The Ford Falcon has become a staple in every Aussie car enthusiast's life. There’s no doubting that it is one of the most popular platforms to modify, daily drive, drag race, grip, or drift. You name it, and there’s likely an enthusiast out there doing it!
One of the main reasons these Australian land yachts have been so incredibly popular is due to their engine. The 4L variant of the Falcon came with a very capable, large, inline-6, cast iron engine — the mighty BARRA. Although most came in naturally aspirated forms, there’s one variant that stands proudly out in front: the infamous Barra Turbo.
During the years 2002 to 2016, a handful of Ford Falcons were sold as XR6 Turbos, G6E Turbos, or F6 Turbos, in both utes and sedans. Not only were they brilliant in stock form, but they were also highly capable with tuning, surpassing horsepower numbers on stock engines that, at the time, could only be achieved by the 2JZ or RB25.
Now, 20+ years on, it is very common to see many Falcons with over 300,000 kilometers on the odometer. Being that we at Demon Pro Parts specialise in rebuilding and providing replacement / upgraded Ford Falcon Turbochargers, we thought we’d highlight three of the biggest issues to look out for to keep your Barra Turbo’s stock Garrett GT3576 or GT3582 boosting healthily for a very long time!
1. Oil Supply Issues
The first issue that plagues every single turbo Falcon is the very common oil feed line problem, which can occur even in cars with a perfect service history. The stock banjo bolt on the passenger side, responsible for connecting the block to the oil feed line, has a small mesh filter inside it. Over time, this filter can not only partially clog but can also collapse inside itself, trapping oil and preventing it from reaching the turbo. This lack of lubrication can lead to catastrophic turbo failure.
To combat this, we sell dedicated oil feed lines that relocate the filter to the top of the engine in an accessible location. This modification also allows you to remove the standard mesh filter inside the banjo bolt altogether.
Check out the Demon Pro Parts Oil Feed Pipe HERE
2. Overboosting
It’s no secret that Falcon owners love to modify their cars. In the pursuit of having the Finest Falcon in all the land, it’s common for enthusiasts to crank up the boost. While the standard GT3576 for the FG XR6 and G6E and the GT3582 in the BA, BF, and FPV F6 can handle a bit of extra boost, every turbo has its limits.
Pushing the turbo to work harder than intended adds extra strain on the bearings, causing them to wear out prematurely and fail—often in spectacular fashion. This failure might manifest as a smoky dyno run or a dramatic plume of smoke after letting off the accelerator.
GT3576: Tops out at around 16 psi before becoming risky.
GT3582: Generally tolerates up to 18-20 psi.
At Demon Pro Parts, we stock a wide range of turbos, whether you’re bolting on another stock unit or looking for something capable of handling more boost. Click [HERE] to check them out.
3. Foreign Object Damage
Another common cause of turbo failure in Ford Falcons is foreign object damage. This issue arises when debris or objects enter the turbo’s intake. Loose bolts, poorly secured filters, or damaged/dirty filters can all lead to this problem. Once foreign material comes into contact with the compressor blades, the damage is often irreversible without a full rebuild. Bent or chipped blades severely compromise the turbo’s performance and balance.
At Demon Pro, we’ve seen our fair share of destroyed turbos due to such incidents. The compressor blades are one of the most critical components of a turbocharger, so ensuring they remain clean and undamaged is paramount.
Conclusion
These are the three most common ways we’ve seen turbochargers fail in Ford Falcons. However, there are additional risks, such as infrequent servicing, boost-related issues, improper driving habits, excessive heat, and simple wear and tear over time.
If you have any turbo-related questions or want to ensure you’re getting the best turbocharger for your Falcon, don’t hesitate to call our friendly staff today!
