transmission FORD MONDEO 1993 Service Manual Online

Buying spare parts
Spare parts are available from many
sources; for example, Ford garages, other
garages and accessory shops, and motor
factors. Our advice regarding spare part
sources is as follows.
Officially-appointed Ford garages- This is
the best source for parts which are peculiar to
your vehicle, and which are not generally
available (eg complete cylinder heads, internal
transmission components, badges, interior
trim etc). It is also the only place at which you
should buy parts if the vehicle is still under
warranty. To be sure of obtaining the correct
parts, it will be necessary to give the storeman
the full Vehicle Identification Number, and if
possible, to take the old parts along for
positive identification. Many parts are
available under a factory exchange scheme -
any parts returned should always be clean. It
obviously makes good sense to go straight to
the specialists on your vehicle for this type of
part, as they are best equipped to supply you.
Other garages and accessory shops- These
are often very good places to buy materials
and components needed for the maintenance
of your vehicle (eg oil filters, spark plugs,
bulbs, drivebelts, oils and greases, touch-up
paint, filler paste, etc). They also sell general
accessories, usually have convenient opening
hours, charge lower prices, and can often be
found not far from home.
Motor factors- Good factors will stock all
the more important components which wear
out comparatively quickly (eg exhaust
systems, brake pads, seals and hydraulic
parts, clutch components, bearing shells,
pistons, valves etc). Motor factors will often
provide new or reconditioned components on
a part-exchange basis - this can save a
considerable amount of money.
Vehicle identification numbers
Modifications are a continuing and
unpublicised process in vehicle manufacture,
quite apart from major model changes. Spare
parts manuals and lists are compiled upon a
numerical basis, the appropriate identification
number or code being essential to correct
identification of the component concerned.
When ordering spare parts, always give asmuch information as possible. Quote the
vehicle model, year of manufacture, Vehicle
Identification Number and engine numbers, as
appropriate.
The vehicle identification plateis located on
the engine compartment front crossmember
(see illustration). In addition to many other
details, it carries the Vehicle Identification
Number, maximum vehicle weight
information, and codes for interior trim and
body colours.
The Vehicle Identification Numberis given
on the vehicle identification plate. It is also
stamped on the engine compartment
bulkhead, behind the air intake plenum
chamber, and into the body, so that it can be
seen through the bottom left-hand corner of
the windscreen (see illustrations).The engine number, consisting of two
letters and five digits, with the three-letter
engine code nearby, is stamped into a flat-
machined surface on the cylinder
block/crankcase’s forward-facing flange,
between the pulse-air filter housing and the
transmission. To read the number without
removing the engine compartment air intake
resonator - see Chapter 4 - it is easiest to
raise and support the front of the vehicle on
axle stands, so that the number can be seen
from underneath (see illustration). If the
number cannot be seen in this location,
possible alternative sites are on a lower flange
on the cylinder block’s forward face,
immediately above the sump mating surface,
or on the left-hand end of the cylinder head,
between the oil filler cap and ignition coil.
REF•5
Vehicle identification plate on engine
compartment front crossmember
Vehicle identification number in body,
visible through bottom left-hand corner of
windscreen
Vehicle identification number on engine
compartment bulkhead
Engine number (arrowed) on front of
cylinder block/crankcase - seen from
beneath vehicle
Spare Parts/Vehicle Identification
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REF•6Fault Finding
Engine 1
m mEngine backfires
m mEngine difficult to start when cold
m mEngine difficult to start when hot
m mEngine fails to rotate when attempting to start
m mEngine hesitates on acceleration
m mEngine idles erratically
m mEngine lacks power
m mEngine misfires at idle speed
m mEngine misfires throughout the driving speed range
m mEngine noises
m mEngine rotates but will not start
m mEngine runs-on after switching off
m mEngine stalls
m mEngine starts but stops immediately
m mOil pressure warning light illuminated with engine running
m mStarter motor noisy or excessively-rough in engagement
Cooling system 2
m
mCorrosion
m mExternal coolant leakage
m mInternal coolant leakage
m mOvercooling
m mOverheating
Fuel and exhaust systems 3
m
mExcessive fuel consumption
m mExcessive noise or fumes from exhaust system
m mFuel leakage and/or fuel odour
Clutch 4
m
mClutch fails to disengage (unable to select gears)
m mClutch slips (engine speed increases with no increase
in vehicle speed)
m mJudder as clutch is engaged
m mNoise when depressing or releasing clutch pedal
m mPedal travels to floor - no pressure or very little resistance
Manual transmission 5
m
mJumps out of gear
m mLubricant leaks
m mNoisy in neutral with engine running
m mNoisy in one particular gear
m mVibration
Automatic transmission 6
m
mEngine will not start in any gear, or starts in gears
other than Park or Neutral
m mFluid leakage
m mGeneral gear selection problems
m mTransmission fluid brown, or has burned smell
m mTransmission slips, shifts roughly, is noisy, or
has no drive in forward or reverse gears
m mTransmission will not downshift (kickdown) with
accelerator fully depressed
Driveshafts 7
m mClicking or knocking noise on turns (at slow speed on full-lock)
m mVibration when accelerating or decelerating
Braking system 8
m
mBrake pedal feels spongy when depressed
m mBrakes binding
m mExcessive brake pedal effort required to stop vehicle
m mExcessive brake pedal travel
m mJudder felt through brake pedal or steering wheel when braking
m mNoise (grinding or high-pitched squeal) when brakes applied
m mRear wheels locking under normal braking
m mVehicle pulls to one side under braking
Suspension and steering systems 9
m
mExcessive pitching and/or rolling around corners, or during
braking
m mExcessive play in steering
m mExcessively-stiff steering
m mLack of power assistance
m mTyre wear excessive
m mVehicle pulls to one side
m mWandering or general instability
m mWheel wobble and vibration
Electrical system 10
m
mBattery will not hold a charge for more than a few days
m mCentral locking system inoperative, or unsatisfactory in operation
m mElectric windows inoperative, or unsatisfactory in operation
m mHorn inoperative, or unsatisfactory in operation
m mIgnition warning light fails to come on
m mIgnition warning light remains illuminated with engine running
m mInstrument readings inaccurate or erratic
m mLights inoperative
m mWindscreen/tailgate washers inoperative, or unsatisfactory in
operation
m mWindscreen/tailgate wipers inoperative, or unsatisfactory in
operation
procarmanuals.com

REF•7
Engine fails to rotate when attempting to start
m mBattery terminal connections loose or corroded (Chapter 5).
m mBattery discharged or faulty (Chapter 5).
m mBroken, loose or disconnected wiring in the starting circuit
(Chapter 5).
m mDefective starter solenoid or switch (Chapter 5).
m mDefective starter motor (Chapter 5).
m mStarter pinion or flywheel ring gear teeth loose or broken (Chap-
ter 5).
m mEngine earth strap broken or disconnected (Chapter 5).
m mAutomatic transmission not in Park/Neutral position, or selector
lever position sensor faulty (Chapter 7, Part B).
Engine rotates but will not start
m mFuel tank empty.
m mBattery discharged (engine rotates slowly) (Chapter 5).
m mBattery terminal connections loose or corroded (Chapter 5).
m mIgnition components damp or damaged (Chapters 1 and 5).
m mBroken, loose or disconnected wiring in the ignition circuit
(Chapters 1 and 5).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mMajor mechanical failure (eg camshaft drive) (Chapter 2, Part A).
Engine difficult to start when cold
m
mBattery discharged (Chapter 5).
m mBattery terminal connections loose or corroded (Chapter 5).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mOther ignition system fault (Chapters 1 and 5).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mLow cylinder compressions (Chapter 2, Part A).
Engine difficult to start when hot
m
mAir filter element dirty or clogged (Chapter 1).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mLow cylinder compressions (Chapter 2, Part A).
m mFaulty hydraulic tappet(s) (Chapter 2, Part A).
Starter motor noisy or excessively-rough in
engagement
m mStarter pinion or flywheel ring gear teeth loose or broken (Chapter 5).
m mStarter motor mounting bolts loose or missing (Chapter 5).
m mStarter motor internal components worn or damaged (Chapter 5).
Engine starts but stops immediately
m
mLoose or faulty electrical connections in the ignition circuit
(Chapters 1 and 5).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mVacuum leak at the inlet manifold (Chapters 1, 4 and 6).
Engine idles erratically
m
mIdle speed control valve faulty (Chapter 4).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mAir filter element clogged (Chapter 1).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty hydraulic tappet(s) (Chapter 2, Part A).
m mUneven or low cylinder compressions (Chapter 2, Part A).
m mCamshaft lobes worn (Chapter 2).
m mTiming belt incorrectly-tensioned (Chapter 2, Part A).
Engine misfires at idle speed
m
mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty spark plug HT leads (Chapter 1).
m mIdle speed control valve faulty (Chapter 4).
m mIncorrect ignition timing (Chapters 5 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mFaulty hydraulic tappet(s) (Chapter 2, Part A).
m mUneven or low cylinder compressions (Chapter 2, Part A).
m mDisconnected, leaking or perished crankcase ventilation hoses
(Chapters 1 and 6).
Fault Finding
The vehicle owner who does his or her own maintenance according
to the recommended service schedules should not have to use this
section of the manual very often. Modern component reliability is such
that, provided those items subject to wear or deterioration are inspected
or renewed at the specified intervals, sudden failure is comparatively
rare. Faults do not usually just happen as a result of sudden failure, but
develop over a period of time. Major mechanical failures in particular are
usually preceded by characteristic symptoms over hundreds or even
thousands of miles. Those components which do occasionally fail
without warning are often small and easily carried in the vehicle.
With any fault-finding, the first step is to decide where to begin
investigations. Sometimes this is obvious, but on other occasions, a
little detective work will be necessary. The owner who makes half a
dozen haphazard adjustments or replacements may be successful in
curing a fault (or its symptoms), but will be none the wiser if the fault
recurs, and ultimately may have spent more time and money than was
necessary. A calm and logical approach will be found to be more
satisfactory in the long run. Always take into account any warning
signs or abnormalities that may have been noticed in the period
preceding the fault - power loss, high or low gauge readings, unusual
smells, etc - and remember that failure of components such as fuses
or spark plugs may only be pointers to some underlying fault.
The pages which follow provide an easy reference guide to the
more common problems which may occur during the operation of the
vehicle. These problems and their possible causes are grouped underheadings denoting various components or systems, such as Engine,
Cooling system, etc. The Chapter and/or Section which deals with the
problem is also shown in brackets. Whatever the fault, certain basic
principles apply. These are as follows:
Verify the fault. This is simply a matter of being sure that you know
what the symptoms are before starting work. This is particularly
important if you are investigating a fault for someone else, who may
not have described it very accurately.
Don’t overlook the obvious. For example, if the vehicle won’t start, is
there petrol in the tank? (Don’t take anyone else’s word on this
particular point, and don’t trust the fuel gauge either!) If an electrical
fault is indicated, look for loose or broken wires before digging out the
test gear.
Cure the disease, not the symptom. Substituting a flat battery with a
fully-charged one will get you off the hard shoulder, but if the underlying
cause is not attended to, the new battery will go the same way. Similarly,
changing oil-fouled spark plugs for a new set will get you moving again,
but remember that the reason for the fouling (if it wasn’t simply an
incorrect grade of plug) will have to be established and corrected.
Don’t take anything for granted. Particularly, don’t forget that a
“new” component may itself be defective (especially if it’s been
rattling around in the boot for months), and don’t leave components
out of a fault diagnosis sequence just because they are new or
recently fitted. When you do finally diagnose a difficult fault, you’ll
probably realise that all the evidence was there from the start.
1 Engine
Introduction
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Engine misfires throughout the driving speed range
m mFuel filter choked (Chapter 1).
m mFuel pump faulty or delivery pressure low (Chapter 4).
m mFuel tank vent blocked or fuel pipes restricted (Chapter 4).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty spark plug HT leads (Chapter 1).
m mFaulty ignition coil (Chapter 5).
m mEngine management system fault (Chapters 1, 4, 5 and 6)
m mUneven or low cylinder compressions (Chapter 2, Part A).
Engine hesitates on acceleration
m
mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
Engine stalls
m mIdle speed control valve faulty (Chapter 4).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mFuel filter choked (Chapter 1).
m mFuel pump faulty or delivery pressure low (Chapter 4).
m mFuel tank vent blocked or fuel pipes restricted (Chapter 4).
Engine lacks power
m
mIncorrect ignition timing (Chapters 5 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mTiming belt incorrectly fitted or incorrectly tensioned (Chapter 2,
Part A).
m mFuel filter choked (Chapter 1).
m mFuel pump faulty or delivery pressure low (Chapter 4).
m mUneven or low cylinder compressions (Chapter 2, Part A).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mBrakes binding (Chapters 1 and 9).
m mClutch slipping (Chapter 8).
m mAutomatic transmission fluid level incorrect (Chapter 1).
Engine runs-on after switching off
m
mIdle speed excessively high (Chapters 4 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mExcessive carbon build-up in engine (Chapter 2, Part A).
m mHigh engine operating temperature (Chapter 3).
Engine backfires
m
mIgnition timing incorrect (Chapters 5 and 6).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mTiming belt incorrectly fitted or incorrectly tensioned (Chapter 2,
Part A).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
Oil pressure warning light illuminated with engine
running
m mLow oil level or incorrect oil grade (Chapter 1).
m mFaulty oil pressure warning light switch (Chapter 2, Part A).
m mWorn engine bearings and/or oil pump (Chapter 2).
m mHigh engine operating temperature (Chapter 3).
m mOil pressure relief valve defective (Chapter 2, Part A).
m mOil pick-up strainer clogged (Chapter 2, Part A).
Engine noises
Pre-ignition (pinking) or knocking during acceleration or under
load
m mIgnition timing incorrect (Chapters 5 and 6).
m mIncorrect grade of fuel (Chapter 4).
m mVacuum leak at the inlet manifold or associated hoses (Chap-
ters 1, 4 and 6).
m mExcessive carbon build-up in engine (Chapter 2, Part A).
Whistling or wheezing noises
m mLeaking inlet manifold gasket (Chapter 2, Part A).
m mLeaking exhaust manifold gasket or downpipe-to-manifold joint
(Chapters 1, 2 Part A, and 4).
m mLeaking vacuum hose (Chapters 1, 4, 6 and 9).
m mBlowing cylinder head gasket (Chapter 2, Part A).
Tapping or rattling noises
m mFaulty hydraulic tappet(s) (Chapter 2, Part A).
m mWorn valve gear or camshaft (Chapter 2, Part A).
m mWorn timing belt or tensioner (Chapter 2, Part A).
m mAncillary component fault (water pump, alternator, etc) (Chap-
ters 3 and 5).
Knocking or thumping noises
m mWorn big-end bearings (regular heavy knocking, perhaps less
under load) (Chapter 2, Part B).
m mWorn main bearings (rumbling and knocking, perhaps worsening
under load) (Chapter 2, Part B).
m mPiston slap (most noticeable when cold) (Chapter 2, Part B).
m mAncillary component fault (water pump, alternator, etc) (Chap-
ters 3 and 5).
REF•8Fault Finding
2 Cooling system
Overheating
m mInsufficient coolant in system (Chapter 1).
m mThermostat faulty (Chapter 3).
m mRadiator core blocked or grille restricted (Chapter 3).
m mRadiator electric cooling fan(s) or coolant temperature sensor faulty
(Chapter 3).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mPressure cap faulty (Chapter 3).
m mAuxiliary drivebelt worn or slipping (Chapter 1).
m mIgnition timing incorrect (Chapters 5 and 6).
m mInaccurate coolant temperature gauge sender (Chapter 3).
m mAir-lock in cooling system (Chapter 1).
Overcooling
m
mThermostat faulty (Chapter 3).
m mInaccurate coolant temperature gauge sender (Chapter 3).
External coolant leakage
m
mDeteriorated or damaged hoses or hose clips (Chapter 1).
m mRadiator core or heater matrix leaking (Chapter 3).
m mPressure cap faulty (Chapter 3).
m mWater pump seal leaking (Chapter 3).
m mBoiling due to overheating (Chapter 3).
m mCore plug leaking (Chapter 2, Part B).
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REF•9
Excessive fuel consumption
m mUnsympathetic driving style, or adverse conditions.
m mAir filter element dirty or clogged (Chapter 1).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
m mIgnition timing incorrect (Chapters 5 and 6).
m mTyres under-inflated (Chapter 1).
Fuel leakage and/or fuel odour
m
mDamaged or corroded fuel tank, pipes or connections (Chapter 1).
m mCharcoal canister and/or connecting pipes leaking (Chapter 6).
Excessive noise or fumes from exhaust system
m
mLeaking exhaust system or manifold joints (Chapters 1, 2 Part A,
and 4).
m mLeaking, corroded or damaged silencers or pipe (Chapter 1).
m mBroken mountings, causing body or suspension contact (Chap-
ters 1 and 4).
Fault Finding
3 Fuel and exhaust system
Noisy in neutral with engine running
m mInput shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7, Part A).*
m mClutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 8).
Noisy in one particular gear
m mWorn, damaged or chipped gear teeth (Chapter 7, Part A).*
Difficulty engaging gears
m
mClutch fault (Chapter 8).
m mWorn or damaged gear linkage (Chapter 7, Part A).
m mIncorrectly-adjusted gear linkage (Chapter 7, Part A).
m mWorn synchroniser assemblies (Chapter 7, Part A).*
Vibration
m
mLack of oil (Chapter 1).
m mWorn bearings (Chapter 7, Part A).*
Jumps out of gear
m
mWorn or damaged gear linkage (Chapter 7, Part A).
m mIncorrectly-adjusted gear linkage (Chapter 7, Part A).
m mWorn synchroniser assemblies (Chapter 7, Part A).*
m mWorn selector forks (Chapter 7, Part A).*
Lubricant leaks
m
mLeaking differential side gear oil seal (Chapter 7, Part A).
m mLeaking housing joint (Chapter 7, Part A).*
m mLeaking input shaft oil seal (Chapter 7, Part A).*
m mLeaking selector shaft oil seal (Chapter 7, Part A).
m mLeaking speedometer drive pinion O-ring (Chapter 7, Part A).
* Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition, so
that the owner can communicate clearly with a professional mechanic.
4 Clutch
5 Manual transmission
Pedal travels to floor - no pressure or very little
resistance
m mBroken clutch cable (Chapter 8).
m mIncorrect clutch adjustment (Chapter 8).
m mBroken clutch release bearing or fork (Chapter 8).
m mBroken diaphragm spring in clutch pressure plate (Chapter 8).
Clutch fails to disengage (unable to select gears)
m
mIncorrect clutch adjustment (Chapter 8).
m mClutch disc sticking on transmission input shaft splines (Chapter 8).
m mClutch disc sticking to flywheel or pressure plate (Chapter 8).
m mFaulty pressure plate assembly (Chapter 8).
m mClutch release mechanism worn or incorrectly assembled (Chapter 8).
Clutch slips (engine speed increases with no
increase in vehicle speed)
m mIncorrect clutch adjustment (Chapter 8).
m mClutch disc linings excessively worn (Chapter 8).m mClutch disc linings contaminated with oil or grease (Chapter 8).
m mFaulty pressure plate or weak diaphragm spring (Chapter 8).
Judder as clutch is engaged
m
mClutch disc linings contaminated with oil or grease (Chapter 8).
m mClutch disc linings excessively worn (Chapter 8).
m mClutch cable sticking or frayed (Chapter 8).
m mFaulty or distorted pressure plate or diaphragm spring (Chapter 8).
m mWorn or loose engine/transmission mountings (Chapter 2, Part A).
m mClutch disc hub or transmission input shaft splines worn (Chap-
ter 8).
Noise when depressing or releasing clutch pedal
m mWorn clutch release bearing (Chapter 8).
m mWorn or dry clutch pedal bushes (Chapter 8).
m mFaulty pressure plate assembly (Chapter 8).
m mPressure plate diaphragm spring broken (Chapter 8).
m mBroken clutch disc cushioning springs (Chapter 8).
Internal coolant leakage
m
mLeaking cylinder head gasket (Chapter 2, Part A).
m mCracked cylinder head or cylinder bore (Chapter 2, Part B).
Corrosion
m
mInfrequent draining and flushing (Chapter 1).
m mIncorrect antifreeze mixture, or inappropriate antifreeze type
(Chapter 1).
procarmanuals.com

6 Automatic transmission
REF•10Fault Finding
Note:Due to the complexity of the automatic transmission and its
electronic control system, it is difficult for the home mechanic to
properly diagnose and service this unit. For problems other than the
following, the vehicle should be taken to a dealer service department
or automatic transmission specialist.
Fluid leakage
m mAutomatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily be
blown onto the transmission by airflow.
m mTo determine the source of a leak, first remove all built-up dirt and
grime from the transmission housing and surrounding areas, using
a degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise
and support the vehicle, and determine where the leak is coming
from. The following are common areas of leakage:
(a) Housing joints (Chapters 1 and 7, Part B).
(b) Dipstick tube (Chapters 1 and 7, Part B).
(c) Transmission-to-fluid cooler pipes/unions (Chapters 3 and 7,
Part B).
(d) Speedometer drive pinion O-ring (Chapter 7, Part B).
(e) Differential side gear oil seals (Chapter 7, Part B).
Transmission fluid brown, or has burned smell
m mTransmission fluid level low, or fluid in need of renewal (Chapter 1).
Transmission will not downshift (kickdown) with
accelerator pedal fully depressed
m mLow transmission fluid level (Chapter 1).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
m mEngine management system fault (Chapters 1, 4, 5 and 6).
General gear selection problems
m
mChapter 7, Part B, deals with checking and adjusting the selector
cable on automatic transmissions. The following are common
problems which may be caused by a poorly-adjusted cable:
(a) Engine starting in gears other than Park or Neutral.
(b) Indicator on gear selector lever pointing to a gear other than the
one actually being used.
(c) Vehicle moves when in Park or Neutral.
(d) Poor gear shift quality or erratic gear changes.
Refer to Chapter 7, Part B for the selector cable adjustment
procedure.
Engine will not start in any gear, or starts in gears
other than Park or Neutral
m mIncorrect selector lever position sensor adjustment (Chapter 7,
Part B).
m mIncorrect selector cable adjustment (Chapter 7, Part B).
Transmission slips, shifts roughly, is noisy, or has no
drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid if needed. If the problem persists, professional
help will be necessary.
7 Driveshafts
Clicking or knocking noise on turns (at slow speed
on full-lock)
m mLack of constant velocity joint lubricant (Chapter 8).
m mWorn outer constant velocity joint (Chapter 8).
Vibration when accelerating or decelerating
m
mWorn inner constant velocity joint (Chapter 8).
m mBent or distorted driveshaft (Chapter 8).
8 Braking system
Note:Before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking the condition of all pipe and hose
connections, any faults occurring on the Anti-lock Braking System (ABS) should be referred to a Ford dealer for diagnosis - the same applies to the
components of the Traction Control System (TCS).
Vehicle pulls to one side under braking
m mWorn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapter 1).
m mSeized or partially-seized front or rear brake caliper/wheel cylinder
piston (Chapter 9).
m mA mixture of brake pad/shoe lining materials fitted between sides
(Chapter 1).
m mBrake caliper mounting bolts loose (Chapter 9).
m mRear brake backplate mounting bolts loose (Chapter 9).
m mWorn or damaged steering or suspension components (Chap-
ter 10).
Noise (grinding or high-pitched squeal) when brakes
applied
m mBrake pad or shoe friction lining material worn down to metal
backing (Chapter 1).
m mExcessive corrosion of brake disc or drum (may be apparent after
the vehicle has been standing for some time) (Chapter 1).
m mForeign object (stone chipping, etc) trapped between brake disc
and splash shield (Chapter 1).
Excessive brake pedal travel
m mInoperative rear brake self-adjust mechanism (Chapter 9).
m mFaulty master cylinder (Chapter 9).
m mAir in hydraulic system (Chapter 9).
procarmanuals.com

REF•15Glossary of Technical Terms
GGapThe distance the spark must travel in
jumping from the centre electrode to the side
electrode in a spark plug. Also refers to the
spacing between the points in a contact
breaker assembly in a conventional points-
type ignition, or to the distance between the
reluctor or rotor and the pickup coil in an
electronic ignition.
GasketAny thin, soft material - usually cork,
cardboard, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
GaugeAn instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
readout is called a digital gauge.
HHalfshaftA rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear
axle.
Harmonic balancerA device designed to
reduce torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
HoneAn abrasive tool for correcting small
irregularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappetA tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
reduce valve noise.
IIgnition timingThe moment at which the
spark plug fires, usually expressed in the
number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifoldA tube or housing with
passages through which flows the air-fuel
mixture (carburettor vehicles and vehicles with
throttle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
JJump startStarting the engine of a vehicle
with a discharged or weak battery by
attaching jump leads from the weak battery to
a charged or helper battery.
LLoad Sensing Proportioning Valve (LSPV)A
brake hydraulic system control valve that
works like a proportioning valve, but also
takes into consideration the amount of weight
carried by the rear axle.
LocknutA nut used to lock an adjustment
nut, or other threaded component, in place.
For example, a locknut is employed to keep
the adjusting nut on the rocker arm in
position.
LockwasherA form of washer designed to
prevent an attaching nut from working loose.
MMacPherson strutA type of front
suspension system devised by Earle
MacPherson at Ford of England. In its original
form, a simple lateral link with the anti-roll bar
creates the lower control arm. A long strut - an
integral coil spring and shock absorber - is
mounted between the body and the steering
knuckle. Many modern so-called MacPherson
strut systems use a conventional lower A-arm
and don’t rely on the anti-roll bar for location.
MultimeterAn electrical test instrument with
the capability to measure voltage, current and
resistance.
NNOxOxides of Nitrogen. A common toxic
pollutant emitted by petrol and diesel engines
at higher temperatures.
OOhmThe unit of electrical resistance. One
volt applied to a resistance of one ohm will
produce a current of one amp.
OhmmeterAn instrument for measuring
electrical resistance.
O-ringA type of sealing ring made of a
special rubber-like material; in use, the O-ring
is compressed into a groove to provide the
sealing action.
Overhead cam (ohc) engineAn engine with
the camshaft(s) located on top of the cylinder
head(s).Overhead valve (ohv) engineAn engine with
the valves located in the cylinder head, but
with the camshaft located in the engine block.
Oxygen sensorA device installed in the
engine exhaust manifold, which senses the
oxygen content in the exhaust and converts
this information into an electric current. Also
called a Lambda sensor.
PPhillips screwA type of screw head having a
cross instead of a slot for a corresponding
type of screwdriver.
PlastigageA thin strip of plastic thread,
available in different sizes, used for measuring
clearances. For example, a strip of Plastigage
is laid across a bearing journal. The parts are
assembled and dismantled; the width of the
crushed strip indicates the clearance between
journal and bearing.
Propeller shaftThe long hollow tube with
universal joints at both ends that carries
power from the transmission to the differential
on front-engined rear wheel drive vehicles.
Proportioning valveA hydraulic control
valve which limits the amount of pressure to
the rear brakes during panic stops to prevent
wheel lock-up.
RRack-and-pinion steeringA steering system
with a pinion gear on the end of the steering
shaft that mates with a rack (think of a geared
wheel opened up and laid flat). When the
steering wheel is turned, the pinion turns,
moving the rack to the left or right. This
movement is transmitted through the track
rods to the steering arms at the wheels.
RadiatorA liquid-to-air heat transfer device
designed to reduce the temperature of the
coolant in an internal combustion engine
cooling system.
RefrigerantAny substance used as a heat
transfer agent in an air-conditioning system.
R-12 has been the principle refrigerant for
many years; recently, however, manufacturers
have begun using R-134a, a non-CFC
substance that is considered less harmful to
the ozone in the upper atmosphere.
Rocker armA lever arm that rocks on a shaft
or pivots on a stud. In an overhead valve
engine, the rocker arm converts the upward
movement of the pushrod into a downward
movement to open a valve.
Adjusting spark plug gap
Plastigage
Gasket
procarmanuals.com

REF•16Glossary of Technical Terms
RotorIn a distributor, the rotating device
inside the cap that connects the centre
electrode and the outer terminals as it turns,
distributing the high voltage from the coil
secondary winding to the proper spark plug.
Also, that part of an alternator which rotates
inside the stator. Also, the rotating assembly
of a turbocharger, including the compressor
wheel, shaft and turbine wheel.
RunoutThe amount of wobble (in-and-out
movement) of a gear or wheel as it’s rotated.
The amount a shaft rotates “out-of-true.” The
out-of-round condition of a rotating part.
SSealantA liquid or paste used to prevent
leakage at a joint. Sometimes used in
conjunction with a gasket.
Sealed beam lampAn older headlight design
which integrates the reflector, lens and
filaments into a hermetically-sealed one-piece
unit. When a filament burns out or the lens
cracks, the entire unit is simply replaced.
Serpentine drivebeltA single, long, wide
accessory drivebelt that’s used on some
newer vehicles to drive all the accessories,
instead of a series of smaller, shorter belts.
Serpentine drivebelts are usually tensioned by
an automatic tensioner.
ShimThin spacer, commonly used to adjust
the clearance or relative positions between
two parts. For example, shims inserted into or
under bucket tappets control valve
clearances. Clearance is adjusted by
changing the thickness of the shim.
Slide hammerA special puller that screws
into or hooks onto a component such as a
shaft or bearing; a heavy sliding handle on the
shaft bottoms against the end of the shaft to
knock the component free.SprocketA tooth or projection on the
periphery of a wheel, shaped to engage with a
chain or drivebelt. Commonly used to refer to
the sprocket wheel itself.
Starter inhibitor switchOn vehicles with an
automatic transmission, a switch that
prevents starting if the vehicle is not in Neutral
or Park.
StrutSee MacPherson strut.
TTappetA cylindrical component which
transmits motion from the cam to the valve
stem, either directly or via a pushrod and
rocker arm. Also called a cam follower.
ThermostatA heat-controlled valve that
regulates the flow of coolant between the
cylinder block and the radiator, so maintaining
optimum engine operating temperature. A
thermostat is also used in some air cleaners in
which the temperature is regulated.
Thrust bearingThe bearing in the clutch
assembly that is moved in to the release
levers by clutch pedal action to disengage the
clutch. Also referred to as a release bearing.
Timing beltA toothed belt which drives the
camshaft. Serious engine damage may result
if it breaks in service.
Timing chainA chain which drives the
camshaft.
Toe-inThe amount the front wheels are
closer together at the front than at the rear. On
rear wheel drive vehicles, a slight amount of
toe-in is usually specified to keep the front
wheels running parallel on the road by
offsetting other forces that tend to spread the
wheels apart.
Toe-outThe amount the front wheels are
closer together at the rear than at the front. On
front wheel drive vehicles, a slight amount of
toe-out is usually specified.
ToolsFor full information on choosing and
using tools, refer to the Haynes Automotive
Tools Manual.
TracerA stripe of a second colour applied to
a wire insulator to distinguish that wire from
another one with the same colour insulator.
Tune-upA process of accurate and careful
adjustments and parts replacement to obtain
the best possible engine performance.TurbochargerA centrifugal device, driven by
exhaust gases, that pressurises the intake air.
Normally used to increase the power output
from a given engine displacement, but can
also be used primarily to reduce exhaust
emissions (as on VW’s “Umwelt” Diesel
engine).
UUniversal joint or U-jointA double-pivoted
connection for transmitting power from a
driving to a driven shaft through an angle. A
U-joint consists of two Y-shaped yokes and a
cross-shaped member called the spider.
VValveA device through which the flow of
liquid, gas, vacuum, or loose material in bulk
may be started, stopped, or regulated by a
movable part that opens, shuts, or partially
obstructs one or more ports or passageways.
A valve is also the movable part of such a
device.
Valve clearanceThe clearance between the
valve tip (the end of the valve stem) and the
rocker arm or tappet. The valve clearance is
measured when the valve is closed.
Vernier caliperA precision measuring
instrument that measures inside and outside
dimensions. Not quite as accurate as a
micrometer, but more convenient.
ViscosityThe thickness of a liquid or its
resistance to flow.
VoltA unit for expressing electrical
“pressure” in a circuit. One volt that will
produce a current of one ampere through a
resistance of one ohm.
WWeldingVarious processes used to join metal
items by heating the areas to be joined to a
molten state and fusing them together. For
more information refer to the Haynes
Automotive Welding Manual.
Wiring diagramA drawing portraying the
components and wires in a vehicle’s electrical
system, using standardised symbols. For
more information refer to the Haynes
Automotive Electrical and Electronic Systems
Manual.
Serpentine drivebelt
procarmanuals.com

REF•17Index
A
A pillar trim - 11•20
ABS - 9•14
Accelerator cable - 4•4
Accelerator pedal - 4•5
Accumulator - 3•9
Acknowledgements - 0•4
Adaptive damping switch - 12•8
Aerial - 12•22
Air bag - 0•5, 1•22, 12•22
Air cleaner - 4•3, 6•19
Air conditioning - 1•15, 3•2, 3•8, 3•9, 6•11
Air distribution control - 3•8
Air induction system - 4•9
Air intake components - 4•3
Air mass meter - 4•3, 6•10, 6•11, 6•12
Air temperature warning sender unit -
12•18
Alarm - 11•17, 12•18
Alternator - 5•5, 5•6
Amplifier - 12•21
Anti-lock Braking System - 9•14
Anti-roll bar - 10•8, 10•12, 10•15
Anti-theft alarm system - 12•18
Antifreeze - 1•2, 1•22, 3•2
Asbestos - 0•5
ATF - 1•2
Automatic transmission- 1•11, 1•17,
2A•24, 2B•3, 2B•4, 6•11, 7B•1et seq,
12•11
Automatic transmission fault finding -
REF•10
Automatic transmission fluid - 1•2
Auxiliary drivebelt - 1•13
Auxiliary warning system - 12•17
B
B pillar trim - 11•20
Backfire - REF•8
Backrest - 11•18
Battery - 0•5, 1•8, 1•11, 5•2, 5•3
Battery fault - REF•12
Big-end bearings - 2B•18, 2B•21
Bleeding brakes - 9•12
Bleeding power steering - 10•21
Blower/air conditioning control - 3•8Body corrosion - 0•10
Body electrical system- 12•1et seq
Bodywork and fittings- 11•1et seq
Bonnet - 1•20, 11•5, 11•6
Booster battery (jump) starting - 0•12
Boot - 11•14, 11•15
Brake check - 1•19
Brake fluid - 1•2, 1•8, 1•26
Brake line check - 1•19
Braking system- 0•7, 0•8, 0•9, 1•20, 9•1et
seq
Braking system fault finding - REF•10
Brush renewal - 5•8
Bulb failure module - 12•18
Bulbs - 12•8, 12•11, 12•18
Bumpers - 11•4, 11•5
Burning - 0•5
C
C pillar trim - 11•20, 11•21
Cables - 4•4, 7B•2, 8•2, 9•16, 11•6, 12•15
Calipers - 9•4, 9•9
Camshaft - 2A•13, 2A•14, 6•11, 6•12
Cassette player - 12•21
Catalytic converter - 6•19
CD player - 12•22
Central locking system - 11•17
Central locking system fault - REF•12
Centre console - 11•21
Charcoal canister - 6•14
Charging - 1•12, 5•5
Check strap - 11•13
Clock - 12•11, 12•15
Clutch and driveshafts- 1•17, 1•20, 8•1et
seq
Clutch fault finding - REF•9
CO emissions (mixture) - 0•10
Coil spring - 10•15
Compact disc player - 12•22
Compression test - 2A•5
Compressor - 3•9
Condenser - 3•9
Connecting rods - 2B•12, 2B•17, 2B•21,
2B•22
Console - 11•21, 11•22
Contents - 0•2
Conversion factors - 0•14Coolant - 1•2, 1•6, 1•7, 1•21
Coolant leakage - REF•9
Coolant low level switch - 3•5
Coolant temperature gauge sender - 3•4
Coolant temperature sensor - 3•5, 6•11,
6•13
Coolant warning switch - 12•18
Cooling, heating, and air conditioning
systems- 1•22, 3•1et seq
Cooling, heating, and air conditioning
systems fault finding - REF•8
Corrosion - REF•9
Courtesy light - 12•8
Crankcase - 2B•13
Crankshaft - 2A•9, 2A•13, 2A•22, 2B•13,
2B•18, 2B•20, 5•4, 6•10, 6•11, 6•12
Crossmember - 10•13, 10•17
Cruise control system - 12•19
Crushing - 0•5
Cushion - 11•18
CV joints - 1•18, 8•7, 8•9
Cylinder block - 2B•13
Cylinder head - 2A•6, 2A•17, 2B•9, 2B•10,
2B•11, 6•19
D
D pillar trim - 11•21
Damping switch - 12•8
Dehydrator - 3•9
Dents in bodywork - 11•3
Depressurisation - 4•2
Diagnosis system - 6•4
Differential - 7A•2, 7B•3
Dimensions - 0•6
Dipped beam switch - 12•7
Direction indicators - 12•7, 12•9, 12•12
Discs - 1•19, 9•5, 9•10
Display warning bulb - 12•18
Doors - 0•8, 1•20, 11•6, 11•7, 11•8, 11•9,
11•10, 11•11, 11•13, 12•7, 12•8, 12•11,
12•18
Drivebelts - 1•13
Driveplate - 2A•24
Driveshafts - 0•9, 1•18, 8•5, 8•6, 8•7, 8•9,
8•10
Driveshafts fault finding - REF•10
Drivetrain - 1•20
Drums - 1•19, 9•6 Note: References throughout this index relate to Chapter•page number
procarmanuals.com

REF•18Index
E
Earth fault - 12•4
Economy/Sport mode switch - 12•7
ECU (Electronic Control Unit) - 6•10, 6•11,
6•12
EGR exhaust gas pressure differential
sensor - 6•16
EGR system - 6•15, 6•16
Electric shock - 0•5
Electric windows fault - REF•12
Electrical system - 0•8, 1•11, 1•20
Electrical system fault - REF•12
Electrically-operated windows - 12•7
Electrolyte - 1•8
Electronic control system - 4•9, 6•2
Emblems - 11•17
Emission checks - 0•10
Emissions control systems - 6•1
Engine compartment light - 12•11
Engine electrical systems- 5•1et seq
Engine fault finding - REF•7, REF•8, REF•10
Engine management system - 4•8, 4•9
Engine oil - 1•2, 1•6, 1•16
Engine oil level sensor - 12•18
Engine removal and general engine
overhaul procedures- 2B•1et seq
Environmental considerations - REF•4
Evaporative emissions control (EVAP)
system - 6•14
Evaporator - 3•9
Exhaust gas pressure differential sensor -
6•11, 6•12, 6•13
Exhaust Gas Recirculation (EGR) system -
6•15, 6•16
Exhaust manifold - 2A•8
Exhaust system - 0•9, 0•10, 1•18, 4•12,
REF•9
Expansion tank - 3•5, 3•6
FFacia - 11•21, 11•23
Fan(s) - 3•4, 12•11
Fault code read-out - 6•6
Fault finding- REF•6et seq
Fault finding - automatic transmission -
7B•1
Fault finding - electrical system - 12•4
Filling - 11•3
Fire - 0•5
Fluid level checks - 1•6
Flywheel - 2A•24
Foglight - 12•7, 12•9, 12•13
Foglight warning indicator - 12•11
Fuel and exhaust systems- 0•10, 4•1et
seq
Fuel and exhaust system fault finding -
REF•9
Fuel consumption high - REF•9
Fuel cut-off switch - 4•8
Fuel filter - 1•26
Fuel gauge - 4•6
Fuel gauge fault - REF•12
Fuel hoses - 1•15
Fuel injection system - 4•8, 4•9
Fuel injectors - 4•10
Fuel lines - 1•19, 4•2
Fuel odour - REF•9Fuel pressure check - 4•5
Fuel pressure regulator - 4•11
Fuel pump - 4•5, 4•6
Fuel rail - 4•10
Fuel system - 4•2
Fuel tank - 4•7, 4•8
Fume or gas intoxication - 0•5
Fumes from exhaust system - REF•9
Fuses - 12•5
G
Gaiters - 1•18, 8•7, 8•9, 10•21
Gashes in bodywork - 11•3
Gaskets - REF•4
Gear lever - 7A•2
Gear selection problems - REF•9, REF•10
Gearbox oil - 1•2
Gearchange linkage - 7A•2
Gearchange selector shaft - 7A•3
Glossary of technical terms - REF•13
Glovebox - 11•22
Glovebox light - 12•11
Grab handle - 11•20
H
Handbrake - 0•7, 9•16, 12•7
Handles - 11•10, 11•11, 11•12, 11•13,
12•11
Hazard flashers - 12•7, 12•11
HC emissions - 0•10
Headlight - 1•8, 12•7, 12•8, 12•12, 12•13
Heated rear window - 12•8
Heated seat - 12•8
Heated windscreen - 12•8
Heater - 3•2, 3•7, 3•8, 12•11, 12•12
Horn - 12•7, 12•15
Horn fault - REF•12
Hoses - 1•14, 3•2, 9•11
HT leads - 1•24
Hub and bearings - 10•5, 10•9, 10•14
Hydraulic fluid - 1•2
Hydraulic pipes and hoses - 9•11
Hydraulic system - 9•12
Hydraulic tappets - 2A•14
Hydrofluoric acid - 0•5
I
Idle speed - 4•9, 4•11, 6•10
Idle-increase solenoid valve - 4•12
Ignition coil - 5•3
Ignition module - 5•4
Ignition switch - 12•6
Ignition system - 5•3
Ignition timing - 5•4, 6•10
In-car engine repair procedures- 2A•1et
seq
Indicators - 12•7, 12•9, 12•12
Information sensors - 6•10
Inlet manifold - 2A•7
Instrument panel - 12•7, 12•11, 12•14
Instruments - 1•20
Instruments fault - REF•12
Intake air temperature sensor - 6•11, 6•13
Introduction to the Ford Mondeo - 0•4
J
Jacking - 0•11
Joint mating faces - REF•4
Jump starting - 0•12
K
Knuckle - 10•5, 10•10, 10•14
L
Leaks - 0•13, 1•14, REF•9
Light units - 12•12
Lights - 12•7, 12•11
Lights inoperative - REF•12
Locknuts, locktabs and washers - REF•4
Locks - 11•6, 11•10, 11•12, 11•13, 11•15,
11•16, 11•17, 12•6, REF•12
Low air temperature warning sender unit -
12•18
Low coolant warning switch - 12•18
Low washer fluid switch - 12•18
Lower suspension arm - 10•8, 10•9, 10•13,
10•16
Lubrication system - 2A•4
Luggage compartment switch - 12•7
M
Main bearings - 2B•18, 2B•20
Maintenance- Also see Routine
maintenance
Maintenance - bodywork and underframe -
11•2
Maintenance - upholstery and carpets -
11•3
Manifolds - 2A•7, 2A•8
Manual transmission- 1•17, 2A•24, 2B•3,
2B•4, 7A•1et seq
Manual transmission fault finding - REF•9
Manual transmission oil - 1•2
Master cylinder - 9•10
Mirrors - 0•7, 11•14, 12•7
Misfire - REF•7, REF•8
Mixture - 0•10, 4•9
MOT test checks- 0•7et seq
Mountings - 2A•24, 7A•7, 7B•5
N
Number plate light - 12•10, 12•13
O
Oil (transmission) - 1•2
Oil (engine) - 1•2, 1•6, 1•16
Oil cooler - 2A•22
Oil level sensor - 2A•22, 12•18
Oil pressure warning light illuminated -
REF•8
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