Clutch and Gears on Mondeo 2.5 V6
Discussion
I've just bought a Zetec S on a 51 plate and I'm having a few probs with the gears and clutch.
The gears to me feel very crunchy and when you depress the cluch above 4000rpm you can feel a heavy grinding underfoot.
I've just got it back from CD Bramall and dissappointingly they've not been much help. They've replaced some of the linkage on the gearbox which to me has made the gears feel worse and they said there's nothing wrong with the clutch.
Also, they're is a flat spot between 3000 - 3500rpm which, again, they're claiming not to exist.
I'm thinking maybe replacing the gearbox oil with some Royal Purple which I've heard good things about but not sure where to turn with the other bits...
Any Suggestion?
The gears to me feel very crunchy and when you depress the cluch above 4000rpm you can feel a heavy grinding underfoot.
I've just got it back from CD Bramall and dissappointingly they've not been much help. They've replaced some of the linkage on the gearbox which to me has made the gears feel worse and they said there's nothing wrong with the clutch.
Also, they're is a flat spot between 3000 - 3500rpm which, again, they're claiming not to exist.
I'm thinking maybe replacing the gearbox oil with some Royal Purple which I've heard good things about but not sure where to turn with the other bits...
Any Suggestion?
Hi without feeling the gear selection it's difficult to establish an accurate diagnosis.
The name of the dealer is not needed either, but what did they replace?
If the cables are correcly adjusted then the likely hood is that the clutch system is the cause of the concern.
The MTX 75 5 speed box has been very good on the whole, the selection mechanism is pretty reliable and can be removed without removing the gearbox.
The grinding noise you speak of, could only be caused by a failing release bearing imo, are you sure it's not a vibration your feeling, as it is usual to feel a slight pulsation through the clutch pedal at high engine speeds.
The name of the dealer is not needed either, but what did they replace?
If the cables are correcly adjusted then the likely hood is that the clutch system is the cause of the concern.
The MTX 75 5 speed box has been very good on the whole, the selection mechanism is pretty reliable and can be removed without removing the gearbox.
The grinding noise you speak of, could only be caused by a failing release bearing imo, are you sure it's not a vibration your feeling, as it is usual to feel a slight pulsation through the clutch pedal at high engine speeds.
If you are getting poor synchronisation then it may be that you do not have sufficient clutch reserve when changing gears. This is easily fixed by bleeding the clutch.
I would also change the oil in the gearbox. You want the stuff that your Ford dealer sells- it's a honey gold colour. DO NOT use ATF, it doesn't have the modifiers in it, and the honey coloured oil has a very advanced formulation. It is made by Castrol and also sold as Castrol SMX-S.
Pulsing through the clutch can be due to clutch finger height problems but it is rare.
I would try to fix with bleeding and oil change before removal of the unit which is going to be labour intensive.
I would also change the oil in the gearbox. You want the stuff that your Ford dealer sells- it's a honey gold colour. DO NOT use ATF, it doesn't have the modifiers in it, and the honey coloured oil has a very advanced formulation. It is made by Castrol and also sold as Castrol SMX-S.
Pulsing through the clutch can be due to clutch finger height problems but it is rare.
I would try to fix with bleeding and oil change before removal of the unit which is going to be labour intensive.
Hi again Gavin 
I forgot to mention oil earlier
Whats the mileage on the car ?
The standard ford oil (75w90) is a very good oil and is designed to stay in there for the life as it's not a service item.
pulsation through the pedal at high speeds is very common, not helped by dual mass flywheel and those LUk/Valeo self adjusting clutch pressure plates. with regards to the pressure plates, finger hight variation is common. but it will not affect the performance of the clutch. you don't normally notice it unless you keep your foot on the clutch too long at speed.
I forgot to mention oil earlier
Whats the mileage on the car ?
The standard ford oil (75w90) is a very good oil and is designed to stay in there for the life as it's not a service item.
pulsation through the pedal at high speeds is very common, not helped by dual mass flywheel and those LUk/Valeo self adjusting clutch pressure plates. with regards to the pressure plates, finger hight variation is common. but it will not affect the performance of the clutch. you don't normally notice it unless you keep your foot on the clutch too long at speed.
Hi chaps thanx for your replies.
To answer a couple of your questions - The car's done just over 37K. And I have been informed that the oil in the gearbox is supposed to never be changed but I don't know enough to know any better. Just to make it clearer on the gearbox - I also struggle sometimes to get it into gear from a standstill (ie first and reverse). BTW - has anyone heard of Royal purple gearbox oil. Apparently its big in the states but just becoming known over here?
The feeling on the clutch could be vibration but it just feels a little too strong to me to be considered 'normal.'
Will speak to them on Monday with regards to changing the gearbox oil and bleeding the clutch. The car is still under warranty so I'm not too concern with the labour involved so maybe I should push for them to look at the release bearing too?
BTW - Anyone got any ideas on the flatspot. In first gear the car can almost shudder when it goes thru 3000rpms?
To answer a couple of your questions - The car's done just over 37K. And I have been informed that the oil in the gearbox is supposed to never be changed but I don't know enough to know any better. Just to make it clearer on the gearbox - I also struggle sometimes to get it into gear from a standstill (ie first and reverse). BTW - has anyone heard of Royal purple gearbox oil. Apparently its big in the states but just becoming known over here?
The feeling on the clutch could be vibration but it just feels a little too strong to me to be considered 'normal.'
Will speak to them on Monday with regards to changing the gearbox oil and bleeding the clutch. The car is still under warranty so I'm not too concern with the labour involved so maybe I should push for them to look at the release bearing too?
BTW - Anyone got any ideas on the flatspot. In first gear the car can almost shudder when it goes thru 3000rpms?
Difficulty getting 1st and rev are classic clutch symptoms. if you engage 3rd,and then 2nd before going into first, it will most probably feel ok, 
It all seems to suggest clutch wear to me.
The flat spot you talk of might be the transition between the long and short inlet tracts, i'd suggest getting the gear selection spot on, and then look at engine performance.
It all seems to suggest clutch wear to me.
The flat spot you talk of might be the transition between the long and short inlet tracts, i'd suggest getting the gear selection spot on, and then look at engine performance.
si762 said:
Hi chaps thanx for your replies.
BTW - Anyone got any ideas on the flatspot. In first gear the car can almost shudder when it goes thru 3000rpms?
The Mk2 mondeo has an electric control on the secondary throttles under the main plenum, below 3000rpm the car runs effectively on 18 valves by shutting off one of the inlets, above 3000rpm this opens, hence the crossover plenum and different inlet duct lengths. The butterflys can get stuck because they tend to gum up with carbon, it's an easy job to rectify by cleaning them, you will need a new gasket for the EGR valve, but he ones on the plenum might be reusable.
Paul
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