2004 Ford Mondeo diesel: common problems and MOT failures

What goes wrong more than usual on a 2004 Ford Mondeo diesel?

Parts flagged at MOT more often on the 2004 Ford Mondeo diesel than on all cars registered in 2004.

• Rigid brake pipes1.9× usual
  Ford Mondeo

  33.4% All 2004 cars

  17.4%

  Failed outright at MOT: 5.4%, against 3% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £100–£400 our estimate

  At the viewing: Ask to see underneath, or check the MOT advisories: corroded brake or fuel pipes get worse every year and fail the MOT when they do.

• Engine oil leaks2× usual
  Ford Mondeo

  28.7% All 2004 cars

  14.4%

  Failed outright at MOT: 0.4%, against 0.4% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £80–£600 our estimate

  At the viewing: Look under the engine and where the car is usually parked for fresh oil. Ask whether the leak has been looked at.

• Exhaust system1.7× usual
  Ford Mondeo

  16.1% All 2004 cars

  9.7%

  Failed outright at MOT: 5.1%, against 2.8% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £100–£500 (pipe or section) ClickMechanic

  At the viewing: Listen for blowing or rattling from underneath at idle, and look for black soot around joints.

• Diesel smoke emissions8.2× usual
  Ford Mondeo

  6.6% All 2004 cars

  0.8%

  Failed outright at MOT: 6.2%, against 0.7% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £175–£900 (catalytic converter) ClickMechanic

  At the viewing: Look for smoke when revving the warm engine and for engine or DPF warning lights.

• Ball joint dust cover2.1× usual
  Ford Mondeo

  10.1% All 2004 cars

  4.7%

  Failed outright at MOT: 3.4%, against 1.8% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £60–£150 (one joint) ClickMechanic

  At the viewing: Listen for knocking over bumps and check the rubber boots behind the wheels aren't split.

Common 2004 Ford Mondeo diesel MOT failures and advisories

The share of 2004 Ford Mondeo diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Brakes
  57% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Suspension
  53% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Lights and electrics
  41% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Tyres
  36% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Oil and fluid leaks
  30% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Exhaust and emissions
  23% of testsRough price £100–£1,200

  At the viewing: Look for black soot in the tailpipe, listen for blowing from the exhaust and check for engine or DPF warning lights.

Questions to ask the seller before buying a 2004 Ford Mondeo diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Any recent work on the rigid brake pipes? (Flagged at MOT 1.9× as often on the 2004 Ford Mondeo diesel as on other cars the same age.)
2. Any recent work on the engine oil leaks? (Flagged at MOT 2× as often on the 2004 Ford Mondeo diesel as on other cars the same age.)
3. Any recent work on the exhaust system? (Flagged at MOT 1.7× as often on the 2004 Ford Mondeo diesel as on other cars the same age.)
4. Can I see the service history and receipts for any big jobs?