Ford Mondeo Mk4 common faults.

2007–2010. The fault list covers this generation and the engines in it. If the listing gives the exact version, pick it below.

What to watch for

What can go wrong on this car?

The list covers the generation, the engines and the transmissions. Once you pick the version, only the faults that apply to it stay.

Crankshaft pulley: the rubber layer of the vibration damper separates

expensive

The accessory pulley of the crankshaft is also a vibration damper: there is a layer of rubber between the outer and the inner part.

Applies to the engine PNBA.

IB5 manual: worn synchros and differential bearings in the larger models

expensive

In the smaller models, the Fiesta, the Fusion and the B-Max, the IB5 holds up well, but in the larger Focus and especially the Mondeo it does less well: there the engine torque and the weight of the car put a heavier load on the same gearbox.

Applies to the transmission IB5.

M66 manual: worn shift mechanism behind the powerful engines

expensive

The gearbox is reliable and durable, but it sits behind particularly powerful engines, and that shows on the shift mechanism: between 100,000 and 150,000 km it often wears out, which makes shifting stiff, and that is most obvious in winter.

Applies to the transmission M66.

MMT6 manual: worn shift mechanism, hard shifting when cold

expensive

The gearbox itself is reliable, but the shift mechanism wears noticeably between 100,000 and 150,000 km.

Applies to the transmission MMT6.

Thermostat housing: the plastic goes brittle and the coolant leaks

expensive

The thermostat housing is made of plastic, and the hose connector is moulded as part of it.

Applies to the engine PNBA.

Injector copper washer: the carbon glues the injector into the head

expensive

The copper washer under the injector is a one-time seal: it is permanently crushed when torqued, so once refitted it can no longer seal.

Applies to the engine AZBA, AZBC, KLBA and 8 more.

High pressure pump: metal debris throughout the whole system

expensive

The high pressure fuel pump wears from the inside, and metal dust forms in the friction pairs.

Applies to the engine AZBA, AZBC, KLBA and 8 more.

MTX75 manual: leaking seals, worn shafts

expensive

The gearbox itself is reliable and has two weak points.

Applies to the transmission MTX75.

1 more faults belong to this generation. On the version page, only the ones that apply stay.

Engines and transmissions in this generation

A fault is often tied to the engine, not to the whole generation. You find the engine code in the registration document.

Mk4 · 2007–2010

Pick the version.

The fault list opens on the version page.

133 versions

EngineVersionPowerFuel · transmissionBody

Showing 60 of 133 versions.

Neighbouring generations

Mk4 · 2007–2010

Mondeo '07. If the listing is from the changeover year, look at the neighbour too.

Previous generation

Mk3.5 · 2003–2007

This generation

Mk4 · 2007–2010

Next generation

Mk4.5 · 2010–2014

Common questions

About this generation

Which years does this page cover?

2007–2010. The changeover year can fall in two generations. If the listing is from that year, look at the neighbour too.

Does the fault apply to every car like this?

No. It depends on the engine and the transmission too.

Is it free?

The fault list is.

Information, not an expert opinion

We write the descriptions, and we put the source next to them. A person reviews them before they go out. They are still information, not a technical expert opinion.

A fault on the list does not mean the car you are looking at has it.
A fault missing from the list does not mean the model is fault-free. Write-ups are made model by model. Not all of them are done.
You decide whether to buy. This is no substitute for an inspection. That needs a workshop and a history check.

Details in the terms