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Clutch Replacement 2.0 Tdci


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#1 monbenkey

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  • Ford Model: mondeo 2.0 TDCI zetec

Posted 01 September 2010 - 08:19 PM

Hi.I am soon to have the pleasure of replacing the clutch on my fathers 2006 2.0 TDCI. Can anybody tell me of any problems i may encounter or things i should be aware of during the job.I have replaced many clutch assemblies before but never on this model, and i would just like to make sure i do not encounter any major problems if possible.Any help appreciated, cheers.Oh by the way the clutch is slipping in 3rd gear upwards.

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#2 chris bowman

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Posted 01 September 2010 - 08:29 PM

best thing to do is replace clutch kit including slave cylinder which is mounted inside the gearbox and also the dual mass flywheel. that way if any of these components fail later, you will have to do the job again. the subframe has to come out to remove the gearbox, so extensive support for the engine is necessary. a pit would help tremendously but not necessary though it does make the job infinitely easier and quicker!

#3 monbenkey

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Posted 02 September 2010 - 12:04 PM

best thing to do is replace clutch kit including slave cylinder which is mounted inside the gearbox and also the dual mass flywheel. that way if any of these components fail later, you will have to do the job again. the subframe has to come out to remove the gearbox, so extensive support for the engine is necessary. a pit would help tremendously but not necessary though it does make the job infinitely easier and quicker!



I have access to a vehicle lift so that should help.Apart from the tools for the job are there any other difficulties.I can remember a friend who had a jaguar with this engine and gear box and he struggled with removing drive shaft?

#4 chris bowman

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Posted 02 September 2010 - 07:36 PM

the driveshafts must be kept as straight as possible to prevent damage and also the cv jointmust not be removed from the driveshaft as it is a press fit.apart from that there seems to be a lot of component removal to create room for access to remove driveshafts

#5 gelliott

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Posted 17 September 2010 - 01:31 PM

hi there i have done many a mondeo clutch they are not that difficult but you can have problems removing the passenger side driveshaft

#6 flying clutchman

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Posted 23 September 2010 - 12:56 PM

hi there i have done many a mondeo clutch they are not that difficult but you can have problems removing the passenger side driveshaft

It's a bit tight getting a chisel in to knock the n/s shaft out but it just needs a bit of patience. I only remove the subframe bolts on the n/s and just drop it down a couple of inches (but then I'm usually working on the floor). Once you've taken of the gearchange cables remove the selector unit (6screws) from the box, it gives you much more room. Makes sure you put a rag in the hole though so that you don't drop any bolts in!

#7 terry arnold

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Posted 05 October 2010 - 11:23 AM

i just replaced my clutch including changing from dual mass flywheel to a solid flywheel but there seems to be a lot of noise now should i have kept to the dual mass one and can anyone fit it for me for a good price i will get the part

#8 flying clutchman

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Posted 05 October 2010 - 11:56 AM

i just replaced my clutch including changing from dual mass flywheel to a solid flywheel but there seems to be a lot of noise now should i have kept to the dual mass one and can anyone fit it for me for a good price i will get the part

I've never actually fitted a solid kit to a Modeo (done lots of transits with similar gearbox) but have used them on peugeots, renaults etc. with no problem. Was it a proper matched kit?

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