feel, and accelerated halfshaft CV joint wear from the resultant misalignment. Performance-oriented or high-mileage examples are most affected.
Symptoms to notice
Clunk or thud from rear on hard acceleration from rest
Clunk on lift-off or engine braking at low speed
Imprecise or vague rear-end feel during cornering
Vibration through floorpan under load, reducing at cruise
Accelerated CV joint wear or halfshaft vibration from differential misalignment
What to check
Have an assistant apply and release throttle in Drive while you observe differential movement — more than a few millimetres of shift indicates worn mounts. During a test drive, note any clunk or thump from the rear on hard throttle take-up from low speed. If a workshop inspection is possible: With the vehicle on a hoist, visually inspect the large front and rear differential mounting bushings for cracking, tearing, or visible separation of the rubber from the metal sleeve.
Where to look: Rear subframe — differential carrier front and rear mounting bushings
Ask the seller
“Has the rear differential mounting bushings ever been replaced or inspected?”
“Is there any clunking or banging sound from the rear during hard acceleration or when lifting off the throttle?”
“Has the car been used for towing, track days, or performance driving that would accelerate bushing wear?”
TransmissionCritical
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SuspensionCritical
CoolingCritical
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28 more documented faults on the Ford Falcon
Symptoms, what to check, where to look and what to ask the seller — for every fault above. Free with an account, no card needed. One account covers one vehicle, so make it the car you’re actually looking at.
This page covers the model. Enter the plate of the actual car you’re looking at and see its year, engine, safety rating and register flags — free, no account needed.
Like any used car, it depends on the specific example and its service history. Across the 30 documented faults for the Ford Falcon, the recurring problem areas are engine, transmission, and cooling. A Ford Falcon with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.
What are the most common problems with a used Ford Falcon?
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We've catalogued 30 known faults for the Ford Falcon, covering engine, transmission, and cooling. Two are written out in full on this page. The rest — with the symptoms to notice, what to inspect, and typical repair costs for each — are free once you create an account.
How much do repairs cost on a Ford Falcon?
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Most single repairs on the Ford Falcon fall between $600–$2,200 at NZ independent-workshop rates. Some of the 30 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.
Should I get a pre-purchase inspection on a Ford Falcon?
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Yes. A Ford Falcon inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $17.90 far less than the cost of missing one of the faults on this page.