Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

Just purchased the above car. Overall it is a very nice, well looked after car but I am rather disappointed by the gearchange. There is sometimes a fair bit of resistance when changing gear... a bit of a push is needed to get it in! But sometimes that resistance is not there and the gear can be selected normally... easily. The issue is most noticeable on gears 1+2 . It's not terrible and perthaps wouldn't bother many. But I'm a little guy with a shoulder injury so it's not fun for me! I'm really wondering what might be causing this issue and whether it might possibly be rectifiable (without replacing gearbox/clutch!)

A bit more info: The car has done 80k, has full service history, and clutch and flywheel were changed at 70k. I notice that when the car is first started from cold, there is a kind of singing sound, which disappears when clutch is depressed and then re-appears when clutch is released (in neutral). This strange phenomenom stops after a minute. It's nice that my car sings to me (!!) but I wonder if this could be related to the gear issue...

Any thoughts most gratefully received.

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - ChannelZ

My 2005 1.8 had that problem when I got it. It got worse when the clutch was changed. Was virtually impossible to select 1st and 2nd, especially when cold. Needed a hell of a stirring on the gearstick to get it in. Took it to a Ford specialist who knew exactly the problem, he'd seen it lots before.

£80 for a new bottom gearbox mount fitted, problem fixed. The rubber bushing was totally collapsed on the old one, so the gearbox and engine were able to move forwards and back, putting the gearbox cables out of alignment.

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

Many thanks for your reply, that's very interesting. I hope my problem is the same as yours. The issue is worse than I first thought, actually, and is indeed very much worse when the car's cold. I can almost feel the teeth when pushing into gear and on a couple of occasions I simply couldn't get into 2nd gear without releasing clutch in neutral and then trying again. Other times it glides into gear as it should...

Not quite sure what is meant by 'stirring' the gearstick. I've so far employed the 'hard shove technique'...

Think I'll take it to my local Ford dealer and get them to have a quick look.

Edited by cosmicjazzer on 30/01/2012 at 17:22

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

Oh dear. Ford dealer said clutch was dragging...

I did put the possibility of gearbox mount being the issue to the tech there. He said he'd NEVER encountered that as being a cause of tough gear change. He also said it wouldn't make sense for this to be the culprit as the Mondeo has a cable clutch. Oh dear...!

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - ChannelZ

Oh dear. Ford dealer said clutch was dragging...

I did put the possibility of gearbox mount being the issue to the tech there. He said he'd NEVER encountered that as being a cause of tough gear change. He also said it wouldn't make sense for this to be the culprit as the Mondeo has a cable clutch. Oh dear...!

Ignore the tech - all Mk3 Mondeos have hydraulic clutches. Take the car to a decent independent who specialises in Fords. The dealer's tech is obviosly an idiot, or is talking about the cable operated gear selection. Clutch is definitely hydraulic.

As I said, I had the exact same problem. Clutch was done, problem was still there. Mechanic said it was common for the bottom mount to go, so knew exactly what was wrong once he'd taken it out for a test drive after doing the clutch. My clutch wasn't worn, but it was contaminated by fluid leaking from the slave cylinder (see? Hydraulic!)

He fitted a new mount from a breakers for £60 including the fitting.

The mechanic is use is an ex-Ford Master Technician who worked at a local Ford dealership that closed a few years ago. He's then gone and opened his own garage, specialising in Fords.

Edited by ChannelZ on 01/02/2012 at 20:16

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - unthrottled

I had a broken engine mount that made selection of 1,2 and R almost impossible. Why the diagnosis by substitution wuth the clutch? You can test if the clutch is dragging at home on your drive!

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

I took the car back to the dealer who supplied it. His mechanic does not agree the clutch is dragging (but he would say that...) and says the gear change problem is 'slight' (he would say that too!). But he has replaced gearbox oil with the correct oil - resulting in a slight improvement, apparently. At my behest, he is about to check the gearbox mount.

Please excuse my complete ignorance about mechanical matters... is the gearbox mount in fact the same thing as the engine mount? Also, I am very interested as to how I could definitely determine whether clutch is dragging 'at home on on my drive'.

Many thanks for all replies. :)

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - unthrottled

Also, I am very interested as to how I could definitely determine whether clutch is dragging 'at home on on my drive'.

Get both the front wheels off the ground. Start the car, put it in gear, and push the clutch in. The front wheels should stop spinning. If they don't the clutch is dragging.

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

Well the latest on this is that dealer's mechanic changed the gearbox oil (with little improvement) and checked lower gearbox mount and engine mounts. He found all mounts to be fine. He is of the opinion that the issue could be down to gearbox cables having stretched...

I've also now tested the clutch in the way unthrottled described and the wheels do stop immediately the clutch is depressed. What has become apparent is that the problem seems to disappear in the wet weather! Yes really, I've noticed this a few times now. So perhaps I will repeat the clutch test in the dry...

Might the 'whining' I mentioned (when car is in neutral and clutch not depressed) provide any clue?

Edited by cosmicjazzer on 22/02/2012 at 14:32

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

I did notice when testing clutch that the front wheels did go round when in neutral and clutch not depressed. Is this normal?

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

The car is a good'un apart from the gear change issue so I'm dabbling with the idea of getting the complete gearbox replaced (with a used box from breakers).

But before thinking about going there I must ask: Given that it appears clutch cannot be the issue and that gearbox/engine mounts have been ruled out too, am I right in thinking that the issue MUST be the gearbox?

As mentioned, the dealer's mechanic has already replaced gearbox oil and has also lubricated at top of box. He speculated that a stretched gearbox cable might be the culprit. Presumably, changing the box would include cable right? (really showing my ignorance here, I know!)

Am also wondering how many hours labour replacing the box might take...

Edited by cosmicjazzer on 25/02/2012 at 18:29

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - mss1tw

The singing sound could possibly be the clutch release bearing on its way out

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - ChannelZ

The car is a good'un apart from the gear change issue so I'm dabbling with the idea of getting the complete gearbox replaced (with a used box from breakers).

But before thinking about going there I must ask: Given that it appears clutch cannot be the issue and that gearbox/engine mounts have been ruled out too, am I right in thinking that the issue MUST be the gearbox?

As mentioned, the dealer's mechanic has already replaced gearbox oil and has also lubricated at top of box. He speculated that a stretched gearbox cable might be the culprit. Presumably, changing the box would include cable right? (really showing my ignorance here, I know!)

Am also wondering how many hours labour replacing the box might take...

The cables won't come with the box.

It's an 8 hour job to swap a box on an Mondeo.

I still think it's the bottom mount - for £60 I think you should get it replaced first, I had exact same symptoms, and a new mount fixed it.

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - sandy56

I had the 2.5l petrol with a similar problem with engaging reverse and first.

1 -solution engage reverse and then start car- problem solved.

2 - solution with engaging first when cold- dont- just start off in 2nd - no problem.

check to Ford Mondeo owners forums - LOTS of useful info

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

ChannelZ: I have some reason to think the dealer's mechanic DID check the mounts, as he claimed.. He struck me as being a decent chap and seemed to want to get to the bottom of the issue. He spoke about the indents in the mount washers showing no sign of having been replaced in a different position (or something like that - I didn't follow 100% if the truth be known...) Having said that, I guess it could do no harm to get a second opinion - presumably it wiil be evident if a mount is persished?

I do have a question I'd like to throw out there: As I mentioned, I checked the clutch by raising front wheels and putting into gear. The wheels immediately stopped turning when the clutch was depressed while in gear.

Now it's obvious that if the wheels had continued spinning this would prove the clutch was dragging, but I am wondering if the fact that the wheels stopped necessarily proves that the clutch is NOT dragging. If a clutch was dragging only slightly is it possible the wheels would still stop?

It seems that used gearboxes are available from £75, so if gearbox replacement seems the way to go, it need not be a complete disaster financially.

Edited by cosmicjazzer on 28/02/2012 at 03:46

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - ChannelZ

www.mondeospares.co.uk/ford-mondeo-mk3-lower-engin...p

That site has a picture of the mount. Mine, the rubber in the larger end was ripped. When it was on the car, it looked fine. When taken off, the centre of the bush fell out. It's a 5 minute DIY job if you have axle stands and a jack.

Basically, when the rubber was gone, the engine was able to move back and forward at the gearbox end, which meant the gear shift cables were not aligning properly. "Stirring" the gear stick forward and back to get it in to 1st would actually move the engine forward (or back) again, allowing 1st gear to be selected. Once on the move, the engine was free to move so gear selection was easy. Only in slow traffic was 1st and 2nd difficult.

As I said, I though my gearbox was gone, got the fluid changed, got the clutch changed, problem persisted. Changed that £20 part, job done. £360 for clutch and £40 for gearbox oil, wasted.

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - cosmicjazzer

Thank you ChannelZ. Appreciate it!

I'm not mechanically inclined and have no axle stands so will have to take car somewhere....

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - napper t

look dont bother.i guarantee you it aint the mount.dont care what he says fixed it

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - napper t

what a loada garbage mate.talking outta yer a***

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - Collos25

Your so knowledgable I assume you looked at the date of the OP before you gave such a detailed solution to the problem.

Ford Mondeo 2.0 petrol 2002 - Gear change is hard work.... - david atkins

Is that the one shaped like a banjo .. "tourque restrictor", or something like? cheers

 

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