Parts for your 2003 Ford Falcon-Exhaust mount

2003 Ford Falcon exhaust-mount: what it does and when to replace it

Yes, an exhaust-mount is fitted to the 2003 Ford Falcon (BA series). Technical references including the Ford Australia BA Falcon Workshop Manual (Exhaust System, 309-00), the Ford Microcat Electronic Parts Catalogue for BA/BF, and the Gregory’s/Autodata BA Falcon service manual all depict the exhaust system suspended on rubber hanger insulators (often listed as “insulator – exhaust mounting”) at multiple points along the pipework, resonator and rear muffler.

On a BA Falcon, the exhaust-mount (rubber hanger/insulator) supports the weight of the exhaust while isolating vibration from the cabin. It keeps the system centred, maintains clearance to the underbody, suspension and bumper, and helps prevent knocks on start-up or over bumps. They’re simple, cheap bits of rubber, but they make a big difference to noise, harshness and the life of the exhaust.

Typical Falcons of this era run several mounts from the front pipe through to the rear muffler. Over time, heat and road grime harden or crack the rubber, letting the exhaust sag or shift. If the tailpipe looks low or off-centre, there’s a thud over speed humps, or there’s a new buzz/drone at idle, the mounts are prime suspects.

As part of regular servicing, it’s smart to eyeball every exhaust-mount while the car’s on a hoist. A quick check at each service interval (or roughly every 10,000–15,000 km) is plenty. If any mount shows splits, glazing, stretched holes or is heat-shrunken, replace it. The job is straightforward:

• Let the exhaust cool fully, support it with a stand.
• Spritz silicone spray on the pegs to ease removal.
• Lever the old insulator off, fit the new one the same way round.
• Confirm clearances around the crossmember, diff and bumper, and tighten any brackets to manufacturer spec.

When choosing replacements, quality OE-style rubber suits most Falcons. Stiffer polyurethane can sharpen control for modified or lowered cars, but may transmit more vibration. If one mount has failed, consider doing the neighbouring ones—they’ve lived the same hot, hard life. With fresh exhaust-mounts, the BA’s system will sit correctly, stop knocking, and feel quieter and tighter on the road.

Technical sources referenced: Ford Australia BA Falcon Workshop Manual (Exhaust System 309-00), Ford Microcat EPC for BA/BF Falcon (exhaust mounting insulators), Gregory’s/Autodata Ford Falcon BA 2002–2005 Service Manual (Exhaust System chapter).

Popular questions

How many exhaust-mounts does a 2003 BA Falcon have?
It typically uses several rubber hangers from the front pipe to the rear muffler—usually three to four depending on model and exhaust configuration. The exact count can vary with sedan vs ute and with aftermarket systems. A quick visual check on a hoist will confirm what’s fitted to a given car.

Will worn exhaust-mounts cause vibration or drone?
They can. Perished mounts let the exhaust touch the body or sit misaligned, which adds vibration at idle and a low-frequency drone on the highway. Replacing the tired hangers often restores proper clearance and smooths things out without touching the mufflers.

Are polyurethane hangers worth it on a BA Falcon?
For a stock daily, OE-style rubber is usually best for comfort. Poly hangers are firmer and suit lowered or performance setups where extra support prevents the system from shifting under load. Expect a small increase in transmitted vibration with stiffer mounts.