Subject: Starter motor Failure
Model: Ford 2.0 TDCI FWD & 2.4 TDCi RWD/2.0 TDCi FWD
On inspection, the units do not exhibit any manufacturing defects. The premature failure of the unit is due to contamination of the pinion/drive area from metal dust particles produced within the Dual-mass Flywheel, when the clutch wears or becomes overheated. During scheduled servicing, it is recommended that the clutch is checked and if found to be showing signs of wear should be replaced.
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For the first time, Ford is using a front-wheel drive in a middle range vehicle. For this reason, the well-proven MTX 75 transmission from the Fiesta/Escort has been modified and adapted to the requirements of the Ford Mondeo. At the same time, a 4×4 version is also offered, in which the MTX 75 transmission is extended, as on the Escort 4×4, by a transfer box. The transfer box in the Ford Mondeo is a new development and effectively transfers the higher torque to the front axle. This brochure describes all new features and modifications implemented on the MTX 75 transmission compared to the MTX 75 transmission of the Escort ‘91 as well as on the MTX 75 4×4 drive concept and vehicle compared to the Ford Mondeo with front wheel drive.
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Introduction: Remove/Install rear sub-frame bushes in Mondeo. Can be used in situ – no need to remove sub-frame from vehicle. Applications: Ford Mondeo 2001, 10/2000 onwards
3.1 Ensure that the vehicle is adequately supported on axle stands before working under the vehicle.
3.2 Although there is no need to remove the sub-frame from the vehicle it will be necessary to lower it to gain access to both sides of the bush housing.
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You AC should be cooling more effectively than that on MaxAC − I’d take it back and get the pressure checked to ensure you don’t have a leak. Something is funny about your problem though as MaxAC should work even with a bad blend door. MaxAC opens the recirculating air damper, shuts off the flow to the heater core and cranks the AC so you should get full cooling. If you look on this picture below you will see how it all is setup − the blend door is in the middle and controls air flow around the heater core after the AC evaporator. If the heater core is off then you should still get full cooling even if the blend door is wonky.
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Some vehicles may exhibit clutch chatter or judder when releasing the clutch during cold conditions. This concern may be caused by the clutch surface materials creating a chatter or judder during clutch engagement. Customers experiencing this concern should have their vehicle repaired using this repair procedure.
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The Boxster is now in its sixth model year and proving to be one of the most popular models Porsche has ever built. The used market is proving to be good and many fine early examples can be found reasonably priced in comparison to other marques. I am of the mind that a used Porsche is still a much better buy than something new and cheaper for other Read the rest of this entry »

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To increase the durability of the clutch in 2.4L manual transaxle Santa Fe vehicles, the Dual Mass Flywheel and its components may be replaced with the Single Mass Flywheel (SMF) system in accordance with the applicable Shop Manuals’ replacement procedures.
AFFECTED VEHICLES: All Santa FE (SM) 2.4L vehicles with manual transaxles produced through July 16, 2003.
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Volkswagen > A3 Platform > 1993 – 2002 5 Spd. Manual Transmission 020 34 – Manual Transmission – Controls, Housing Clutch housing, servicing 1 – Oil drain plug Without magnet 25 Nm (18 ft lb) 2 – Dowel sleeve Qty: 2 Shim S2 Always 1 mm thick (0.04 in.) 4 – Outer race of tapered roller bearing for differential Removing and installing => page 39-5 When replacing: adjust differential => page 39-17 5 – Magnet Retained in housing joint surface Install with AMV 188 200 03 sealant 6 – Shim S3 Adjustment summary => page 39-16 7 – Outer race for output shaft tapered roller bearing Removing and installing => page 35-14 When replacing: adjust output shaft => page 35-27 8 – Needle bearing for input shaft Removing => Fig. 1 Installing => Fig. 2 9 – Bolt With locking teeth 25 Nm (18 ft lb) 10 – Relay lever 11 – Spring 12 – Read the rest of this entry »

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The Ford supplied Sierra 4×4 Supplementary Workshop Manual is a “must have” for any owner of one of these cars. The biggest problem can be actually finding one to purchase. I got lucky and managed to get mine direct from a Ford dealer, brand new for Ł8, who was having a clearout. They do appear regularly at autojumbles and it is just a case of keep looking. The manual only covers those items unique to the 4×4 Sierra’s and Read the rest of this entry »

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Tests/Procedures: 1. Ground the Violet/Yellow wire (disarm circuit) that goes to either front door and the theft alarm module. Have the keys out of the ignition and all doors closed when grounding the wire. This should disarm the theft alarm system and prevent the theft alarm from arming. 2. Check that the interior lights do not stay on due to the wire being grounded. If they do, the illuminated entry relay will need to be removed or another method of disabling the theft alarm will have to be used. 3. Another method if the theft alarm module is faulty would be to disconnect the module and replace the Powertrain Control Module (PCM) with a new one.
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