What's Bad
Criticised for "unstable body structure" in 2001 NCAP test, despite four star score. Still seems to lack space for oddments inside cockpit.
Reports of poor 35mpg economy from stop-gap 2.0 litre 115bhp TDDI engine. 2.0 TDDI diesel engine also prone to flat spots and surging.
All Mondeo IIIs, petrol and diesel manuals have dual mass flywheels that can fail.
On early LX and Zetecs the bottom of the seat is not very friendly to the coccyx. Also uncomfortable for heavier drivers because the plastic pins holding the molded padding in place can actually protrude through to the seat face. Later models much improved.
Possible security issue in that access can be gained via passenger door when car is locked and immobilised.
Petrol models rated fewest breakdowns but poor for problems and faults in 2003 Which survey.
What to Watch Out For
WARNING An engine rattle from 2000-2003 1.8i and 2.0i petrol engines might indicate wearing of the shaft of the injection air inlet manifold flaps. If the shaft breaks and the flaps come off they are then ingested by the engine, wrecking it. This is becoming increasingly common. Also affects 1.8i engines. See
www.talkford.com/topic/97564-important-inlet-manifold-failure-in-graphic-detail/ This was rectified from 2003 by an improved inlet manifold design.
Two reports of timing chain tensioner rattles on 2001MY 2.0 litre petrol engines, fixed under warranty.
Several complaints of wind noise from front and rear door seals. Reports in 2008 of water leaks through lower front door seals.
TDCI 130bhp engine may suffer from starting problems and uneven idling, may misfire between 1,800 and 2,000rpm, may sometimes cut out and may not be particularly economical with 42.5 mpg fairly typical. Partially cured by a an ECU software download, but head and injectors have also been modified on later cars.
Also reports of the TDCI smoking and of high oil consumption, which may be turbo oil seals.
Reports of problems with camshaft position sensors of TDCI 130s. Spate of clutch and dual-mass flywheel failures on 2003 built 2004 model year TDCIs. Starting problems with diesel may be due to impending clutch failure. Iron filings from failing dual mass flywheels can get into the starter motor and cause starting problems. 13/10/07 Voluntary Recall letter to some owners of TDDIs and TDCIs to replace faulty dual mass flywheels. Ford will sometimes contribute to the very high replacement costs of dual mass flywheels and clutches if the car has done less than 45,000 miles. On diesels used as taxis, DMFs and clutches typically last 30,000 - 40,000 miles.
TDCI injectors seem to be very fuel sensitive. Many have needed to be replaced after 3-4 years and circa 60,000 miles.
Report of turbo oil-seal failure in 2.2 TDCi turbo caused engine to run on its sump oil and self-destruct. Bill for replacement engine, turbo, catalytic converter, exceeded £7,000. By early 2010, diesel pump failures also damaging the injectors were on the increase for both the 2.0 and 2.2 litre diesels.
When replacing injectors, the new improved Delphi injectors are smaller than the originals and require a different seal. Use of original type of seal will result in fuel leaks.
Diff problem starting to crop up on TDCI 130 6-speeds from around 3 years old.
Reports of failures of fuel tank lifter pumps leading to fuel delivery problems in 2.0 petrol models.
Reports of out of true alloy wheels.
Check inside edges of the bottoms of all doors of 2000 - 2003 cars for paint lifting and corrosion because the wax sealing between the door frame and skin can fail.
Check for corroded rear brake pipes where they pass over the fuel tank (an MOT failure point).
Check rear suspension bushes which can become loose in the attachment points (an MOT failure point) and used to require a new subframe costing £300 - £500 to replace. Ford now has a procedure that removes the need for a new subframe involving a new type of bush, a special tool (part number is 205-047-07) and Loctite 270 superglue (part number 1128-392). Unfortunately the tool and glue have been in short supply. The solution will not work if the subframe has corroded around the attachment points.
Look for rust around chrome number plate light cover on Ghia estates.
Undertray of ST very difficult to remove to get to engine supm plug, then very difficult to put back. 16 fasteners and a two man job.
Reports of 2nd gear band breaking up in 4-speed autobox, contaminating the ATF and requiring the box to be rebuilt. These boxes tend to have a life of 60k - 90k.
JATCO advises owners of later 5-speed autoboxes not to carry out AUTOMATIC transmission fluid changes hemselves because it's difficult to ensure the correct amount is added (the gearbox needs to be run to a specific temperature - This requires diagnostic equipment) and probably they will use the wrong oil, e.g. Land Rover Discovery ATF is different from a Land Rover Freelander, and Jaguar X-Type (Jatco) uses different ATF to a Land Rover Freelander (Jatco).
ST models can suffer from drooping rear bumper/valence mouldings (
www.stdrivers.co.uk
Rear tracking is adjustable for toe in / toe out, but cannot be set with some types of alloy wheel because they do not have continuous rims and confuse the laser. Too much toe in will make the steering very light. Too much toe out will lead to severe tyre inner shoulder wear.
Flexible front brake hoses vulnerable to chafing when not secured properly, and this can cause total brake failure if ruptured.
One reader's catalogue of failures from his 1.8SCi: "Coolant leaks, water leaks, alloy wheel paint flaking around the valves, the Sat-Nav/Air/CD control has a tendency to freeze but worst of all the fuel consumption is very bad. Less than 30 mpg, where my previous 2001 1.8 Zetec gave me 35mpg." Seems to have a problem with the air con pipe at the front of the engine. Fix is new type of pipe £227 all in.
One case of rust-through of water jacket of 2.0i petrol engine.
On pre-2003 cars an a/c hose can chafeon the vertical joint of two flanges behind the front bumper and eventually sever, losing the refrigerant. Replacements are £80 but are modified so they do not chafe on the flange.
Engine surging of 2.0 litre petrol can be cured by a new idle control valve.
Wired in Quickclear screen tend to fail after 9 years or so.
Problem with rear hatchback lock causes by cold d and bad weather in the switch itself cured by a new switch at £25 from Ford.
