Chassis Parts with Fitting Position Front and Rear, Front Axle for FORD FALCON XE, XF Sedan

4WD chassis parts are the braces, mounts, brackets and bushes that hold the body, chassis and supporting components in their correct positions. On a lifted or hard-working 4WD, these parts take on extra importance. A lift can change clearances around front braces and alter how headlight levelling sensors read ride height, while years of corrugations and off-road flex wear out the bushes that separate the body from the chassis. Smaller bushes in the cabin, such as window regulator and pedal bushes, also wear with age. Use the vehicle search to find chassis parts to suit your XE, XF Sedan FALCON.

Types of XE, XF Sedan FALCON Chassis Parts

Chassis parts cover several distinct jobs, and each type addresses a different problem. Some restore clearance or geometry after suspension changes, some isolate the body from the chassis, and others remove slack and noise from moving components inside the cabin. Knowing which job a part does makes it easier to identify what your XE, XF Sedan FALCON needs.

XE, XF Sedan FALCON Chassis Bracing and Strengthening Kits

Chassis bracing includes cross braces, support brackets and drop spacers that stiffen the front section of the chassis or reposition a brace to clear other components. On independent front suspension vehicles, a front brace often runs beneath the front differential, which is why its position matters after a lift or differential drop.

XE, XF Sedan FALCON Body Mount Bushes

Body mount bushes sit between the body and the chassis on body-on-frame 4WDs and bakkies. They locate the body on the chassis, absorb vibration and allow a small, controlled amount of movement as the chassis flexes. Body mount bushes are made in both rubber and polyurethane.

XE, XF Sedan FALCON Headlight Sensor Brackets

Vehicles with automatic headlight levelling use a height sensor linked between the body and the axle or suspension. Sensor brackets and spacers correct the sensor?s position after a lift, so the levelling system reads ride height as it was designed to.

XE, XF Sedan FALCON Cabin, Pedal and Body Bushes

Smaller bushes support moving parts in and around the cabin, including window regulators, sun visors, throttle pedals and bonnet stops. When they wear, the result is usually slack movement, rattles or binding rather than a safety issue, but replacing them restores the precise feel of the original parts.

Do You Need Chassis Brace Spacers After a XE, XF Sedan FALCON Lift?

On some vehicles, yes. On many independent front suspension 4WDs, the front differential is held by mounts on the chassis, with a cross brace running beneath it. When a lift is fitted, a differential drop kit is often used to reduce the angle of the CV joints by lowering the differential slightly. The brace beneath it then sits too close to, or in contact with, the lowered differential, so a drop spacer kit lowers the brace by a matching amount to restore clearance.

Whether your XE, XF Sedan FALCON needs brace spacers depends on its front suspension design, the lift height and whether the differential has been lowered. On some vehicles they are part of the recommended hardware for a lift, while on others they are not needed at all. Check the lift kit specification for your XE, XF Sedan FALCON, or ask a suspension technician, before fitting or leaving them out.

Why Chassis Bracing Matters on Your XE, XF Sedan FALCON Off-Road

The front section of a 4WD chassis carries the weight of the engine, any bull bar or winch, and the loads fed in through the front suspension. Braces and crossmembers tie the chassis rails together, helping them resist twisting and spreading under those loads. They also sit low under the vehicle, where they can be the first point of contact on rocks, ruts and ledges.

That creates a trade-off between strength and clearance. A brace lowered by drop spacers restores clearance around the differential but can sit closer to the ground. High-clearance brace designs aim to keep the brace?s structural role while lifting it out of harm?s way. When choosing bracing, consider both how much protection and stiffness the vehicle needs and how much underbody clearance the terrain it covers demands.

What Do XE, XF Sedan FALCON Body Mount Bushes Do?

On a body-on-frame 4WD, the body is not welded to the chassis. Instead, it sits on a series of mounts, each with a bush that clamps between the body and a bracket on the chassis rail. These bushes do three jobs. They locate the body accurately on the chassis, they absorb vibration and road noise before it reaches the cabin, and they allow the chassis to flex slightly without forcing the body to flex with it.

That last role matters most off-road. When a 4WD articulates over uneven ground, the chassis twists, and the body mount bushes take up some of that movement. Over time, heat, oil, water and repeated compression cause the bushes to harden, crack or compress. A worn mount lets the body move more than it should, which increases noise, vibration and stress on the body structure.

What Are the Signs of Worn XE, XF Sedan FALCON Body Mounts?

Possible signs include clunks or knocks from beneath the cabin over bumps, more vibration or harshness felt through the floor and seats, and a change in how the body sits on the chassis. You may notice door, bonnet or tray gaps that no longer line up as they used to, or a cab that appears to have moved relative to the tray on a bakkie. Visible cracking, splitting or flattening of the bush material is a clear indicator when the mounts can be inspected.

These symptoms are not unique to body mounts. Worn suspension bushes, loose exhaust or heat shield mounts, failing engine or transmission mounts, and loose fasteners elsewhere can all produce similar noises and vibration. Have a technician inspect the vehicle to confirm the cause before replacing parts.

Replacing XE, XF Sedan FALCON Body Mount Bushes

Replacing body mounts involves supporting the body, removing the mount bolts and raising the body slightly at the relevant mounts to remove the old bushes. The work is usually done one side or one section at a time, so the body stays located on the chassis throughout. Body mount bolts are often heavily corroded on older 4WDs, which can turn a straightforward job into a longer one, and threaded cages in the chassis can break if bolts are forced.

Because the body must be raised safely and the mounts tightened to the vehicle manufacturer?s torque specification, this work is best carried out by a qualified technician. Check door and panel alignment afterwards, since new mounts can change how the body sits.

Polyurethane or Rubber Chassis Bushes: Which Suits Your XE, XF Sedan FALCON?

It depends on how you use the vehicle. Rubber bushes are softer and absorb vibration well, which keeps the cabin quiet, but they deteriorate with heat, oil and age. Polyurethane bushes are firmer, and polyurethane bush makers commonly state that the material resists oils, water and temperature extremes, which suits vehicles that see harsh conditions.

The firmer material holds components more precisely, but it can transmit more vibration and noise into the cabin than rubber. For a 4WD that spends most of its time on sealed roads, comfort may be the priority. For one that works hard off-road or carries heavy loads, durability and precise location may matter more. Consider how the vehicle is used before choosing.

Does a Lift Affect XE, XF Sedan FALCON Headlight Levelling?

On vehicles with automatic headlight levelling, often fitted with high-intensity headlights, a rear height sensor tells the system how the vehicle is sitting so it can adjust the headlight aim. A suspension lift changes the angle of the sensor?s linkage, so the system can misread ride height and aim the headlights too high or too low.

Headlights aimed too high can dazzle oncoming drivers, while lights aimed too low reduce how far you can see at night. A sensor bracket or spacer restores the sensor?s original geometry at the new ride height. Have the headlight aim checked after any lift, whether or not a bracket is fitted.

Do XE, XF Sedan FALCON Cabin Bushes Wear Out?

They can, particularly on older vehicles and those that spend time on corrugated roads, where constant vibration accelerates wear. Worn window regulator bushes can cause windows to rattle, bind or travel unevenly. Worn throttle pedal bushes can make the pedal feel loose or vague, and worn sun visor clips and bonnet stops can lead to rattles and parts that no longer hold their position.

These bushes are inexpensive to replace compared with the components they support, and replacing a bush early can prevent wear spreading to the regulator, pedal assembly or mounting points. Check that the replacement matches your vehicle?s part design before ordering, since these bushes vary between models.

Get the Right XE, XF Sedan FALCON Chassis Parts with Formula 4x4

Lifted? Headlight sensor brackets bring the automatic levelling back into line after the ride height changes.

Start with the job the part needs to do: restoring clearance after a lift, renewing worn body mounts, correcting headlight levelling or removing slack from cabin components. Search by your XE, XF Sedan FALCON to find parts that suit it, and check whether your lift kit already specifies brace spacers or sensor brackets. If you are unsure what your XE, XF Sedan FALCON needs, contact the Formula 4x4 team.