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SPECIAL

Ford Territory

SPECIAL

Ford Territory

Product Details

Staff, Friday October 11, 2002.

Page 1 of 1

In the view of Ford Australia Design Director Simon Butterworth, the BA Falcon Ute boasts an exterior design combining both elegance and power.

"A major contributor to that look is the proportion of the vehicle ? or the relationship of wheels to body, the height from the ground and front and rear overhangs. With Falcon Ute we have achieved an excellent stance and visual road presence.

?In addition, the clean contemporary surface language combined with simple, geometric line work and great attention to detail, gives the ute a solid, premium look of refined power.?

Butterworth said the BA Falcon Ute embodied a strong Ford DNA identity, instantly connecting the car with other Ford products from around the world. He said the BA Falcon Ute offered Australian customers everything they would want from a new design.

?Its clean, elegant look, great proportions, and attention to detail identify it as a product of genuine quality.?

INTERIOR

Customers can look forward to a luxurious environment, with BA Falcon Ute boasting a total redesign of the interior.

The main feature of the dash is a new Interior Command Centre, a prominent centre stack containing a large LCD panel that gives information on air conditioning (where fitted), the audio system, trip computer and time.

Ford Interior Design Manager Marcus Hotblack said the Falcon Ute interior was designed with the driver in mind.

?We wanted to create a cockpit feel, with all the necessary controls falling easily to hand. We angled the centre console towards the driver and moved the gear shifter rearwards, which helps create an intuitive ergonomic feel.

Marcus said a great deal of attention was paid to the tactile impact of controls in the car.

?A lot of work went into the feel of the interior surfaces. Items such as braille controls and rubberised thumbwheels help create a Ute interior quite unlike those of the past.

"We've created a real prestige feel to the interior, while still maintaining the robustness and useability that's been a hallmark of Falcon Ute interiors," Hotblack said.

Lighting the way

The instrument panel and Interior Command Centre lighting uses latest technology LEDs, green for XL and XLS, and blue for XR.

Similarly, the LCD readouts have green illumination on XL and XLS and white for XR.

The Interior Command Centre has a PC-style layout, with drop-down menus and cursors.

?The overall look of the ICC is similar to high range stereo systems, with its brushed aluminium look and high-tech read-outs,? Marcus said.

The instrument cluster has more closely grouped dials that are easier to read in one sweep through the upper arc of the steering wheel.

The large tachometer and speedometer dials are spaced outward, while two smaller stacked centrally positioned circular gauges display water temperature and fuel tank information.

A nice touch

Ford?s designers left nothing to chance with a deliberate and thorough policy of harmonising all switches, buttons and knobs to ensure the interior both looks and feels cohesive.

The attention to detail extends down to the markings on dials as well as the grooves on switchgear.

Circular switchgear features radial grooves, while Braille identifiers on alternate audio switches help the driver or passenger locate a particular button without distraction.

The new-style steering wheel has additional buttons to provide increased auxiliary audio function control. Cruise control, where fitted, is operated entirely via steering wheel mounted buttons.

Braille markings are also embossed on the heating, ventilation and air-conditioning control switches and on the electric window switch control bank on the driver?s door armrest.

The translucent panels surrounding the audio control knobs and the CD entry slot are illuminated in green (XL and XLS), and blue (XR).

A cigarette lighter is now optional: the 12V plug is dedicated to powering mobile phones or other accessories.

The light switch control has been moved from the dash to the end of the indicator stalk, making it easy to locate without having to remove hands from the wheel. The on-off button for the cruise control has been moved onto the steering wheel.

The steering wheel itself has also been redesigned, with a thicker rim and a flat, grained centre housing the dual-inflator airbag.

Also new is the central mounting of the wheel on the steering column, so the wheel doesn't ride up and down as it is turned from lock-to-lock. This also helps reduce rattle and shake vibrations fed through the steering wheel rim.

The dome light cursor switch has been moved to the centre console so the front passenger can reach it, while the hazard warning lamp switch has been moved from the top of the steering column to the left-hand side of the instrument binnacle.

Take your seat

All new designs, luxurious trims and standard power adjustment across the range highlight the dramatic changes to seating in the new Falcon Ute.

BA Falcon Utes will have all-new seats with four-way power adjustment as standard.

The four-way adjuster controls the height and tilt angle of the seat cushion for greater personal comfort.

Comfort behind the wheel was a key priority of the BA development team and the seats have been completely redesigned to deliver for the customer.

Both seats will feature manually adjustable lumbar support and seat back adjustment.

Ford devised the new seats using considerable feedback from customers. There are simple, clean lines and richer fabrics.

Greater cushion height adjustment and increased fore and aft track travel also improves comfort, while attention to detail will improve the backrest recliner mechanism action.

The new seats feature upright, formal architecture, with wide, soft bolsters, guaranteeing better lateral support to hold occupants in place.

Head restraints are bigger and positioned higher up and further forward for greater rear impact safety.

In a first for Australian utes, power adjustable pedals complement the new seats. On automatic models, the optional brake and accelerator pedals can be moved forward and back over a range of 65 mm. In tandem with the electric seat and fully adjustable steering wheel, this makes the optimum driving position easier than ever to find.

BA Falcon Ute buyers will also appreciate changes such as the on-glass antenna, which reduces wind noise and eliminates the possibility of the antenna being damaged in a car wash.

Other changes include windscreen washer nozzles being relocated under the bonnet line, contributing to the clean look of the new Ute and further reducing wind noise.

POWERTRAIN

Customers will enjoy a stunning new range of high-technology six and eight cylinder engines in the new BA Falcon Ute.

Engineering priorities for the entry level Barra 182 in-line six included boosting performance and reducing NVH.

The variable camshaft timing technology has been expanded to add infinitely variable camshaft adjustment within a 60-degree range (previously it was a fixed, two-stage variation). There is a VCT phaser on each of the two camshafts.

The engine, which remains at 4.0-litres capacity, now produces class-leading 182 kW of power and 380 Nm of torque.

Its torque spread is extremely generous across the entire operating range and is lifted to 6000 rpm.

For XR6 models a turbo-charged version ? the Barra 240T ? is available for the first time, producing 240 kW and 450 Nm, assuring XR6 Ute of class dominance.

The four-valve head and dual VCT is a significant upgrade, but there?s more.

The entire engine has been revised, with new combustion chambers and port design, the adoption of coil-on-plug ignition, a single chain drive for the camshafts, electronic ?drive-by-wire? throttle control and a crank-mounted oil pump.

The results are improved power and torque, lower fuel consumption, cleaner emissions and better suppression of noise, vibration and harshness levels.

The engine note has improved, thanks to better top-end smoothness, while inlet and exhaust manifold noise has been reduced.

All petrol engines in the BA family now feature failsafe-cooling protection (previously restricted to I6 engines)

Barra 240T

The XR6 turbocharged and intercooled engine produces a stunning 240 kW.

Tickford's engineers were tasked with the challenge of increasing low speed torque and reducing turbo lag, to provide an exhilarating driving experience.

The result is an engine that provides maximum torque of 450 Nm from 2000 rpm through to 4500 rpm.

The bountiful low-down torque is achieved via a boost pressure of 6 psi.

The turbocharger employed on the Falcon XR6 Turbo engine is the aptly named Garrett GT40, mounted off a cast stainless steel exhaust manifold.

For increased durability the turbo uses engine oil-lubricated and water-cooled bearings and the latest ball bearing technology.

An electronic single by-pass wastegate controls boost pressure accurately and reliably to achieve maximum torque through to 4500 rpm.

The new turbo unit uses an air-to-air intercooler to increase the density of air reaching the inlet manifold.

The intercooler regulates the temperature of the charged air to maintain boost pressure and power and torque outputs, even under extremely high ambient operating temperatures.

Within the engine there are new pistons and piston rings, while the compression ratio is lowered to 8.7:1.

Exhaust valves tolerant of higher temperatures are incorporated and fuel delivery pressure is raised to 4 bar.

New V8 talks the torque

BA Falcon is the first Ute in the world to use the new 5.4-litre 3-valve engine from Ford's Windsor plant in Canada. It boasts VCT variable camshaft timing on the single overhead camshaft per bank as well as three valves per cylinder, electronic throttle control, failsafe cooling system and unique, Australian-designed inlet and exhaust manifolds.

The BA Falcon Ute?s new high-tech 5.4-litre 3-valve Barra 220 V8 engine offers a tower of power with 220 kW and an exceptional 470 Nm of torque between 3250 rpm and 4000 rpm.

The surfeit of torque makes towing a breeze, while the muscular thumping beat of a traditional V8 sound will appeal to enthusiast drivers.

The engine has undergone significant development to make it perfectly suited to Falcon Ute buyers with their appreciation of huge reserves of low down torque.

A fat, flat torque curve means that the engine develops plenty of torque low down and keeps on pulling all the way up the rev band.

The 3-valve system uses two inlet valves and one large circular exhaust valve positioned between the inlet valves.

The use of two intake valves enhances fuel-air mixing prior to combustion. This helps to squeeze all the energy out of each combustion event, improving power delivery and fuel efficiency.

Multiple valves also enhance the engine?s ability to ?breathe? ? that is, to move large volumes of air in and out of the cylinders ? a key to generating maximum power.

Variable Cam Timing (VCT)

Ford?s new three-valve cylinder head uses a single overhead camshaft for each bank of cylinders. The cams press down on roller finger followers to open the intake and exhaust valves that are closed by coil springs.

Conventional camshafts are permanently synchronised with the engine?s crankshaft so that they operate the valves at a specific point in each combustion cycle.

Variable cam timing allows the valves to be operated at different points in the combustion cycle, to provide performance that is precisely tailored to the engine?s specific speed and load at that moment. The timing is set to allow the best overall performance across the engine?s normal operating range.

The result is enhanced efficiency under low-load conditions, such as at idle or highway cruising, and increased power for brisk acceleration or at times of high demand.

Engineers were able to shape a torque curve that is higher at low revs, without sacrificing high-end power. Torque increases at a relatively steady rate throughout the operating range.

TRANSMISSIONS

The new engines are mated to a superb new Sequential Sports Shift transmission available as an option across the range.

The SSS transmission is a key feature of BA Falcon Ute?s switch to a more athletic and agile performance base that will attract sporty, aspirational drivers.

The system offers the choice of three distinct driving styles, the freedom and excitement of sequential manual shifting, a more responsive fully automatic mode with top gear lockout or the more relaxed, intuitive adaptive automatic mode.

The SSS enhances Falcon DNA of spirited driving with refinement, the ability to provide comfortable touring with good city response, as well as total manual control for more demanding roads.

Performance Automatic Mode

When the gearshift lever is moved to the left, the transmission is in Performance Auto Mode. The transmission will automatically select the appropriate gear for spirited driving.

"PEF" will be displayed on the instrument cluster for 5 seconds. This is the recommended mode for towing.

Manual shifting and DPEF

Manual sequential downshifts are achieved by pushing the shifter forward and up-shifts by pulling backward.

Having studied the operating system used by three of the best comparable sequential manual automatic gearboxes, Ford?s engineers adopted a shifting strategy that serves the needs for the sports driver.

In manual mode, the SSS control software won?t change to a higher gear when the revs reach the red line, but will initiate the now more refined electronic rev limiter to advise the driver to make a manual up-shift.

The system does not circumvent driver control if it thinks a higher gear should be selected. However, under certain circumstances, the gearbox will downshift in response to a kick-down style wide-open-throttle movement by the driver.

This may be during a prolonged steady cruise when the driver suddenly wishes to perform an overtaking manoeuvre and depresses the accelerator all the way to the floor. If certain dynamic parameters are met, the gearbox will slot back a gear to provide the required overtaking acceleration.

This feature is locked out above a certain speed to prevent damage to gearbox components. Both gearbox and engine management computers work in tandem to prevent inappropriate gear selection.

The gearbox will also downshift sequentially to first gear if the car cruises to a halt, for instance at an intersection. The system locks into first gear for launch and requires the driver to return to manual changes.

Both Sequential Sports Shift and adaptive shifting contribute to Ford?s efforts to build the new Falcon around the driver.

New levels of refinement and NVH reduction were engineered into the BA program.

During higher speed gear changes, engine torque is electronically reduced (via spark retard) to improve shift feel and quality.

Gearshifts are now activated via cable rather than by rods, for quieter and more reliable performance.

The cable travels through the bulkhead, allowing engineers to seal the previous hole in the transmission tunnel and closing off an NVH path into the cabin.

Customer feedback resulted in engineers slightly increasing the effort rate to move from Park through to Reverse, adding a more positive feel to the detents.

Inside the naturally aspirated I6 gearbox, a new higher contact ratio gear set has been installed for quieter performance, especially at launch. Improvements to the first gear ratio deliver smoother shifting between gears and better fuel consumption due to a higher efficiency transmission internal hydraulic pump.

The gearbox hardware has been updated to the tune of $1 million. This was spent on the new gear sets and revised oil pump and valve bodies, aimed at greater transmission efficiency and refinement.

By redesigning all the gears so more teeth mesh at any one time, the higher frequency of the meshing does not resonate on the gear set casing, a previous source of NVH.

An additional benefit is the eradication of audible gear whine.

DYNAMICS

Falcon BA Ute rear suspension retains the tried and tested live rear axle for its excellent load carrying capacity.

However, all elements of the rear suspension have been retuned to offer improved ride performance, while maintaining established Falcon values including safe, reliable handling, towing capabilities and robustness.

New shock absorbers have been incorporated in the rear. The bigger diameter (36 mm compared to 30 mm on AU) and lower friction shock absorber offers improved ride comfort and greater resistance to overheating.

Dynamics engineers have also included a voided bush, replacing the solid bush used previously, to improve NVH.

Falcon?s renowned steering system has been comprehensively overhauled to provide even greater driver involvement and precision.

The steering wheel has been redesigned and includes new ergonomic audio controls (and cruise control buttons where fitted). The rim diameter is reduced and rim thickness increased compared with the previous model.

The steering column and its mountings have been strengthened to diminish NVH, particularly on rough roads.

Steering offers increased road feel and responsiveness, especially on centre. Steering effort is reduced with a tighter 2.8-turns lock-to-lock.

?Drivers will notice an improved linearity between steering inputs and the car?s response, adding to peace-of-mind motoring,? said Ford Chassis Development Manager Alex de Vlugt.

The steering gear itself has been improved with reduced friction, less compliance and a more direct ratio. Steering and suspension ball joints offer reduced friction, assisting responsiveness and feel.

The BA Falcon Ute is available in three levels of suspension tune ? Standard, Sports and One Tonne.

The XL Styleside Box is available with Standard Suspension that rides on Dunlop 215/60 R16 tyres. The Chassis Cab version features the One Tonne Suspension set-up, featuring heavier leaf springs, a slightly raised ride height and Dunlop 215/60 R16 C (Commercial) tyres. The One Tonne Suspension package is optional on the XL Styleside Box.

The XLS comes standard with the Sports Suspension pack, which rides 20 mm lower than the Standard Suspension and features stiffer front and rear springs and FPV-supplied sports shock absorbers. They ride on lower profile Dunlop 215/55 R16 tyres.

One Tonne Suspension is optional on XLS.

Sports Suspension is the only available set-up on XR6 and XR6 Turbo Utes.

Better brakes

BA Falcon Ute boasts a new generation Australian-designed braking system that offers shorter stopping distances, longer pad life and a firmer pedal feel.

All BA Falcons use a twin-piston aluminium caliper at the front and a single piston aluminium caliper at the rear.

The diameter of the rotors has been increased, with the front ventilated rotor now measuring 298mm x 28mm (previously 287mm x 28mm). At the rear, the solid rotor is now 303mm in diameter and 16mm thick, up from 287mm x 16mm.

Ford Chassis Development Manager Alex de Vlugt said the refinements meant Falcon?s brakes could work harder while maintaining a consistent and secure pedal feel.

?The braking system is well suited to the higher performance now available on all BA Falcon Utes,? he said.

?The brakes are more resistant to heat build-up, which means they are less likely to fade under hard use, including towing,? he said.

With a light but stiff feel to the brake pedal Ford engineers have been able to deliver the best of both worlds.

Electronic Brakeforce Distribution is now fitted on all BA Utes fitted with ABS.

The BA Falcon?s new aluminium caliper is 40 per cent stiffer than the AUII/III unit it replaces.

Much of the increased stiffness is the result of a thicker, stronger bridge that connects the caliper's two clamping arms.

This helps prevent the rotor flexing in heavy-duty operation and provides a firmer, more progressive pedal feel. Stiffer brake hoses also contribute to a firmer brake pedal feel.

The asbestos-free brake pad material has been further refined for improved performance and life.

Computer Aided Engineering helped optimise the new braking system on screen prior to prototypes being tested, saving valuable development time.

Electronic Brakeforce Distribution (EBD)

EBD replaces the fixed front-to-rear proportioning valve in the master cylinder that previously determined the ratio of hydraulic braking effort.

Without a rear brake-proportioning device, under harsh braking the rear wheels could lock up sooner than the front wheels, due to weight transfer.

This has the capacity to send the car into a skid. To prevent this from happening the EBD software will detect the onset of a lock-up by comparing wheel rotation speeds, and gently alter the braking pressure acting on the rear brakes by means of the ABS controller mounted in the engine bay.

The proportion of braking effort delivered to the rear wheels is now infinitely variable and calibrated to suit each individual braking action.

In addition to improving braking performance, it provides more even brake pad wear, prolonging pad life.

The EBD software is integrated into the ABS modulation software.

SAFETY

The new BA Falcon Ute comes packed with a host of active and passive safety upgrades, headed by new dual stage airbags.

The new features are part of Ford?s sophisticated Intelligent Safety System (ISS), a comprehensive occupant restraint system designed to deliver appropriate safety responses to a range of crash situations.

The ISS features an integrated network of early-warning crash severity sensors, monitors and electronic triggers, all linked to ?talk? to each other in the event of crash.

The ISS is backed up by extensive revisions to the Falcon?s body structure, developed during an exhaustive CAE-based test program.

The Falcon Ute benefits from the BA sedan front structure upgrades which have seen foot well intrusion reduced by 45 per cent, A-Pillar movement reduced by 40 per cent, instrument panel movement reduced by 30 per cent, brake pedal intrusion reduced by 55 per cent and steering column intrusion reduced 53 per cent.

A range of active safety features, including seatbelt reminder chimes and steering wheel-mounted audio controls, complements Falcon's world-class passive safety systems.

The BA Falcon builds on the award-winning safety upgrade introduced on the AUII, which included a laminated impact protection panel to enhance lower leg protection, wide ranging structural enhancements, pyrotechnic seat belt buckle pretensioners and new technology seat belt energy management retractors

The AUII safety package won the Gold Award at the Australian Society of Automotive Engineers? 2001 Engineering Excellence Awards.

Intelligent Safety

The BA Falcon Ute will feature a local adaptation of Ford?s Intelligent Safety System, a combination of latest generation safety devices and safety strategies developed in Europe by Ford.

The system combines state-of-the-art restraint systems with intelligent monitoring of crash severity and occupant positioning.

?The Falcon Ute offers a fully-integrated safety system, where monitoring devices, crash sensors and activation triggers are linked electronically to produce an appropriate safety response for each individual accident situation,? Ford?s Environmental and Safety Engineering Manager Bruce Priddle said.

?The safety aids talk to each other, exchanging information about impact severity, positioning of occupants and seat belt usage,? Mr Priddle said.

Dual stage airbags

Dual stage airbags provide tailored protection by pressurising the airbags according to the severity of the crash, the seating position of the driver, passenger (where fitted) and whether seat belts are in use.

The system uses a sophisticated combination of sensors to detect triggering thresholds, allowing the airbag to be inflated in two stages: stage one only for less severe crashes or stages one and two for more severe impacts.

In the case of stage one firing, the second stage is fired milliseconds later as a ?scrapping measure?. This assures rescue crews there is no danger of secondary deployment.

A new early warning crash severity sensor is mounted in the front of the car to provide additional initial crash data to the main severity sensor mounted on the transmission tunnel.

This helps the Advanced Restraints Module (ARM - the ISS?s electronic brain) decide the level of protection required.

Mr Priddle said many real world accidents required only first stage inflation of the airbag, as seat belt wearing rates are about 95 per cent in Australia.

If the crash severity sensor triggers the airbag, the pyrotechnic seat-belt pre-tensioners also deploy. Energy management seat belt retractors also help to control the force on the occupant?s chest.

The pre-tensioners reduce the amount of slack in the belt caused by clothing, thereby enhancing the belt?s effectiveness in a crash.

The pre-tensioners don?t fire unless the seat belts are buckled and the crash is severe enough to trigger airbag deployment.

Falcon?s energy management seat belt retractors control web forces resulting from the passenger lurching forward. The system allows a short length of webbing to spool out under severe deceleration.

Passenger airbags are optional across the BA Falcon Ute range.

Unbuckled driver reminder chimes in

BA Falcon?s new seat belt usage monitor - Belt Minder - provides additional reminders, beyond the mandatory ADR warning requirement, if the driver?s seat belt is not buckled.

Vic Roads statistics show that 20 per cent of people involved in fatal accidents in Victoria were not wearing seat belts.

The Belt Minder concept was initially developed by Ford Motor Company in North America and has been engineered into the BA instrument cluster message centre.

If the driver?s seat belt is not buckled the sensor in the buckle informs the ARM. The ARM provides this information to the instrument cluster, which activates the Belt Minder chime and warning light when the vehicle speed exceeds 5kmh. The chime and warning light repeats every 30 seconds for about five minutes.

?By making the warning speed-dependent, we believe we are offering a more user-friendly system than traditional warning chimes that activate the moment the key is turned,? Mr Priddle said.

Virtual testing

BA Falcon?s body shell has been comprehensively re-engineered using sophisticated computer modeling to provide enhanced crumple zones and a stronger passenger cell.

?CAE technology has moved ahead at an incredible pace in recent years and the correlation between computer simulated data and real world data is exceptional.

?With Falcon, it has given us the confidence to explore safety issues through CAE more thoroughly than ever before. We can dig deeper and optimise structures prior to physical crash testing. Instead of running only a couple of iterations, we can now test literally hundreds of different iterations.

?Ultimately, it means a better car because so much more of the car has been tested before it gets to prototype stage,? he said.

Ford Australia engineers had unlimited access to one of the most potent computer resources in the world.

?Our designers have dedicated access to some of the 20-plus supercomputers at Ford?s Dearborn headquarters, which means we can crunch our safety data on Ford?s Michigan supercomputers overnight. If you tried to run one of our crash models on your average home computer you would need to wait 236 years for the answer,? Mr Priddle said.

PRICING

BA Falcon recommended retail pricing will start at $25,590 for the Falcon Ute XL Chassis Cab manual, with the Styleside Box version costing $26,190.

Sequential Sports Shift automatic transmission is available as a $920 option.

Recommended retail pricing for XLS Chassis Cab starts at $28,580, and $29,380 for the Styleside Box version.

Falcon Ute XR6 recommended retail price is $34,205, while the stunning new Falcon XR6 Turbo, boasting an exhilarating 240 kW turbocharged engine, will retail at $39,675.

For further information contact:
Ford Australia Communications
Phone: 03-9359 8491

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