Six star Falcon

FORD Australia’s worst-kept secret is out: a new six-speed automatic transmission will join the Falcon and Territory range later this year.

The first of its kind in an Australian-built vehicle, the German-sourced ZF six-speed automatic is the headline act in the BF Falcon and SY Territory series, which will make their public debut at the Australian International Motor Show in October.

The model upgrade also includes minor engine modifications, cosmetic enhancements and increased equipment levels.

The new transmission is restricted to premium models, leaving the XT Falcon, Futura, Fairmont and rear-drive Territory models with a recalibrated version of the existing Ion four-speed automatic.

Ford claims the new ZF auto and its revised 4.0-litre inline-six – now known as Barra 190 and producing 190kW (up 8kW) at 5250rpm and 383Nm (up 3Nm) at 2500rpm – combine to achieve fuel economy gains of between two and six per cent, more refinement and less emissions.

The self-shifter is a compact, lightweight unit that Ford has modified for Australian conditions and driving habits.

It has engineered two versions – a standard version with a torque capacity of 450Nm, and a performance version rated to 600Nm – and has the option of offering low-range gearing, a feature almost certain to be engineered into future Territory models.

"We wanted architecture that we could use in the future," said Ford Australia’s vice president of product development, Trevor Worthington.

"By the time we made the decision to go six-speed it was the right transmission and that’s the way it worked out." He said fuel economy gains were also high priorities.

"Our aim was to maximise real-world economy figures," he said. "We are confident all customers will gain better economy than the official figures suggest." Other attributes of the gearbox include sequential-manual operation (via the T-bar, not the steering wheel like on Commodore and Adventra), grade logic control for automatic downshifting (to provide increased engine braking downhill), and a transient rpm limit that allows the engine to momentarily exceed the prescribed 6000rpm rev limit by 250rpm during upshifts.

Importantly, the transmission also offers a lower first gear ratio, higher top gear and smaller, more graduated shift points between each gear.

"The low first gear improves launch feel while it offers livelier performance, especially with a wide open throttle," Mr Worthington said.

The unit will be standard on the Fairmont Ghia, Fairlane Ghia, Fairlane G8, LTD, Territory TX AWD, TS AWD and Ghia AWD. It will be optional (for an estimated $1500-$1800) on the XR6 Turbo and XR8 sedan and utes, and will be specified as a mandatory fitting when the Barra 230 V8 engine is combined with either Falcon XT or Fairmont.

As well as the new Barra 190, Ford’s Australian-vehicle engine line-up includes the turbocharged 4.0-litre Barra 245T – now with an extra 5kW and 30Nm (245kW at 5250rpm and 480Nm at 2000rpm) – and the 5.4-litre Barra 230 V8, now with another 10kW and 30Nm to achieve a maximum 230kW at 5350rpm and 500Nm at 3500rpm.

The Barra E-Gas engine now produces 156kW at 5000rpm and 374Nm at 2750rpm.

The Tremec T56 six-speed manual, which has been available on XR6T and XR8 models, will now also be offered on the XR6 sedan.

Ford counts the addition of dual independent variable camshaft timing and dual knock sensors as the biggest change to the 4.0-litre six.

The dual independent VCT is claimed to deliver better low-speed torque, while the six also now has a lower idle speed of 550rpm (down from 700rpm).

At 100km/h, the natural-breathing Falcon six turns over at 1500rpm while at the same speed the Territory hums along at 1800rpm.

Ford Australia’s powertrain development supervisor, Ian Cole, said a fleet of Falcons covered 2400km of city and country driving to identify a test that best determined real-world fuel consumption figures.

It found that neither the Australian Design Rule 81/01 or NEDC Euro II/III test were indicative of "real-world" situations so Ford developed its own test concentrating on city driving of 60-65km/h and highway accelerations from 100km/h.

Ford is also hopeful the revised Falcon line-up will revive sales of the large car, which have slipped 20 per cent since the Territory’s arrival in 2004.

The next-generation car is not due out until 2007.