Ford Mondeo Common Problems and Solutions
Interior Light Staying On
Problem:
The interior light remains on even when the doors are closed. The anti-theft warning system is also not working.
Solution:
There will be a faulty contact switch in the local striker of the B or C pillar. It's preventing the interior light from working properly, which has the side-effect of causing the PATS to stay disarmed. You'll have to order the upgraded lock striker from BreakerYard and install it.
Difficulty level
Crunching Noise From Gear Assembly
Problem:
There is a crunching noise when you move into 3rd gear.
Solution:
You have a faulty 3rd gear synchroniser ring. Ford has issued a revised version of the ring, which you can find on our parts page. We always have them in stock and can deliver the replacement to wherever you need it.
Difficulty level
No Cold Air From AC
Problem:
There is no cold air coming from your aircon vents. It may also be making strange noises when turned on.
Solution:
The AC condenser unit in the Mondeo can often wear out far too quickly, and you're going to have to replace it. Enter your registration number on our homepage and then browse for a new AC condenser unit for the Mondeo. It's a fiddly replacement job, but it's very doable.
Difficulty level
Aircon Condensor
Window Rolling Down
Problem:
Every now and again, one or more of your windows rolls down by itself.
Solution:
A known weak spot of the Mondeo, this is nothing more than a faulty power window motor. You'll have to remove the inside door panels to get at the part, but you can find a new motor easily on our parts page for the Mondeo.
Difficulty level
Window Motor
Engine Rattle
Problem:
You can hear a rattling sound coming from the engine while it's running.
Solution:
While engine rattle can mean a variety of issues, on the Mondeo, the most likely cause is a damaged or worn out dual-mass flywheel. If you've been driving at high speeds, then it's a part that's very likely to suffer. You can find a new flywheel in the BreakerYard store, and although it's a challenging part to install, there are many online guides available that will take you through the process.
Difficulty level
Dual Mass Flywheel
Problem with fuel gauge reading
Problem:
Any Mondeos up to 2001 have been known to have problems with inaccurate readings on the fuel gauge. This is usually caused by a fault in the fuel pump module.
Solution:
The best way to fix this problem is to fit a new fuel lever sender card.
Difficulty level
Problem with fuel gauge reading
Problem:
Mondeos produced before 2001 have been known to have problems with inaccurate readings on the fuel gauge. This is usually caused by a fault in the fuel pump module.
Solution:
The best way to fix this problem is to fit a new fuel lever sender card.
Difficulty level
Power steering faults
Problem:
The 1996-99 Mondeos are known to suffer from a knocking noise coming from the power steering system.
Solution:
The best way to fix this problem is to fit a new power steering return line which will stop this noise. Take a look at Ford Mondeo steering parts available now.
Difficulty level
Clicking from front on 97 Mondeo
Problem:
If you have noticed a clicking noise coming from the front of your 1997 Mondeo it is most likely caused by the outer CV joint. The clip on the boot can either be missing or broken, causing water to leak into the CV.
Solution:
You are best fixing this as quickly as possible if you want to avoid damaging the CV joint. To fix this, you will need to fit new clips to resolve the issue.
Difficulty level
Noise From Power Steering System
Problem:
You can hear a groaning noise coming from the power steering system.
Solution:
Your Mondeo is likely suffering from pressure fluctuations in the power steering system (PAS), which is causing issues across the entire vehicle body. Order the revised PAS high-pressure pipe assembly, as well as the newer version of the PAS pump.
Difficulty level
Power Steering Pump
Rough Idling
Problem:
The engine is very hard to start and has rough idling when it does start. There is also a power reduction. A diagnostic check shows the fault code P0340.
Solution:
The good news is that this is a very easy fix. The camshaft position sensor is sending an insufficient signal, which means you'll need to have a revised wiring harness and sensor delivered by our parts team. This will increase the voltage to 12 volts, which is a much stronger signal.
Difficulty level
Camshaft Position Sensor
Heating problems
Problem:
The 2002 Mondeo has been known to only blow out cold air when set to hot. This problem occurs when the heater flap gets stuck in the heater housing.
Solution:
The best way to fix this problem is to use a torx T50 which should free the heater flap, allowing it to move to the correct setting.
Difficulty level
Remote control unlocking issues
Problem:
Any Mondeo after 2001 could experience issues with unlocking the car using the remote from a distance of more than five metres. This is caused by the radio transmission being overly shielded.
Solution:
You can solve this problem by having an extension fitted to the transmission line to improve the signal.
Difficulty level
Rear brake wear
Problem:
The 2001-02 Mondeo can have excessive rear brake pad wear due to the pads sticking.
Solution:
This can be fixed by changing the pads and 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
Fuel flap problems
Problem:
Again with the 2001 Mondeo there are problems associated with the fuel flap not opening. The problem is due to the fuel flap not integrating properly with the spring release.
Solution:
This can be remedied by fitting a new revised flap which connects properly with the release spring.
Difficulty level
Handbrake lever clutch problems
Problem:
This problem is associated with the 2001 Mondeo. You may find that you are having to pull the handbrake lever too far, which is due to deterioration of the clutch mechanism.
Solution:
This can be fixed by having a clip fitted to the clutch spring stop which will then stop the spring from extending as far.
Difficulty level
Front Axle Rattling
Problem:
There is a rattle coming from the front of the car when driving.
Solution:
A very common problem, there is excessive friction between the front lower suspension arm bearing bush and the rear hydraulic rubber bushes. Ford released revised suspension arms that come with modified rubber bushes and silicone coated bearing bushes. Order replacements from BreakerYard and install these easily.
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 failing to start or doesn't run properly when it does turn over.
Solution:
When your Mondeo was built, insufficient bedding was installed, which results in issues with the diesel pump and extreme wear on the rollers and shoes. This then leads to small metal particles getting into the diesel, which will end up damaging multiple engine components. You can order a revised diesel pump that comes with the revised rollers and shoes directly from our parts list, although you may have to order any other damaged parts 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 spots 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 more than likely that your Mondeo has not had the revised software update that prevents overheating of the engine. That overheating will cause the oil sump to crack. If you ignore this issue, then your engine is eventually going to seize up and die. If the crack is not too large, then you may be able to weld it for a fast and low-cost repair. However, the larger the crack, the more likely it is that you will better off ordering a new oil sump from our parts list.
Difficulty level
Headlights Keep Switching Off
Problem:
The headlights are switching off without any warning, increasing the risks of driving at night.
Solution:
This is a well-known software glitch of the Mondeo. Your only option is going to be taking the car to a Ford dealer for a software update. This will usually be 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 a lot faster than you'd expect.
Solution:
These two complaints are the most common issues you'll get with the Mondeo, and it's nothing more than a design flaw. Order more long-lasting light bulbs from our parts list, and non-standard more durable windscreen wiper blades. These are both easy to install.
Difficulty level
Burning Smell
Problem:
There is a burning smell coming from somewhere, and the vehicle has dramatically slowed down. You may also hear a loud bang.
Solution:
The cause of a recall by Ford, this is the result of a fracture in the clutch pressure plate. If your car is under warranty, then Ford should replace the plate for free. If not, then you can find low-cost pressure plates for the Mondeo on our parts list, and installation is relatively straightforward.
Difficulty level
Clutch Pressure Plate
