Falcon (XK-XP)

1960-1966 / Sedan / Convertible / Estate / Australia

All Falcon (XK-XP) problems All workshop issues

Critical Rust (The Big One)

Floor Pan Corrosion

Symptoms

Visible rust perforation on the underside of the floor. Soft, spongy metal when prodded. In severe cases, daylight visible through the cabin floor.

Cause

Water enters the cabin through deteriorated door seals, windscreen rubber, and the firewall. Road spray attacks from below. Australian conditions, heat, humidity in the north, salt air on the coast, accelerate the process. Sixty years of moisture exposure is devastating to untreated mild steel.

Fix

Minor surface rust can be treated with rust converter and sealed.

Perforated panels must be cut out and replaced.

Reproduction floor pan sections are available from early Falcon specialists, though supply is inconsistent.

A full floor pan replacement is a major undertaking, budget $2,000-6,000 depending on extent.

Cost mentioned in fix

budget $2,000-6,000

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// More Falcon (XK-XP) problems

Other known issues

Critical Rust (The Big One)

Sill (Rocker Panel) Rot

Bubbling paint along the lower body sides, soft metal when prodded, visible perforation.

Common Rust (The Big One)

Boot Floor and Spare Tyre Well

Rust in the boot floor, water pooling in the spare tyre well, perforation around the tail-light mounting points.

Common Rust (The Big One)

Lower Quarter Panels

Bubbling, blistering, or perforation on the lower rear quarter panels behind the rear wheels.

Critical Engine: 144ci and 170ci Inline-Six

Cooling System Inadequacy

Temperature gauge climbs in slow traffic, on hot days, or when towing. The engine may boil over, pushing coolant out of the overflow.

Critical Engine: 144ci and 170ci Inline-Six

Worn Valve Guides

Blue smoke on startup that clears after a few minutes. Increased oil consumption. In severe cases, blue smoke under all conditions.

Common Engine: 144ci and 170ci Inline-Six

Crankshaft Rear Main Seal Leak

Oil leak from the rear of the engine, dripping onto the bellhousing and gearbox. Oil on the clutch causes slipping (manual cars) or contaminates the torque converter (automatics).

View all 18 Falcon (XK-XP) problems