The Ford Falcon (BA) is a full-sized car produced by Ford Australia from 2002 to 2005. It was the second significantly re-engineered iteration of the sixth generation of this Australian-made model, and also included the Ford Fairmont (BA)Ãthe luxury-oriented version of the Falcon. This platform also formed the basis of the Ford Territory sport utility vehicle. To address the relatively poor reception of the preceding AU series, the BA series was heavily updated for launch in September 2002Ãthe same time as its biggest rival, the Holden Commodore (VY). It featured a substantially revised and more conservative exterior styling, with every panel new except for the carry-over door skins. Interiors, too, were substantially revised, while mechanically, a new independent rear suspension setup was fitted to all sedan derivatives and the engine and transmissions received extensive upgrades. In October 2004, Ford introduced a Mark II update, bringing subtle styling and mechanical changes, and in October 2005, replaced the BA with the BF. In the final months of 2002, the BA model received the influential Wheels Car of the Year award, breaking a 36-year drought.The BA also won four consecutive Australia's Best Cars awards, spanning three years. The model's market share briefly topped that of its chief competitor, the Holden Commodore on two occasions, but have failed to match those of the record-breaking EL Falcon. Powerplants consisted of both straight-sixes and V8s, with the entry-level Barra 182 six-cylinder being a significant improvement over the AU Falcon's six. The base model engine contained substantial mechanical changes such as dual infinitely variable cam timing for a gain of 25 kW (34 hp) of power for a total of 182 kW (244 hp). The Barra 182 can also take advantage of higher octane fuels, where a small increase of torque can be achieved.The 156 kW (209 hp) LPG-only Barra E-Gas engine was offered as an option on lower specification models. A turbocharged variant of the Barra engine was introduced in a new XR6 Turbo model and produced 240 kW (320 hp) of power. A 5.4-litre V8 replaced the Windsor engine of the AU. The new V8 was a modified version of Ford's North American Modular V8 available in two variants: the Barra 220 generating 220 kW (300 hp) and a 260 kW (350 hp) Boss 260. The Boss 260 was known to make significantly more power than its nominal "260" name figure where figures closer to 288wHp or 290 kW (390Hp) at the engine were not unusual and 400 lb-ft. The new engine was smoother, more fuel efficient, and quieter than the engine it replaced. Two transmissions were available for the BAÃa four-speed automatic and a five-speed manual, both floor-mounted. The automatic unit featured Sequential Sports Shift, a first for the Falcon nameplate in Australia. Utility body styles were also available with an optional column-mounted automatic shifter (without Sequential Sports Shift) in lieu of the floor-mounted system also offered. The new Control-Blade independent rear suspension (IRS) fitted to all sedansÃfirst used in development of the Ford Focus and the Jaguar X-Typeà was superior to the optional double wishbone IRS suspension used on AU sedans, and was cheaper. However, it was heavier than the previous live rear axle used for base models, and the change contributed to the base model XT sedan's 130-kilogram (287 lb) weight increase from the previous model. The wagons and utilities retained the leaf spring live axle rear suspension of the AU wagon and utility; consequently, they did not gain as much weight as the sedan. The BA Falcon was also smoother on the road, with increased towing capabilities from previous models. Fuel consumption in the Barra 182 was measured at 12.5 L/100 km (18.8 mpgUS) for city driving and 8.2 L/100 km (29 mpgUS) for highway driving. These numbers were government figures, measured indoors using a dynamometer. Real-world testing has shown that an extra 12% is actually consumed.Falcon XT Marketed largely towards the fleet industry, the entry-level Falcon XT sold in the most numbers.Featuring the base Barra 182 six-cylinder engine, air conditioning, front power windows, and five-speed manual transmission, with the choice of a four-speed automatic, the XT was sold in sedan and station wagon body types. The Barra 220 V8 engine was available as an option. Judges of the Australia's Best Cars awards crowned the XT Best Family Car in 2002, and again in 2004, with the Futura receiving the award in 2003. Futura The semi-luxury Futura variant was heavily based on the XT, and marketed towards families. Futura models gained cruise control, 16-inch alloy wheels, rear power windows and full body-coloured side-view mirrors and side-protection moldings. But, side-impact airbags and power adjustable pedals were only available as options. Falcon XR6 Building on the features of the XT, Ford Australia at one point considered not releasing the sports-oriented Falcon XR6 because of the new XR6 Turbo model. However, Ford overturned this decision before production.A specifically designed body kit distinguished the XR6 from other variants, except for the XR6 Turbo and XR8 which shared the sports bodywork. The naturally aspirated engine was identical to the engine used on the XT and Futura, and the five-speed manual transmission came as standard.The newly introduced Falcon XR6 Turbo (XR6T) received critical acclaim at launch, and the Australia's Best Car's judges even awarded it the Best Sports car under $57,000 in 2002. At heart visually identical to the XR6, the turbocharged derivative gained extra features, with the additional turbocharger boosting the car's total power output to 240 kW (320 hp). The turbocharger is a Garrett GT35/40 unit.Falcon XR8 Being the flagship sports variant, the XR8 credited specially tuned sports suspension, seating trim displaying the "XR" insignia, 17-inch wheels and the new 5.4-litre Boss 260 engine, outputting 30 percent more power than the previous model. Fairmont The Fairmont model opened up the luxury sector for the BA range. Externally, the Fairmont could be distinguished from the other BA models with its 16-inch alloy wheels and grey mesh grille with chrome surround. Some of the standard features included traction control and dual-zone climate control air conditioning, an analogue clock on the top centre console stack, wood grain highlights,and velour upholstery. Automatic headlights, which turn off or on depending on surrounding environmental conditions, were now standard on the Fairmont model.In addition to this, the Fairmont also received illuminated footwells. The basic mechanical setup carried over from the XT, although buyers could opt for the Barra 220 V8 engine. Fairmont Ghia By far the most expensive variant in the BA range, the Fairmont Ghia featured leather upholstery, wood grain highlights, full power options and a unique suspension assembly. The premium sound system, which incorporated a full-colour LCD screen, was standard, and the centre console stack was characterised by an analogue clock. Reverse parking sensors were available for the first time in the BA, standard on the Ghia. The sensors feature an automatic turn-off function for use when towing a boat or trailer for example. Falcon Ute The BA series Falcon utility was introduced in October 2002 in six model guises.XL Cab Chassis XL Wellbody XLS Cab Chassis XLS Wellbody XR6 Wellbody XR6 Turbo These were later joined by two additional models: XR8: reintroduced to the range early in 2003 (last seen in the previous AU III series). RTV: was released in September 2003. The name "RTV" stood for "Rugged Terrain Vehicle" and featured an increased ride height, additional underbody protection, a lockable rear differential, a unique grille, flared guards and 16-inch alloy wheels. Originally dubbed "Hi-Ride" prior to release, in early 2003 Ford Australia held a competition to find a name for this variant, with "RTV" announced as the winning entrant in July.

The accelerator linkage in a Ford Falcon BA Series connects the accelerator pedal to the throttle body, controlling the engine's air intake and, consequently, its power output. Understanding the theory behind the repair helps in diagnosing and fixing faults effectively.

### Theory of the Accelerator Linkage

1. **Function of Accelerator Linkage**: The accelerator linkage translates the mechanical movement of the accelerator pedal into a corresponding movement of the throttle valve in the engine's intake system. When the pedal is depressed, the linkage pulls the throttle open, allowing more air into the engine, which increases power.

2. **Common Issues**: Problems can arise due to wear, misalignment, or failure of components in the linkage system. Symptoms may include unresponsive acceleration, a sticking throttle, or erratic engine performance.

3. **Components**:
- **Pedal Assembly**: The starting point where driver input occurs.
- **Linkage Rods**: Connect the pedal to the throttle body.
- **Throttle Body**: The component that controls airflow into the engine, which the linkage directly affects.

### Steps to Repair and Their Theoretical Basis

1. **Diagnosis**: Start by checking for any visible wear or damage in the linkage system. This includes inspecting the pedal assembly, rods, and throttle body. Understanding how each component interacts helps identify where the fault lies.

2. **Disassembly**: Remove the accelerator pedal assembly and linkage rods. This allows for a thorough inspection and access to replace or repair any damaged parts. Understanding the assembly's layout ensures you can reassemble it correctly.

3. **Component Replacement or Repair**:
- Replace worn bushings or rods that may cause sloppiness in the linkage. This ensures a direct and efficient transfer of pedal movement to the throttle.
- If the throttle body is sticking, clean it to remove carbon buildup. This allows for smooth operation and ensures the throttle responds accurately to pedal input.

4. **Reinstallation**: Once repairs are made, carefully reinstall the components. Proper alignment is crucial; misalignment can lead to improper throttle response or increased wear.

5. **Testing**: After reassembly, test the pedal operation. Ensure that pressing the pedal results in smooth and proportional throttle response. This confirms that the linkage is functioning as intended.

### Conclusion

Repairing the accelerator linkage on a Ford Falcon BA Series addresses issues related to the mechanical connection between the accelerator pedal and the throttle body. By ensuring that the components are in good condition and properly aligned, you restore the precise control needed for optimal engine performance. Understanding the theory behind each step allows for effective troubleshooting and implementation of the repair.
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Pushing the pushrods on a Ford Falcon BA Series involves understanding the engine's valve train and how the pushrods function within it. Here's a concise explanation of the theory and the process:

### Theory:

1. **Engine Configuration**: The Ford Falcon BA Series has an overhead cam (OHC) design, which means the camshaft is located above the valves, operating them via pushrods in a pushrod engine setup.

2. **Pushrod Function**: Pushrods transfer motion from the camshaft to the rocker arms, which in turn open and close the engine's intake and exhaust valves. If pushrods are bent, damaged, or improperly aligned, it can lead to valve timing issues, poor engine performance, or even engine damage.

3. **Common Faults**: Symptoms of faulty pushrods may include abnormal engine noise, misfiring, loss of power, or noticeable performance issues due to improper valve operation.

### Repair Process:

1. **Diagnosis**: Before replacing or adjusting pushrods, diagnose the issue using engine codes, visual inspections, and listening for unusual noises. This helps confirm that the pushrods are indeed the problem.

2. **Disassembly**: Remove necessary components such as the engine cover, intake manifold, and valve covers to access the pushrods and rocker arms.

3. **Inspect Pushrods**: Check for bends, wear, or damage. If any pushrods appear faulty, they must be replaced.

4. **Replace Pushrods**: Remove the damaged pushrods and install new or straightened pushrods. Ensure they are the correct length and fit properly in their respective locations.

5. **Reassembly**: Reinstall the rocker arms and ensure they are properly torqued to specifications. Replace the valve covers and any other removed components.

6. **Adjustment**: If applicable, adjust the valve lash to ensure proper clearance between the pushrods and rocker arms.

7. **Testing**: Start the engine and listen for any abnormal noises. Monitor engine performance to ensure that the repair has resolved the issue.

### Conclusion:

By replacing or adjusting the pushrods, you restore the correct operation of the valve train, ensuring that the valves open and close at the correct times. This, in turn, maximizes engine performance, efficiency, and longevity, effectively fixing the underlying faults caused by the original pushrod issues.
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### Tools Needed:
1. **Alignment Rack** (or alignment machine)
2. **Camber/Caster Gauge** (if manual alignment)
3. **Toe Plates**
4. **Torque Wrench**
5. **Socket Set** (including ratchets and extensions)
6. **Pry Bar** (for leverage)
7. **Level**
8. **Measuring Tape**
9. **Safety Glasses**
10. **Wheel Chocks**
11. **Jack & Jack Stands**

### Safety Precautions:
1. **Wear Safety Glasses** to protect your eyes from debris.
2. **Ensure the Vehicle is Secure** on jack stands before working underneath.
3. **Use Wheel Chocks** to prevent the vehicle from rolling.
4. **Check for Fluid Leaks** before starting work to avoid slips.
5. **Follow Manufacturer Specifications** for torque settings and adjustments.

### Step-by-Step Suspension Alignment:

#### Step 1: Prepare the Vehicle
- **Park on a Level Surface**: Ensure that the vehicle is on a flat surface to get accurate readings.
- **Check Tire Pressure**: Inflate tires to the manufacturer's recommended pressure.

#### Step 2: Inspect Suspension Components
- **Visual Inspection**: Check for worn parts (ball joints, bushings, tie rods).
- **Replace Worn Components**: If any parts are damaged, replace them before alignment.

#### Step 3: Set Up Alignment Equipment
- **Position Alignment Rack**: If using an alignment machine, position it according to the manufacturer's instructions.
- **Attach Sensors**: For a digital machine, attach sensors to each wheel, following the guidelines for your specific machine.

#### Step 4: Measure Initial Angles
- **Take Initial Measurements**: Use the alignment machine or camber/caster gauge to measure the current camber, caster, and toe angles.
- **Record the Values**: Write down the initial measurements for reference.

#### Step 5: Adjust Camber and Caster
- **Adjust Camber**:
- Use the upper strut mounts to adjust camber. Loosen the bolts and manipulate the strut to achieve the desired angle.
- Tighten the bolts to the specified torque.
- **Adjust Caster**:
- If applicable, adjust the caster using the lower control arm adjustment bolts.

#### Step 6: Adjust Toe
- **Toe Adjustment**:
- Measure the distance between the front and back edges of the front tires using toe plates.
- Adjust the tie rods by turning them to achieve the desired toe setting. Ensure both sides are equal.

#### Step 7: Final Measurements
- **Recheck All Angles**: After making adjustments, take a final set of measurements.
- **Ensure Specifications are Met**: Compare values to manufacturer specifications.

#### Step 8: Test Drive the Vehicle
- **Test Drive**: Take the vehicle for a short drive to ensure proper handling and alignment.
- **Recheck Alignment**: After the test drive, check the alignment again to ensure it hasn’t changed.

### Common Pitfalls to Avoid:
- **Not Checking Tire Pressure**: Incorrect tire pressure can skew alignment results.
- **Ignoring Worn Parts**: Always check for wear before aligning; replacing parts post-alignment can lead to incorrect settings.
- **Not Using the Right Torque Settings**: Ensure bolts are torqued to specifications to prevent misalignment.
- **Misinterpretation of Measurements**: Double-check readings for accuracy before making adjustments.

### Replacement Parts:
- **Strut Mounts**: If worn, they should be replaced for proper camber adjustment.
- **Tie Rod Ends**: Replace if there is play, affecting toe settings.
- **Control Arm Bushings**: Worn bushings can lead to misalignment and should be replaced.

By following these steps, you can perform a thorough suspension alignment on a Ford Falcon BA Series effectively.
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