First look: FPV tech revealed

THE transition from Falcon to Ford Perfomance Vehicle involves a lot more than replacing the standard engine with the 290kW/520Nm "Boss 290" 5.4-litre quad-cam V8.

While plenty is known about that engine already, a bevy of other mechanical changes exclusive to the three-car FPV range were announced this week.

While automatic versions of FPV models will not be available until the second quarter of 2003, the Tremec TR3650 five-speed manual transmission incorporates a number of changes specific to its Boss 290 application.

That transmission has previously seen service here mated to the previous T-Series' 5.6-litre Windsor V8 and is also now comes with the Boss 260-engined Falcon XR8.

Exclusive to Ford Australia are a specific input shaft, clutch housing, extension housing, shift rail and 31-spline output shaft, said to result in cleaner, more precise shift feel.

The revised manual also features a shorter fifth gear ratio (0.675:1 versus the stroked T-Series' 0.625:1), while the clutch and one-piece flywheel are mounted to the engine with a six-bolt design instead of just three.

According to Ford: "Unlike some six-speed transmissions, the TR3650's five speeds are all useable under local speed limits with a more than adequate top speed" - an obvious reference to the six-speed manual Holden and HSV employ with its moon-shot sixth gear.

Other changes include a larger, 291mm SAC-LUK pressure plate combined with a smaller 280mm Mustang Terminator clutch plate featuring Valeo F808 clutch material, which is more resistant to fade.

The hydraulic clutch's concentric slave cylinder works directly on the self-adjusting pressure plate, replacing traditional clutch levers and linkages and reducing clutch throw from 160 to 135mm.

The two-piece tailshafts fitted to all FPV vehicles have undergone extensive strengthening and balancing, while all FPV cars also get a Dana M86 limited-slip differential.

Finally, although identical externally to the BA Falcons' four-speed automatic transmission with sequential manual control, Ford says the new M97-019 auto was developed in conjunction with BTR specifically for FPV.

Claimed to be "the first automatic to offer console-mounted sequential shifting with full manual override in a premium V8 performance model in Australia", the stronger, recalibrated auto is also a quicker shifting device.

On the suspension front, Ford says the BA Falcon's 88 per cent better structural rigidity allowed FPV engineers to increase front spring stiffness dramatically while also increasing damper compliance when developing FPV's new 18-inch wheel/suspension specification.

Previous optional adjustment kits to change castor, camber and toe are now standard on all models, while the Control Blade independent rear suspension for GT and GT-P models will sport negative 0.5 degrees camber, reduced from the Falcon XT's negative 0.9 degrees.

Rear toe-in was also reduced from 3mm to 2mm, while the higher spring rates measure 38Nm/mm versus 28Nm/mm for XT. Rear anti-roll bar diameter was increased from 18 to 19mm, while rear damping was reduced from 19.5 to 14Nm/mm.

Front suspension for the FPV Pursuit ute, meantime, features all the BA Falcon bush revisions and FPV sedans' uprated spring rates, but without the FPV geometry changes. Of course, the leaf-sprung live rear axle remains, although both ends receive new tuned Delphi dampers.

Like the sedans, Pursuit ute gets the BA Fairmont Ghia's slightly heavier, sharper steering rack, which features reduced friction, strengthened steering column and mountings and, thanks to the 18-inch wheels, fewer turns lock-to-lock and greater road feel and responsiveness.

Ford also revealed both GT and Pursuit models will feature Performance Brakes (optional on XR8) as standard, with the GT-P getting Brembos as standard (optional on GT and Pursuit).

The first Australian manufacturer to employ PBR Australia's new high performance C6 calliper, Ford says it features 20 per cent greater pad area and two 40.5mm pistons.

Both front and rear rotors are vented and grooved, and measure 325 x 32mm (versus 298 x 28mm for regular BA Falcons). ABS and EBD is standard, with the single-piston rear callipers (also blue) gripping 303x16mm grooved discs.

The GT-P's Brembo package includes four-piston callipers up front, in tandem with 355x32mm vented and cross-drilled rotors, while the smaller four-piston rear callipers (with 28/30mm front/rear pistons instead of 40/44mm items up front) work with 330x28mm grooved and vented rear rotors.

Rounding out the FPV package is a full interior makeover, including a machined, metallic start button on the dash centre that glows red when the ignition is switched on.

Satin alloy highlights include the door handles, dash controls, sill scuff panels and FPV build number plate on the console, while FPV customers have the choice of race-check patterned cloth or an optional perforated alloy embossed leather upholstery for the FPV sports seats.

Stitching on the seats, console lid and manual gear lever is colour coded to exterior colour, while the model name is embroidered into each seatback. Dash and door highlights echo the check pattern, as do the 270kmh/8000rpm instruments.

An FPV performance steering wheel features alloy spoke inserts and is optional on GT and Pursuit, as are plush FPV floor mats with embossed logos. All FPV cars will feature drilled alloy-look pedals, with auto GT-P examples getting power pedal adjustment.

Based on the low-series BA Falcon, GT sedan and Pursuit ute models feature air-conditioning, 100-watt audio with single-CD player, cruise control and four-way power driver's seat adjustment.

The GT-P dash shares the same satin alloy-look as GT/Pursuit but gets prestige equipment including dual-zone climate control, large LCD screen, trip computer and prestige audio system with six-CD in-dash stacker. All manual FPV vehicles go on sale in March.

For the run-down on the styling and pricing of the FPV range, check out our separate Future Models story: "First look: GT Falcon a star in stripes"