Ford Falcon: Barra 4.0L Power Steering Rack Leak and Hose Failure

The hydraulic power steering system on the Barra-powered FG/FGX Falcon uses high-pressure hoses that are routed close to the exhaust manifold, causing the outer rubber to harden and crack over time. The steering rack seals also deteriorate, resulting in power steering fluid weeping from the rack ends or returning hose unions. Low fluid from undetected leaks leads to pump cavitation noise and eventually pump failure, significantly increasing repair cost.

• Whining or groaning from the power steering pump at full lock or during slow manoeuvres
• Power steering fluid drops on the ground under the front of the car after parking
• Low or discoloured power steering fluid in the reservoir
• Stiff or inconsistent steering assistance, particularly when cold
• Burning smell from the engine bay as fluid contacts the exhaust

1. 1

   Inspect the power steering fluid reservoir level and condition — burnt or low fluid indicates a leak.

2. 2

   With the car idling, turn lock-to-lock slowly and listen for whining or growling from the pump.

3. 3

   Inspect the underside of the engine bay and front crossmember for red/brown fluid deposits near the rack and hose unions.

4. 4

   Check the high-pressure hose for cracks or swelling, particularly where it passes near the exhaust manifold.

5. 5

   Look for wet patches on the ground beneath the front of the car after it has been parked.

Parts involved: Steering rack.

$350 to $2,200 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

• “Has the power steering fluid level ever dropped or needed topping up, and was the source of any leak investigated?”
• “Has the power steering rack or high-pressure hose been replaced?”
• “Is there any whining noise from the steering when turning at low speed or on full lock?”

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.