Austin of England Posted July 14, 2020 Share Posted July 14, 2020 During these Covid times I was furloughed from work for a few weeks, what to do with this spare time I had? Well my MK2 Mondeo was lurking at the end of the drive with a disintegrated clutch release bearing so I picked up a clutch kit at a reasonable price and thought why not have a go at fixing it. I think its a 4 or 5 spanner job in the Haynes manual and by all accounts its a pig of a job to do on your own on the drive - I do like a challenge Triumphant pose at gearbox removal stage T Its very messy in here, result of leaking thermostat housing and brake fluid from the release bearing maxxo, Shep Shepherd, Crusty Sills and 14 others 17 Link to comment Share on other sites More sharing options...
Parky Posted July 14, 2020 Share Posted July 14, 2020 Did “Time Team” unearth that gearbox while digging up an old Tank or something??? outlaw118, Jamie, Dave_Q and 2 others 1 4 Link to comment Share on other sites More sharing options...
Jamie Posted July 14, 2020 Share Posted July 14, 2020 was gonna say, looks like someones been growing plants in that box' Link to comment Share on other sites More sharing options...
Austin of England Posted July 14, 2020 Author Share Posted July 14, 2020 Its what happens when you neglect a leaking thermostat housing and just top up the coolant instead as required instead of fixing the housing, some coolant got into the bell housing, the release bearing started leaking fluid and it all mixed together with 157,000 miles of clutch dust - lovely Link to comment Share on other sites More sharing options...
Parky Posted July 14, 2020 Share Posted July 14, 2020 Have to admit that pose of a man, his breaker bar, and his gearbox prey is truly inspirational! I presume it’s a solid clutch in these? What brand replacement have you got to go in? Link to comment Share on other sites More sharing options...
sutty2006 Posted July 14, 2020 Share Posted July 14, 2020 I think they are dual mass? But an early style of dual mass that doesn’t fail all the time. Could be wrong though is it fixed yet? Link to comment Share on other sites More sharing options...
Austin of England Posted July 14, 2020 Author Share Posted July 14, 2020 Its all back together now and to my amazement it all works fine, I think the job took me about 3 weeks, The bastard part of the job was one of the sub frame bolts, the rear drivers side one, I knew I was in trouble when I put the put the breaker bar on the socket and the head of the bolt broke off. the bolt was seized in the bush, I had to destroy the bush to enable me to remove the subframe, then cut a hole in the floor of the car to cut off the captive nut outlaw118, Shep Shepherd, paulplom and 2 others 3 1 1 Link to comment Share on other sites More sharing options...
sierraman Posted July 14, 2020 Share Posted July 14, 2020 Never fitted a DMF on the Mk2 they’re all SMF. sutty2006 and stuboy 2 Link to comment Share on other sites More sharing options...
Austin of England Posted July 14, 2020 Author Share Posted July 14, 2020 8 minutes ago, Parky said: I presume it’s a solid clutch in these? What brand replacement have you got to go in? Its just a standard type clutch, its 2.0 petrol, not dual mass, I went with a Borg & Beck clutch kit Link to comment Share on other sites More sharing options...
egg Posted July 14, 2020 Share Posted July 14, 2020 Great work. Nice engine brace too! Link to comment Share on other sites More sharing options...
stuboy Posted July 14, 2020 Share Posted July 14, 2020 good to see mk2 being saved Link to comment Share on other sites More sharing options...
sierraman Posted July 14, 2020 Share Posted July 14, 2020 I hope you swapped the crank end seal, they’re rotten for those going and pissing oil all over the clutch. Link to comment Share on other sites More sharing options...
Austin of England Posted July 15, 2020 Author Share Posted July 15, 2020 21 hours ago, sierraman said: I hope you swapped the crank end seal, they’re rotten for those going and pissing oil all over the clutch. Ahh ....ermm ....hmmm .... didn't know about that, in my defence the flywheel face looked good and felt good with no scoring or wear lip and there was no sign of an oil leak, so I went with the "it didn't look broke so I won't fix it and potentially break it" and left it well alone Link to comment Share on other sites More sharing options...
maxxo Posted July 15, 2020 Share Posted July 15, 2020 very nice indeed! good to see some love for the MK2 is this a "duct tape edition"? or the super rare undamaged bumper model Link to comment Share on other sites More sharing options...
Austin of England Posted July 15, 2020 Author Share Posted July 15, 2020 13 minutes ago, maxxo said: is this a "duct tape edition"? or the super rare undamaged bumper model The rear bumper is undamaged, the front is cracked on the front drivers side corner, araldited back together, no duct tape yet maxxo 1 Link to comment Share on other sites More sharing options...
maxxo Posted July 15, 2020 Share Posted July 15, 2020 4 minutes ago, Austin of England said: The rear bumper is undamaged, the front is cracked on the front drivers side corner, araldited back together, no duct tape yet that's absolutely lovely! always loved the styling of the mk2 Link to comment Share on other sites More sharing options...
sierraman Posted July 15, 2020 Share Posted July 15, 2020 2 minutes ago, Austin of England said: The rear bumper is undamaged, the front is cracked on the front drivers side corner, araldited back together, no duct tape yet That’s a shame I weighed one in last month with a clean I cracked silver bumper on it. Link to comment Share on other sites More sharing options...
Austin of England Posted July 15, 2020 Author Share Posted July 15, 2020 The next major hurdle with this is the ABS. It is combined with traction control on this car and in the last year I was running the car before the MOT lapsed the sometimes the ABS light and the TCS light would not come on at start up and the red brake warning light would be on. You could drive a few miles then the ABS light would flash and the red light would go out and the ABS would be working again, This got worse until the brake warning light was on permanently and the ABS was dead. I have replaced the wheel sensors and toothed rings and its still the same, I have a feeling it could be the Electronic control unit that is bolted to the side of the pump, my options are to obtain a second hand one, but there are a few variants about and finding the correct one is proving difficult or I may have to send it away for fixing Link to comment Share on other sites More sharing options...
sierraman Posted July 15, 2020 Share Posted July 15, 2020 That’s the later Bosch pump not like on the mechatronics MK1, I’d just bypass it, take the pump out and change the master cylinder for the non ABS unit. Link to comment Share on other sites More sharing options...
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