Falcon (EA-AU)

1988-2002 / Sedan / Estate / Australia

All Falcon (EA-AU) problems All workshop issues

Critical Engine

TFI Module Failure (EA-ED)

Symptoms

The engine cuts out while driving and won't restart. After cooling for 30-60 minutes, it may restart and run normally for a while before dying again. Sometimes fails permanently.

Cause

The Thick Film Ignition (TFI) module is mounted on the distributor, directly exposed to engine heat. The module's internal solder joints crack from thermal cycling. This is a design flaw, the module should never have been heat-soak mounted. Bosch designed the unit; Ford Australia (via Motorcraft) just relabelled it.

Fix

Replace the TFI module.

Genuine Motorcraft units are the most reliable but increasingly hard to find.

Aftermarket Bosch units are available ($80-150).

Some owners relocate the TFI module away from the engine using an extension harness to reduce heat exposure.

Carry a spare in the glovebox, this is the number one stranding failure on EA-ED Falcons.

Cost mentioned in fix

$80-150

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Other known issues

Common Engine

Hydraulic Lifter Tick (AU especially, all models)

A ticking or tapping noise from the top of the engine, often worst on cold start. May persist for minutes or be constant. The noise comes from the rocker cover area.

Common Engine

Coil Pack Failure (EF-EL)

Misfiring on specific cylinders, rough idle, loss of power. May be intermittent initially, then become constant.

Critical Engine

Crank Angle Sensor Failure (EA-ED)

Engine cranks but won't start, or starts and dies. No spark at all cylinders.

Common Engine

Idle Speed Control (ISC) Valve Issues

Erratic idle speed, high idle (1,500+ rpm), stalling when coming to a stop, or inability to maintain idle.

Common Engine

Rocker Cover Bolt Breakage

A rocker cover bolt snaps during routine maintenance, leaving the threaded portion stuck in the head.

Critical Fuel System

Fuel Pump Failure

Engine cranks but won't start. No fuel pressure at the rail. The fuel pump may be silent (normally an audible whine for 2 seconds when the ignition is turned to ON).

View all 21 Falcon (EA-AU) problems