The all-new FG Falcon builds on Ford's global reputation for vehicle dynamics excellence and reasserts the company's dominance of this important attribute in Australia's large car sector.

Building on Australian-firsts that were introduced with the BA Falcon, BF Falcon and Territory, the FG Falcon provides drivers with precision, agility, certainty and confidence in every aspect of their vehicle's handling performance.

"The 2008 Falcon rightly takes its place on the global list of Ford vehicles that achieve excellence in vehicle dynamics," said Ford Australia Vice President of Product Development Trevor Worthington.

"Mondeo, Focus, Fiesta, Territory and Falcon all have deserved reputations for providing drivers with fun-to-drive vehicles that deliver exactly what they expect at all times, and the new Falcon takes the best of all that's come before it and improves it even further."

Major dynamics enhancements for the FG Falcon include:

• An all-new lightweight Virtual Pivot Control Link front suspension;
• All-new forward mounted steering gear with variable ratio and Y-shaped rack;
• Significant modifications to the Control Blade Independent Rear Suspension across all sedans;
• Monotube shock absorbers across all sedans and most Ute variants;
• Specifically developed tyres with appropriate suspension tunes for each model in the range;
• A retuned Dynamic Stability Control system for all petrol sedans and expanded availability of Traction Control on Utes; and
• The first Australian-manufactured application of a self adjusting park brake.

Importantly, all these elements work together to provide a seamless dynamics experience for both driver and passengers. Vehicle Dynamics Manager Alex de Vlugt stressed the importance of a systems engineering approach to each individual element so that the overall package delivers the ultimate driving car.

"Each individual element has been precisely engineered to ensure an optimum result," he said.

"Those results are then combined and engineered from a total vehicle perspective to ensure that the front and rear suspension work in harmony with the monotube shock absorbers and tyres. No part of the car works in isolation. "This approach is ultimately responsible for developing a vehicle that delivers on Ford's global vehicle dynamics DNA of being precise and agile, without being nervous. The steering has a level of control and responsiveness that also enhances the perception of the new Falcon being a fun-to-drive vehicle, while also inspiring confidence."

Virtual Pivot Control Link front suspension

The all-new Virtual Pivot Control Link front suspension is a key component of the Falcon chassis system and introduces a set-up similar to that which has already proved so effective and popular on the Ford Territory.

The width of both the front and rear suspension tracks has been increased, along with a corresponding increase in wheelbase, for improved stability.

Although similar to the Territory front suspension, the springs, dampers, anti-roll bars, suspension bushes and suspension geometry have all been optimised for Falcon to deliver the perfect balance of ride, handling and steering best suited to a sedan on Australian roads.

Incorporating a highly sophisticated double wishbone design with two lower ball joints that is usually seen on far more expensive vehicles, the new front suspension provides a weight saving of 22 kilograms over the BF Falcon through the use of aluminium and high strength steel.

It also provides for reduced King Pin offset packaging and allows the introduction of a forward mounted steering rack.

In comparison to other locally-built rear-wheel-drive sedans that use a virtual pivot control link with a McPherson strut, the FG Falcon system uses a virtual pivot control lower link and an upper A-arm, which results in better camber when cornering, leading to improved tyre contact with the road and increased assurance for the driver.

The new suspension system incorporates two ball joints that connect the separate lower arms to the suspension knuckle. These two separate lower links define a virtual pivot of the lower arm, which allows the suspension to behave as though the lower pivot point is at the intersection of the two arms.

The virtual pivot point is further outboard than can be achieved by a conventional suspension system, leading to a reduction in the King Pin Axis offset, which thereby reduces the ability for wheel disturbances from wheel balance and tyre non-uniformities to disturb the driver through the steering wheel.

Similarly, the negative scrub radius that is generated by the new front suspension allows the wheel to generate some self-correcting steering torque while braking, which improves braking stability on mixed surfaces and provides better control under adverse conditions.

Steering

"One of the greatest benefits of Falcon's new front suspension system is that it has allowed us to package a forward mounted steering rack," said de Vlugt.

"In order to achieve the optimum balance of steering precision, handling stability and high speed controllability, we needed to deliver an increased level of front axle compliance understeer, and this can be best achieved with a forward mounted steering rack.

"For drivers of the new FG Falcon, this will translate to very confident control of their vehicle in busy traffic and through narrow roadways and road works. In addition to excellent manoeuvrability, the new virtual pivot control link front suspension, in combination with the new steering gear geometry, also contributes to reduced tyre wear."

The new steering gear introduces variable ratio technology, which provides the optimum sensitivity at low speeds and a relaxing drive at higher speeds. This results in a reduction in the number of turns lock-to-lock, without being too sensitive during straight ahead driving.

FG Falcon combines an 11.0 metre turning circle with 2.6 turns lock-to-lock steering.

This direct steering is mostly felt at low speeds where significant steering wheel angles are used, however, the variable ratio steering allows for a less direct steering ratio when the steering is "on centre" or near the straight ahead position.

The FG Falcon is also the first Australian-built vehicle to incorporate a Y-shaped steering rack, which was invented by Bishop Steering Technology in Australia.

The Y-shaped steering rack significantly improves stiffness and smoothness of motion and operation, eliminating the knobbly, discontinuous feel that is normally prevalent in vehicles with a variable ratio steering gear, which is generated by rolling torque around the steering gear axis whenever the steering wheel is turned.

Enhancements to steering for the FG Falcon also include two new power-assisted steering calibrations to optimise steering feel across all models.

A new ergonomically designed steering wheel for base and luxury models also contributes to a more relaxed driving experience, while a sports steering wheel for the performance models provides for a more confident grip on the steering wheel during enthusiastic driving.

"The combination of steering advances we have introduced with the FG Falcon ensures we have rebalanced the level of vehicle response to steering inputs over the speed range," said de Vlugt.

"At low speeds the new Falcon offers high levels of response thanks to the variable ratio steering rack, while at higher speeds it responds less, making it less 'nervous' during highway driving."

Control Blade IRS

The FG Falcon continues with the acclaimed Control Blade IRS architecture that was first introduced on the BA Falcon in 2002. However, all suspension springs, dampers and the anti-roll bar links have been significantly revised to match the introduction of the new front suspension.

One important change is an increased roll centre height to match the new front suspension, which reduces in-corner roll and improves straight line stability, along with a revised toe-angle that provides improved steering feel and vehicle stability.

Other rear suspension advances include new "point three" bushings, which improve NVH and deliver a quieter drive without loss of steering or handling performance, along with a small increase in track width.

Revised roll steer and the introduction of a new rear anti-roll bar connection link both also combine to deliver greater steering efficiency and precision.

"Since 2002, Falcon's IRS has been recognised as one of the best in its class, particularly compared to other Australian-made vehicles," said de Vlugt.

"We've been able to continue developing and enhancing that system and match it to the new Virtual Pivot Control Link front suspension without losing any of the technical advantages that have led to an enjoyable and confident driving experience for Falcon customers.

"The core system was engineered to stand the test of time and the engineering changes we've made now enhance that."

Monotube shock absorbers

The introduction of monotube shock absorbers front and rear on all Falcon sedans and most Utes will further enhance the dynamics capability of the FG Falcon through better body control and handling. Improved plushness and vibration absorption will also contribute to a more comfortable ride without any perceived 'floatiness'.

Monotube shock absorbers have one tube with a gas cup to separate the gas and oil, and accommodate the oil displaced by the rod entering the working area. In contrast, traditional twin tube shocks have no physical separation of the oil and gas in the damper and operate by transferring the oil from the pressure chamber via a base valve as the shock rod displaces.

The larger piston area of the monotube shock reduces hydraulic pressure, which improves sensitivity and control, especially on short strokes and reversals.

Significantly higher internal gas pressure of 18 bar, in lieu of 4 bar with twin tubes, allows the damper to build controlling forces faster and nearly eliminates cavitation or foaming during normal operation. This guarantees consistent ride feel and control as well as markedly improving performance.

In addition, the higher operating temperature capability (160◦C) of monotube shock absorbers ensures control in strenuous duty cycles such as over corrugated and gravel roads.

Monotubes also dissipate heat more quickly and can absorb more energy for longer periods of time than twin tubes in equivalent conditions, which delivers increased robustness under all driving conditions.

"By introducing monotube shock absorbers into Falcon we are able to improve its road holding capability even further," said de Vlugt.

"Drivers will notice appreciably enhanced handling and steering without any loss of ride performance."

Tyres

A range of new tyres was specifically developed for the FG Falcon range, bringing improvements in road noise, wet grip, dry grip and handling, steering compliance, ride, rolling resistance and steering linearity. The new tyres include:

• Goodyear Eagle Excellence 215/60R16 for use on the XT - this tyre provides excellent grip, comfort and NVH, offering a smoother, quieter ride.

• Goodyear Eagle Excellence 235/50R17 for use on vehicles higher in the Falcon range - as with the 16-inch tyre, this variant provides excellent grip, comfort and NVH, as well as an improved vehicle stance when combined with the accompanying 17-inch alloy wheel.

• Dunlop SP Sport 01A 245/45R17 for the XR6 sedan and Ute - this tyre offers excellent grip and handling characteristics while maintaining a high level of comfort and NVH.

• Dunlop SP Sport Maxx 245/40R18 for the high-series sports and sports luxury vehicles in the Falcon range - this tyre utilises Dunlop's ultimate ultra-high performance Sport Maxx tyre, which offers a high level of ride, steering and handling along with accompanying improvements in NVH.

• Dunlop SP Sport Maxx 245/45R17 as a no cost option on select XR sedans and Utes - this tyre has been especially developed with Turbo customers in mind for superior handling and steering. It is also the first time the XR6 Turbo has its own tyre available to distinguish it from the XR6.

• Dunlop SP Sport Maxx 245/35R19 - this tyre is now available in conjunction with optional 19-inch alloy wheels on all sports and sports luxury vehicles in the Falcon range.

Specific tyres were also developed for Falcon Ute models. Information on these new tyres will be included in the Falcon Ute press kit at launch.

Suspension tunes

A range of suspension tunes has also been developed for the Falcon sedan range, including standard, luxury sports, luxury performance, XR sports and heavy duty, depending on the vehicle.

Information on suspension tunes available for Falcon Ute and FPV models will be included in the appropriate press kit at launch.

Chassis controls systems

Dynamic Stability Control (DSC) with Traction Control (TCS) will be standard equipment on all petrol Falcon sedans, along with Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD) and Emergency Brake Assist (EBA).

Falcon's proven DSC system has been retuned to suit the combination of new engine, transmissions and suspension designs and calibrations to continue providing enhanced vehicle stability under all driving conditions. It also continues to offer tailored control strategies for expected different driver preferences across the vehicle range.

All Falcon Ute models will be fitted as standard with ABS and EBD, while TCS will continue as standard equipment on XR Utes. The availability of TCS has been expanded to include the rest of the petrol Falcon Ute range.

Self adjusting park brake

The FG Falcon will be the first locally-produced vehicle to incorporate a self-adjusting park brake on all sedan and utility vehicles, with the exception of column auto Falcon Ute models with a seat mounted park brake.

Fully integrated within the styled console mounted cabin lever, the self adjusting park brake automatically removes any slackness that develops over time, providing short, predictable and consistent lever travel while also ensuring secure park brake operation.

This reduces the risk of the vehicle being parked with a poorly applied hand brake and also avoids the potential re-adjustment cost for the customer at regular service intervals.

Whenever the driver returns the park brake to rest or the fully off position, an internal feature within the self adjuster automatically activates, applying tension to the front cable of the system. The appropriate level of tension has been incorporated into the vehicle's design to ensure adequate pretensioning while preventing any risk of the driver over adjusting and resulting in unwanted drag within the system.

When the park brake is again applied, the self adjusting action is automatically locked out within the first click of operation and normal manual function is returned to the lever.

In effect, the full self adjusting action occurs without any additional input or special action on the part of the driver.

Vehicle dynamics summary

The combination of an all-new front suspension, significantly modified rear suspension, new steering gear, the introduction of monotube shock absorbers and a range of other advancements over the prior model ensures that the 2008 FG Falcon delivers on Ford's global vehicle dynamics DNA.

It provides improved steering precision and feel; optimised high speed responsiveness for a more relaxed drive; improved manoeuvrability; enhanced body control, ride performance and plushness; an increased choice of suspension tunes; and improved handling in both wet and dry conditions. "The new Ford Falcon fully meets our goal of developing a vehicle that offers drivers an enjoyable, relaxed and confident driving experience," said de Vlugt.