Parts for your 1996 Ford Falcon-Exhaust mount

1996 Ford Falcon exhaust mount — what it does and how to look after it

Yes, the 1996 Ford Falcon uses exhaust mounts. Technical sources including the Ford EF/EL Falcon Workshop Manual (Section 309-00 Exhaust System), the Gregory’s Service and Repair Manual No. 271 (EF–EL), and Ford Microcat parts diagrams list “insulator—exhaust” and muffler hangers supporting the system at the transmission crossmember, centre muffler, and rear muffler/tailpipe. So an exhaust mount is absolutely relevant for a 1996 Falcon.

An exhaust mount’s job is simple but crucial: it suspends the exhaust under the car on flexible rubber insulators, keeping weight off the manifolds and cat, isolating vibration, and letting the system move a little as the engine rocks and the pipework heats and cools. That flexibility prevents metal-to-metal knocks, cracked welds, and annoying cabin buzz.

On a ’96 Falcon, the mounts typically live near the gearbox crossmember, midway around the main muffler, and at the rear muffler or resonator. Over time the rubber perishes, stretches, or splits, especially with heat, oil contamination, or rough roads. When they’re tired, the tailpipe can sit off-centre, the exhaust can thump on take-off, and there’ll often be a rattle at idle or over bumps.

• Common signs: sagging tailpipe, visible cracks in the rubber, metallic knocks, or a droning vibration in the cabin.
• Service tip: inspect the mounts at each service (every 10–15,000 km) and after any exhaust work or speed-bump strike.

Replacement is straightforward with the car safely on stands. Support the exhaust with a jack and a block of wood, then swap the rubber insulators. A mist of silicone spray helps them slide on, avoid petroleum grease, which can attack rubber. Refit brackets and tighten to the workshop manual spec (often in the 20–30 Nm ballpark, model and location dependent). If the brackets are rusty, replace the hardware while you’re there.

For cars with lowered suspension or that tow, fresh mounts make a big difference to clearance and comfort. OEM-style rubber usually gives the best refinement, heavy-duty options can help longevity but may transmit a touch more vibration. Always check alignment when finished — the tip should sit centred in the bumper cut-out with decent clearance to the body, spare wheel well, and heat shields.

• Handy extras: new exhaust clamps, a dab of anti-seize on bracket bolts, and a quick look at heat shields and hangers near the cat where heat is highest.

Popular questions about the 1996 Ford Falcon exhaust mount

How many exhaust mounts are on a 1996 Falcon?
Most EF/EL sedans have three main rubber mounts: front (near the transmission crossmember), centre (main muffler), and rear (muffler or resonator). Wagons and some XR or V8 variants can have an extra hanger at the rear section. Always match what’s on the car to the parts listings for the specific body and engine.

Can a home mechanic replace the mounts?
Yes, with stands, basic spanners, and care. Support the exhaust before removing any hangers, use silicone spray to slip new rubbers on, and tighten bracket bolts to the workshop spec. If hardware is badly corroded or the system has poor clearance, a workshop visit is a smart move.

How often should exhaust mounts be replaced?
There’s no fixed interval. Inspect every service, many last years, but heat, oil leaks, and rough roads shorten their life. Replace at the first sign of cracking, elongation, or contact between the exhaust and body to protect the cat, welds, and sensors.