Recalls: Ford Mk.4 Mondeo
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Ford Mk.4 Mondeo
Ford MA Mondeo TDCi: loss of power braking assistance
In May 2009, a recall was issued for 730 Ford MA Mondeo vehicles fitted with 2.0-litre turbo-diesel engines. In these vehicles, the supply of vacuum to the brake booster could be interrupted – this could result in a hard brake pedal and increased stopping distances (PRA 2009/10807).
2007-09 Ford MA/MB Mondeo: Takata airbag recall
In October 2018, recall campaign 17S32 was issued for Ford MA and MB Mondeo vehicles that were manufactured from 1 March 2007 to 14 August 2009. The driver’s side front airbag inflator in these vehicles contained propellant wafers that could absorb moisture over time. In the event of deployment, excessive internal pressure could cause the metal airbag inflator housing to explode or rupture such that metal fragments would be projected through the airbag and into the cabin – these fragments posed a risk of serious injury and fatality. For the VINs of the recalled vehicles, please see PRA 2018/17077.
Problems and faults: Ford Mk.4 Mondeo
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
Ford Mk.4 Mondeo: Powershift transmission
For Ford Mondeo vehicles with the ‘Powershift’ double clutch transmission, there have been reports of harsh gearshifts, hesitations in-gear or a failure to change gear – these symptoms may be caused by faulty sensors or the transmission control module.
To prevent premature wear of the PowerShift transmission, it should not be driven like a conventional automatic transmission. As such, drivers should not hold the car inclines by using the accelerator; by braking when coming to rest on an incline, the hill launch assist function will engage to prevent the vehicle rolling backwards when the driver removes their foot from the brake to accelerate. Furthermore, drivers should not engage in stop/start creeping which may cause the clutch to slip.
Ford Mk.4 Mondeo: other problems and faults
- For early Ford Mondeos fitted with automatic transmissions, harsh downshifts could be rectified by a software update.
- For Mondeo liftback models manufactured before early 2008, water would drip into the boot if opened after rain – this requires a rubber seal to be fitted around the boot.
- Mondeo models with turbo-diesel engines should not be driven through floodwaters due to the low air intake.
- The tyre pressure monitoring valves – where fitted – may fail due to metal fatigue or corrosion.
- Where fitted, the sunroof may shudder when operated or leak water. If so, the seals should be replaced.
- Incorrect fuel readings may require the fuel level sensor to be replaced.
Problems and faults: Ford Mondeo XR5 Turbo
Ford Mondeo XR5 Turbo: PCV diaphragm rupture (B5254T3)
For the 2.5-litre B5254T3 turbocharged petrol engine, the positive crankcase ventilation (PCV) diaphragm – located in the oil filter housing – may rupture. Symptoms of a ruptured PCV diaphragm include:
- A high-pitched, whining/whistling noise that increases with engine speed. This noise is caused by excessive crankcase pressure escaping via the oil seals. For reference, this noise stops when the dipstick is removed (since removing the dipstick releases back pressure, see video below);
- A lack of boost pressure in low gears;
- Excessive oil consumption;
- High oil pressure at idle;
- Blue smoke from the exhaust; and,
- Illumination of the engine warning light.
To fix, the air filter housing assembly needs to be removed so that the oil filter housing can be replaced. Sometimes, the breather hose from the assembly to the block may be damaged and also require replacement.
If the PCV diaphragm has ruptured, the vehicle should not be run until the oil filter housing is replaced since doing so could damage the camshaft or crankshaft oil seals and cause oil leaks. If an oil leak occurs at the timing belt end, the timing belt and seals must be replaced. If, however, an oil leak occurs at the crankshaft’s main oil seal, then the gearbox must be removed, the seal replaced and, in extreme cases, the clutch replaced.
It is understood that Ford/Volvo (for the C30 T5) subsequently introduced an uprated diaphragm which had an additional vent on the diaphragm cover, though failures of the updated diaphragm do still occur. Failures are more common in low mileage vehicles that:
- Have been used to drive short distances since the engine does not reach its operating temperatures; and,
- Reside in high humidity environments.
Ford Mondeo XR5 Turbo: cracked cylinder liners (B5254T3)
The 2.5-litre B5254T3 engine had an open deck block and steel cylinder liners that were press-fitted into the block. For standard B5254T3 engines, however, there have been rare cases of cracked cylinder liners (also known as sleeves). Symptoms of cracked cylinder liners include:
- Misfire when cold;
- Loss of coolant;
- Excessive white smoke; and,
- Rough running on start-up.
Engines that have been modified for greater power are considered more vulnerable to cracked cylinder liners (particularly beyond 240 kW) due to the following factors –
- Excessive boost pressure;
- Aggressive ignition timing from poorly developed aftermarket tunes; and,
- Coolant leaks that have not been rectified (see also ‘coolant leaks’, below).
It has also been suggested that cracked cylinder liners were most common for pre-April 2008 engines, though cracked liners have been observed in all years of Mondeo XR5 Turbo engines.
For B5254T3 engines to produce more than 300 bhp (224 kW), OEM Denied recommends a ‘block mod’ in which the cylinder head is removed and stainless steel shims are fitted in the expansion gaps between the cylinder liners. Although this does not guarantee that cracked cylinder liners will not happen, OEM Denied has not seen this occur in the vehicles they have worked upon.
B5254T3 engine: solenoid boost valve
For the 2.5-litre B5254T3 turbocharged petrol engine, the solenoid boost valve is susceptible to failure. If there is a lack of performance and the boost gauge boost doesn’t go beyond a quarter of the dial, this is indicative of a failed solenoid boost valve. If the valve is operating properly, the dial on the boost pressure gauge should go beyond halfway before settling down in the middle.
Ford Mondeo XR5 Turbo: coolant leaks
Ford Mondeo XR5 Turbo vehicles are susceptible to coolant leaks from –
- The thermostat housing at the cylinder head side gasket. Specifically, the leak occurs at the bottom corner and a mirror is required to see it;
- The turbo coolant feed and return; and,
- The radiator top hose joint at the back of the engine on the gearbox side.
The coolant hoses may also experience internal delamination as the vehicle ages. Where internal delamination has occurred, the hoses will appear swollen in size.
Ford Mondeo XR5 Turbo: suspension
For the Ford Mondeo XR5 Turbo, the following suspension components may wear prematurely:
- The front anti-roll bar drop links;
- The rear bushes on the front wishbones bushes (oil-filled).
It is recommended that the oil-filled bushes be replaced with more durable polyurethane bushes.
Ford Mondeo XR5 Turbo: clutch does not return
For the Ford Mondeo XR5 Turbo, the clutch pedal may not fully return to the ‘up’ position. This may be due to:
- The seal from the original slave cylinder tearing and becoming stuck in the clutch line – this usually occurs after the clutch has been replaced. To fix, the clutch line has to be removed, blown out with compressed air and then have clean brake fluid poured through it. The brake fluid should flow easily and consistently in both directions; or,
- In the case of hard driving (during or after), hydraulic fluid may boil and cause air bubbles to form. To fix, the clutch should be bled and high boiling-point DOT 5.1 fluid used.
AustralianCar.Reviews thanks OEM Denied for their contributions to this page.
