Parts for your 2002 Ford Falcon-Cv joint

2002 Ford Falcon CV joint — what’s fitted and how to look after it

Technical sources including the Ford BA Falcon Workshop Manual (Driveline 205-02 Rear Drive Halfshafts), Ford Australia’s 2002 BA press materials on Control Blade independent rear suspension, and Gregory’s Service and Repair Manual for BA–BF models all confirm that 2002 Falcon sedans with independent rear suspension use constant velocity (CV) joints on the rear half‑shafts. By contrast, the BA Falcon Ute runs a live rear axle with a tailshaft using universal joints (U‑joints), not CV joints at the wheels, as outlined in the Ford Ute workshop driveline sections. So, CV joints are relevant to 2002 Falcon sedans (and many late AU III sedans), but not to the BA Ute’s rear axle.

On a 2002 Falcon sedan, the CV joint’s job is to let the rear wheels put power down while the suspension moves up and down and the hub steers for toe change. With one CV at the differential end and another at the wheel end of each half‑shaft, they keep rotation smooth under angle, cutting vibration and driveline shudder. When a CV starts to wear, it’ll often show up as a rhythmic click, clunk, or shudder on take‑off or during steady cruise, particularly under load.

Servicing is mostly about keeping the boots intact. Those rubber boots hold the grease and keep grit out — a split boot is what kills a good joint. During routine services, a quick look underneath for sling marks (grease flung around the inner guard or suspension arms), cracked rubber, or dampness at the boot is well worth it. If a boot’s torn, get it re‑booted promptly and the joint re‑greased if there’s no internal damage. If there’s play, roughness when rotating by hand, or metal‑on‑metal noise, it’s time for replacement.

When replacing a CV or complete half‑shaft on a BA sedan, use quality parts, new circlips and nuts, and follow torque specs from the workshop manual. It’s smart to check wheel bearings, hub splines, and diff seals at the same time. After refitting, a brief road test for noise and vibration and a recheck for any grease seep is good practice. There’s no strict kilometre interval for CV replacement — condition rules — but inspecting the boots every service or two (say 10–20,000 km) keeps small issues from turning into big bills.

• Watch for clicking on acceleration, vibration at highway speeds, or grease spray near the rear wheels.
• Fix split boots early, once grit gets in, the joint wears fast.
• If towing or carrying heavy loads often, inspect more frequently.

Popular questions about 2002 Ford Falcon CV joints

Do all 2002 Falcons have CV joints?
Most 2002 Falcon sedans (late AU III and BA) with independent rear suspension have rear CV joints. The BA Falcon Ute uses a live rear axle with U‑joints on the tailshaft, so it doesn’t have CV joints at the rear hubs. If unsure, a quick look underneath will show either half‑shafts to each wheel (IRS with CVs) or a solid axle tube (no rear CVs).

What are the signs a BA Falcon’s rear CV joint is failing?
Common signs include clicking or clunking on take‑off, a shake under load, or grease flung around the inner wheel arch from a split boot. Jack the car safely and spin the wheel by hand, any gritty feel or obvious play in the shaft usually means the joint or half‑shaft assembly needs attention.

Can a split CV boot be repaired without replacing the joint?
If the joint hasn’t run dry or ingested grit, a new boot and fresh grease can save it. Once there’s rumble, play, or metal flakes in the old grease, replacement of the joint or complete half‑shaft is the better long‑term fix.