Last question first. The bleed nipple is defferent from the 5-speed. It's not available on it's own, it's not available with the t-piece, it's only available with a complete pipe right back to the master cylinder! As far as the fitting sequence, I can't really remember (don't often get mondeo master cylinders). Generally though with Ford cylinders get the cylinder in first. Make sure the fluid is coming through the cylinder before you push in the outlet pipe.
there is a clip holding it to the top of the slave cylinder and a clip (which you should be able to see ) holding the t-piece to the pipe.Before I go any further I should tell you about a recent experience I had with one of these. Having fitted a new clutch/dmf and cylinders to a mondeo 6 months before the customer complained that she had lost pedal pressure. As I saw a drip of fluid underneath I concluded the slave cylinder must have failed and fitted a new one under warranty. Having put it all back together (6 hours later) I found I was unable to bleed the clutch properly. Having closed the bleed nipple I decided to pump continuously to see if I could get a little bit of pressure. No I couldn't!. When I came and looked in the engine bay I saw that fluid was dribbling down the front of the gearbox. I discovered to my horror and amazement that the bleed nipple was allowing fluid though even when closed! Fords do not sell the t-piece seperately so I had to buy a complete pipe for £63. I natrually only fitted the t-piece. To Make sure this isn't happening to you, top the fluid up to the brim, close the bleed nipple and pump the pedal about 30 times. Check the fluid level. It shouldn't have moved.
It's almost certainlty the clutch or dmf that has failed. If it was a driveshaft you wouldn't be able to select the gears easily without touching the clutch, as the gearbox internals would still be moving. 40k is not fantastic mileage but well within the normal range. Most likely the clutch linings have stripped off completely, this often happens on the motorway and gives no warning
the seal fits with the wide end onthe plastic fitting. Open the bleed nipple and (making sure the pedal is fully up) leave for a few minutes. Make sure the rearvoir is kept popped up. Close the bleed nipple and pump the pedal until you get some pressure. Now bleed in the normal way.
Yes that's what I thought. The seal fits over the pipe and the top of the plastic bit so that the end of the pipe is flush with the seal. These are a common source of anguish. Be careful not to lose it Fords don't sell them seperately from the pipe. You can however buy exactly the same part for a transit (yes they fit!)
My first thought would be the master cylinder is faulty. Unless the circuit is interrupted you should never need to bleed the clutch system in normal use. As previously said unless the internals of the master are fully returned new fluid cannot enter the system. Unfortunately the plastic cylinders used in the modern cars don't have an internal return spring, so the problem is accentuated. Change the master cylinder. Pressure bleeding is not recommended (nor needed) for hydraulic systems using a concentric slave cylinder
£350 sounds about right for a 5 speed. You ideally want either LUK, Sachs or Valeo. I wouldn't advise buying of ebay personally, unless it's one of the big suppliers. If you're not doing the job yourself I'd advise against buying you own parts. In the event of a component failure you would have to pay the labour again. If you pay for the whole job, the whole responsibility goes with it.
Unfortunately on the diesels you have to regard the dmf as part of the clutch assembly. In fact in most cases the clutch outlasts the flywheel. It's also virtually impossible to assess the condition of the dmf. There is a special; tool available for about £300, but it's really pretty pointless. Petrol models very rarely need the dmf changing