Ford Mondeo Common Problems and Solutions
Noise From Power Steering System
Problem:
You can hear a groaning noise emanating from the power steering system.
Solution:
Your Mondeo is probably experiencing pressure fluctuations in the power steering system (PAS), which are causing issues throughout the vehicle. Order the updated PAS high-pressure pipe assembly and the newer version of the PAS pump.
Difficulty level
Power Steering Pump
Front Axle Rattling
Problem:
There is a rattling noise from the front of the car while driving.
Solution:
A common problem is excessive friction between the front lower suspension arm bearing bush and the rear hydraulic rubber bushes. Ford released revised suspension arms with improved rubber bushes and silicone-coated bearing bushes. Order replacements from BreakerYard and fit these easily.
Difficulty level
Rough Idling
Problem:
The engine is very difficult to start and runs roughly when it does. There is also a loss of power. A diagnostic check shows the fault code P0340.
Solution:
The good news is that this is a simple fix. The camshaft position sensor is sending a weak signal, so you will need a revised wiring harness and sensor supplied by our parts team. This will boost the voltage to 12 volts, providing a much stronger signal.
Difficulty level
Camshaft Position Sensor
Interior Light Staying On
Problem:
The interior light stays on even when the doors are shut. The anti-theft warning system is also not functioning.
Solution:
There is a faulty contact switch in the local striker of the B or C pillar. It prevents the interior light from functioning correctly, which in turn causes the PATS to remain disarmed. You will need to order the upgraded lock striker from BreakerYard and fit it.
Difficulty level
Crunching Noise From Gear Assembly
Problem:
There is a grinding noise when you engage 3rd gear.
Solution:
You have a faulty third gear synchroniser ring. Ford has issued a revised version of the ring, which you can find on our parts page. We always keep them in stock and can deliver the replacement wherever you need it.
Difficulty level
No Cold Air From AC
Problem:
There is no cold air coming from your aircon vents, and it may also be making strange noises when turned on.
Solution:
The AC condenser in the Mondeo often wears out quite quickly, so you'll need to replace it. Enter your registration number on our homepage and search for a new AC condenser for the Mondeo. It's a tricky job to replace, but it's definitely achievable.
Difficulty level
Aircon Condensor
Window Rolling Down
Problem:
Every now and then, one or more of your windows rolls down by itself.
Solution:
A common fault of the Mondeo, this is simply a faulty power window motor. You'll need to remove the interior door panels to access the part, but you can easily find a new motor on our parts page for the Mondeo.
Difficulty level
Window Motor
Engine Rattle
Problem:
You can hear a rattling noise coming from the engine while it is running.
Solution:
While engine rattle can indicate various issues, on the Mondeo, the most probable cause is a damaged or worn-out dual-mass flywheel. If you've been driving at high speeds, this part is especially vulnerable. You can find a new flywheel at the BreakerYard store, and although it's a difficult component to fit, there are many online guides that will walk you through the process.
Difficulty level
Dual Mass Flywheel
Problem with fuel gauge reading
Problem:
Any Mondeos up to 2001 have been known to experience issues with inaccurate fuel gauge readings. This is typically caused by a fault in the fuel pump module.
Solution:
The best way to resolve this issue is to fit a new fuel lever sender card.
Difficulty level
Clicking from front on 97 Mondeo
Problem:
If you notice a clicking noise from the front of your 1997 Mondeo, it is most likely caused by the outer CV joint. The boot clip may be missing or broken, leading to water leaking into the CV.
Solution:
You should fix this as soon as possible if you want to avoid damaging the CV joint. To resolve this, you will need to fit new clips.
Difficulty level
Rear brake wear
Problem:
The 2001-02 Mondeo may experience excessive rear brake pad wear because the pads stick.
Solution:
This can be fixed by replacing the pads, ensuring the support area is cleaned, and then well greased. Have a look at the video below for more information. Remote control unlocking issues.
Difficulty level
Brake Pads
Problem with fuel gauge reading
Problem:
Mondeos produced before 2001 are known to have issues with inaccurate fuel gauge readings. This is typically caused by a fault in the fuel pump module.
Solution:
The best way to resolve this issue is to fit a new fuel lever sender card.
Difficulty level
Power steering faults
Problem:
The 1996-99 Mondeos are known to produce a knocking noise from the power steering system.
Solution:
The most effective way to fix this problem is to fit a new power steering return pipe, which will eliminate the noise. Check out available Ford Mondeo steering components now.
Difficulty level
Heating problems
Problem:
The 2002 Mondeo has only been known to blow out cold air when set to hot. This problem happens when the heater flap becomes stuck in the heater housing.
Solution:
The best way to resolve this issue is to use a Torx T50, which should release the heater flap, enabling it to move to the correct setting.
Difficulty level
Remote control unlocking issues
Problem:
Any Mondeo manufactured after 2001 may encounter problems unlocking the car with the remote from a distance beyond five metres. This issue arises because the radio transmission is excessively shielded.
Solution:
You can resolve this issue by fitting an extension to the transmission line to enhance the signal.
Difficulty level
Fuel flap problems
Problem:
Again, with the 2001 Mondeo, there are issues related to the fuel flap not opening. The problem stems from the fuel flap not aligning correctly with the spring release.
Solution:
This can be remedied by fitting a new, revised flap that connects properly with the release spring.
Difficulty level
Handbrake lever clutch problems
Problem:
This issue relates to the 2001 Mondeo. You might find yourself pulling the handbrake lever too far, which is caused by deterioration of the clutch mechanism.
Solution:
This can be resolved by attaching a clip to the clutch spring stop, which will prevent the spring from extending too far.
Difficulty level
Metallic Rattling Sound From Boot (Estates)
Problem:
You can hear a metallic rattling noise coming from the boot while driving.
Solution:
It's likely that there is too much distance between the boot door and the side bump stops. Since 2001, revised rubber bump stops have been fitted, and you'll find them easily in our online store.
Difficulty level
Loud Noise From Rear Brakes
Problem:
You can hear a loud noise coming from the rear brakes when you apply them.
Solution:
The older Mondeos suffer from a design flaw in the braking system. Vibrations between the brake discs and the brake pads are causing the loud noise. Not only will you need to order new brake pads from our drop-down parts menu, but you can also remove the vibration damper while you're there. Fit a shorter bolt in place of the vibration damper, which is no longer necessary with the revised brake pad design.
Difficulty level
Brake Pads
Engine Not Starting
Problem:
The engine is having difficulty starting or doesn't run smoothly when it does turn over.
Solution:
When your Mondeo was assembled, inadequate bedding was used, which causes problems with the diesel pump and excessive wear on the rollers and shoes. This then results in small metal particles entering the diesel, eventually damaging multiple engine parts. You can order a revised diesel pump with updated rollers and shoes directly from our parts list, although you may also need to replace other damaged components like the injectors.
Difficulty level
Fuel Pump Diesel
5th Gear Not Engaging (Manuals)
Problem:
It's either very hard or completely impossible to engage 5th gear.
Solution:
This is very common in the Mondeos built between 2001 and 2002 and is being caused by a loose roll pin inside the selector mechanism. You can find a new selector mechanism on our parts page for the Mondeo, but you'll also have to adjust the gear shift cables.
Difficulty level
Gear Selector
Oil Leaks
Problem:
There are patches of oil on the floor beneath the car where you've parked. You've also noticed that you're using more oil than you used to.
Solution:
It's quite likely that your Mondeo hasn't received the updated software that prevents engine overheating. Such overheating can cause the oil sump to crack. Ignoring this issue may lead to your engine seizing or failing completely. If the crack isn't too large, you might be able to weld it as a quick, inexpensive fix. However, the bigger the crack, the more sensible it is to order a new oil sump from our parts list.
Difficulty level
Headlights Keep Switching Off
Problem:
The headlights are turning off unexpectedly, increasing the danger of driving at night.
Solution:
This is a well-known software glitch in the Mondeo. Your only option is to take the car to a Ford dealer for a software update. This is usually free of charge.
Difficulty level
Rapid Wear Of Headlight Bulbs and Windscreen Wipers
Problem:
Your headlight bulbs keep burning out very quickly, and your windscreen wipers wear out much faster than you'd expect.
Solution:
These two complaints are the most common issues you'll encounter with the Mondeo, and they are simply design flaws. Order more long-lasting light bulbs from our parts list, along with non-standard, more durable windscreen wiper blades. Both are easy to install.
Difficulty level
Burning Smell
Problem:
There is a burning smell coming from somewhere, and the vehicle has slowed down considerably. You might also hear a loud bang.
Solution:
The reason for a recall by Ford is due to a fracture in the clutch pressure plate. If your car is still under warranty, Ford should replace the plate free of charge. If not, you can find affordable pressure plates for the Mondeo on our parts list, and fitting them is relatively straightforward.
Difficulty level
Clutch Pressure Plate