Rear nearside wheel bearing rumbled badly. The replacement part was a ridiculous £80 because it's an ABS equipped model and apparently you have to buy the hub carrier too. And it was a nightmare to fit.
Wasted-spark ignition system failed. Turned out to be a common problem - a plastic clip that holds the 12V feed for the coil snapped, and the feed draped across a hot EGR pipe. Easy to fix, one fuse, some insulaton tape and a cable-tie.
Sticky idle speed control valve gives uneven idling in cold weather (but fine in the warm).
Rear drum brake cylinder started leaking. Easy job and very cheap to replace.
Blower fan switch works intermittently.
Water pump squeaks every rotation when the engine is hot. It has done since I bought the car, yet it doesn't leak a drop. I'm not too bothered as the water pump is on the ancilliary drive belt on the Mondy, not the cam belt, so if it siezes at least it won't break the valves.
Gears are very notchy, and it's difficult to get into 1st and 2nd when the engine is cold. In my experience of Fords this is due to the clutch release bearing sticking to the drive shaft and will ultimately lead to the whole clutch assembly needing replacement. I don't even want to think about how expensive that'll be.
Very rattly engine when cold. On the recommendation of several websites RE sticky values on MK1 Zetec engines, I started using thinner oil (15W5). This stopped the cold rattle.
Power steering has a little "notch" with no power assist when the wheel is centralised. This goes away after the car has run for a bit.
Uneven tire wear on rear. (Probably a result of the previous owner lowering the suspension).
The exhaust rusted through in two places, but was inexpensive to replace.
Having listed all the bad features of this car I do have to praise it's robust construction. It's big, heavy and solid, perfect for transporting the family. The Si also comes equipped with ABS and drivers airbag.
The power steering is rather too heavy and unresponsive for my liking, but the engine produces a reasonable level of grunt (136bhp) which is great for overtaking slow traffic uphill (or overtaking traffic anywhere, for that matter). But don't expect a great 0-60 time; at 1285kg it takes 9.5 seconds to get to 60mph, but the engine has enough power to give reasonable acceleration beyond 70mph if required.
The suspension is also very good on the Si with no body roll around corners and no skittering when bumps are hit while cornering at speed.
The fuel consumption is terrible when driven with a bit of gusto - I got a mere 24mpg. Motorway driving at a constant 70mph takes this up to about 38mpg in my experience.
The bucket seats are comfortable for long drives and the cabin is spacious. I'm quite tall and some cars I've driven leave little clearance between my head and the roof - the Mondeo has lots of room in this respect, and the seat height is electrically adjustable.
Good review although I'm surprised about your comments regarding the steering. The Mondeo's steering is on the heavy side when moving in order to maximise feel, but it's not usually known for being unresponsive. In fact, after a Vectra or Accord, it responds like a sports car.
You raise an important point about oil - the Zetec engine is very sensitive to it. Ford recommend a 5W/30 and their own "Formula E" brew is available from motor factors for about £12 for 5 litres. I've used this in a Mondeo I service for the past five years and it's now racked up 170,000 miles without so much as a noisy tappet.
Good engines those 2 litre zetecs. 137 mph out of one. Then the head gasket lunched itself. DAMN! (mondeo)
Never heard of 15W5 oil. Might be a mistake.
I used 5W50 and I was not happy with. Changed to 10W40 and I feel better.
Take care with that water pump. It may blow/stick when you not expect it and you'll boil the engine in 1 minute.
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I have a 1995 Mondeo 1.8, with 160,000 on the clock, it does drive and handle like a much faster/expensive car and when needed it will shift, get 28 to 40 mpg depending on speeds distance.
Problems? Sump gasket leaking-its an engine out job! Not looking forward to it and all garages say scrap the car! Pity as it has no rust and have changed all the suspension components recently. Got to be done though as oil is leaking onto the cat/exhaust and leaving spots on road!
Problems- misfiring at low speeds/light throttle settings- still chasing this problem done all the pipes and sensors and of course the ECU does not store fault codes. Will sort when I take the engine out.
Problems-Lower suspension bushes and anti roll bar bushes wear quite quickly and you get knocks over bumps. Anti roll bar job easy if bolts not seized, wish bones harder with N/S bolt being fitted from above and gear box on top of it! Solution chop head of bolt off and fit new one from under car!
Otherwise a fine car and a lovely shape will be in the family for years to come!
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