Parts for your 2002 Ford Falcon-Suspension bushes

2002 Ford Falcon suspension bushes: what they do and when to replace them

Suspension bushes are absolutely fitted to the 2002 Ford Falcon. Technical references including the Ford Workshop Manual for AU Series III and BA (sections 204-01 Front Suspension and 204-02/204-03 Rear Suspension), Gregory’s and Ellery’s service manuals for AU–BA Falcon, and aftermarket parts catalogues from Nolathane, SuperPro and Whiteline all list multiple front and rear suspension bushes for these models. Depending on variant, they include front upper and lower control arm bushes, radius/caster rod bushes, sway bar D-bushes and link bushes, plus rear trailing arm or Control Blade/IRS bushes, differential mount bushes, and Watts linkage bushes on live-axle cars.

On a 2002 Falcon, suspension bushes keep the arms located, soak up noise and vibration, and help the wheels hold their alignment when cornering or braking. Healthy bushes mean the steering feels settled, tyres wear evenly, and the car tracks straight on rough Kiwi or Aussie roads. Worn bushes, on the other hand, bring clunks over speed humps, steering wander, shimmy under braking, and feathered or inner-edge tyre wear.

Given the age of these cars, most original rubber will be past its best. A sensible service approach is to inspect the bushes at each major service (around 20,000–40,000 km) and any time there are changes in steering feel or tyre wear. Look for cracking, splitting, torn voids, or oil-soaked rubber, use a pry bar to check for excess movement.

Common replacement candidates on 2002 Falcons are the front lower control arm rear bush, caster rod bushes, sway bar D-bushes and links, and—depending on model—the rear trailing arm or Control Blade bushes and the diff mount. Live-axle cars often need Watts linkage bushes, IRS cars often need rear arm and diff bushes.

When replacing bushes, it pays to:

• Replace in pairs on the same axle to keep handling balanced.
• Torque all bush fasteners at normal ride height to avoid pre-loading the rubber.
• Choose rubber for factory comfort, or polyurethane for a sharper feel (with a touch more NVH). Poly bushes need the correct grease.
• Book a wheel alignment afterwards—caster, camber and toe can shift as new bushes settle.
• Use a press where required, some bushes are tight in the arms. Many owners leave the big ones (e.g., caster and diff bushes) to a pro.

Do the lot in one go and the Falcon will feel tighter, brake straighter, and be kinder to its tyres for many kilometres.

Popular questions

Which suspension bushes usually wear out on a 2002 Ford Falcon?
Owners most often find the front lower control arm rear bushes, caster/radius rod bushes, sway bar D-bushes and link bushes going soft or cracked. At the back, live-axle cars typically need trailing arm and Watts link bushes, while IRS/Control Blade cars often need rear control arm and differential mount bushes. High‑kilometre or taxi/ute use tends to accelerate wear.

Should a 2002 Falcon use rubber or polyurethane bushes?
For day-to-day street use, quality rubber keeps the factory ride and isolates noise well. Polyurethane sharpens steering response and holds alignment longer, but can transmit a bit more vibration. A common mix is rubber in most arms for comfort, with poly in sway bar D-bushes and links for crisper roll control.

Is a wheel alignment needed after replacing bushes?
Yes. Fresh bushes can change caster, camber and toe, so a proper alignment is recommended straight after installation and again after a short bedding period if the car still feels nervous or the steering wheel isn’t centred.