Falcon (XK-XP)

1960-1966 / Sedan / Convertible / Estate / Australia

All Falcon (XK-XP) problems All workshop issues

Critical Rust (The Big One)

Sill (Rocker Panel) Rot

Symptoms

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

Cause

The sills are enclosed box sections. Water enters through door drain holes, condenses inside the box, and has nowhere to go. The sills rot from the inside out, so by the time you see exterior evidence, the internal damage is extensive.

Fix

Cut out the damaged sections and weld in new metal.

Reproduction sill sections are available.

This is skilled panel work, not a DIY job for most owners.

Budget $1,500-3,000 per side for a proper repair.

Cost mentioned in fix

Budget $1,500-3,000 per side

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// More Falcon (XK-XP) problems

Other known issues

Critical Rust (The Big One)

Floor Pan Corrosion

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

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