Parts for your 2016 Ford Falcon-Exhaust gasket

2016 Ford Falcon exhaust gaskets — what they do and when to replace them

Yes — the 2016 Ford Falcon (FG X) uses exhaust gaskets. This is confirmed in Ford’s FG X Falcon Workshop Manual (Exhaust System and Engine sections), which specifies manifold-to-head gaskets and various flange/donut gaskets, and in Ford’s Microcat/EPC parts listings for FG X models (I6, XR6 Turbo and XR8). Aftermarket catalogues used in Australia and New Zealand, such as Permaseal and Walker Exhaust, also list exhaust manifold and flange gaskets for the 2014–2016 FG X range. So the part is absolutely relevant on the 2016 Falcon, whether it’s the Barra I6, the XR6 Turbo (which adds turbo-related sealing rings), or the supercharged 5.0 V8 in the XR8.

An exhaust gasket’s job is pretty straightforward: it seals the joins in the exhaust so hot gases don’t leak out before they reach the cat and mufflers. On a 2016 Falcon that means a multi-layer steel gasket between the exhaust manifold and cylinder head, and crush-type or ring/donut gaskets at flanged joints (e.g., ahead of and behind the catalytic converter). On turbo models there are additional sealing rings/gaskets at the turbo to manifold and turbo to downpipe connections.

As part of routine servicing, it’s smart to keep an ear and eye out for gasket issues. Tell-tale signs include a ticking noise on cold start that quietens as it warms up, whiffs of exhaust in the engine bay, or sooty marks around a flange. If any of that shows up, a new gasket and fresh hardware is the fix.

• Replacement tips:
  1. Only fit quality gaskets, follow the Ford torque specs and sequence from the FG X Workshop Manual.
  2. Clean and inspect mating faces, warped flanges or a cracked manifold will defeat a new gasket.
  3. Replace rusty studs/nuts and spring bolts on cat/downpipe joints, they provide the clamping force a gasket needs.
  4. Don’t add sealants unless the manual specifically calls for it, most gaskets are designed to seal dry.
• Good times to replace:
  • Anytime the exhaust is removed for other work (turbo, cat, manifold, clutch on manuals).
  • When a leak is detected, or after impact damage that may have stressed the exhaust.

A properly sealed system protects the oxygen sensors and catalytic converter, keeps the cabin quiet, and helps the Falcon pass emissions. With the right parts and correct torqueing, an exhaust gasket job is a once-and-done repair.

Popular questions about 2016 Ford Falcon exhaust gaskets

Do the I6, XR6 Turbo and XR8 use different exhaust gaskets?
They share the concept, but not always the exact parts. All use a manifold-to-head gasket and flange/donut gaskets in the system. The XR6 Turbo adds turbo-related sealing rings at the turbine outlet and sometimes at the turbo-to-manifold join. The XR8 V8 uses V8-specific manifold gaskets. Always order by VIN or engine code to match the correct gasket set.

What are the symptoms of a blown exhaust manifold gasket on an FG X?
Common signs are a sharp ticking on cold start that softens when hot, a faint exhaust smell in the bay, and black sooty tracks around the manifold or flange. In some cases the O2 sensor readings go skew-whiff, triggering a fault code, because fresh air gets sucked into the leak and confuses fuelling.

Should manifold bolts be re-tightened after installation?
On the FG X, follow the Ford Workshop Manual torque and sequence and don’t re-torque hot. If bolts or studs were corroded, replace them. Re-check for leaks after a few heat cycles, but only re-torque if the manual specifies, overtightening can warp the manifold or crush the gasket.