A spacious, refined executive car with excellent motorway performance. Rated the most reliable used executive car in the 2023 What Car? survey (98.3%). The 2.0 TDCi engine is generally robust and can reach 200,000+ km with proper maintenance. Main concerns: DPF clogging on short journeys, dual mass flywheel/clutch wear, EGR valve carbon buildup, and Powershift DCT issues if oil changes are neglected. Early 2014-2015 cars have multiple recalls - verify all completed. The wet-clutch Powershift gearbox is more reliable than the dry-clutch version in Focus/Fiesta. Manual gearbox recommended for best reliability.
DPF clogs on short journeys, related components often fail before the filter itself · more· less
The Diesel Particulate Filter gets blocked if the car is mainly used for short journeys where the engine never reaches optimal temperature for regeneration. Symptoms include "Engine Malfunction" warning, DPF light, and limp mode. The fuel vaporiser (used to heat the DPF for regeneration) commonly fails around 100,000 km as it clogs with soot - replacement costs around €300. Pressure sensor replacement is around €80. A full DPF replacement costs €400-1,500 depending on whether OEM or aftermarket. Many issues are caused by failed vaporisers, blocked grill shutters, or software problems rather than the DPF itself. Regular motorway driving helps prevent issues.
Dual mass flywheel / clutch wear€700 - €1,400
DMF and clutch wear together, typically between 120,000-200,000 km · more· less
The dual mass flywheel on the Mk5 TDCi is more robust than earlier generations, with many lasting 140,000+ miles (225,000 km). Symptoms of failure include rattling noise at idle, vibration through the clutch pedal, and difficulty engaging gears. Replacement typically costs €700-1,000 at an independent garage including both DMF and clutch, or €1,200-1,400 at a Ford dealer. Parts alone (LUK kit with DMF, clutch, and concentric slave cylinder) cost around €600-750. Labour is 5-6 hours as the gearbox must be dropped. Driving style significantly affects lifespan - riding the clutch or lugging the engine at low RPM accelerates wear.
EGR valve carbon buildup€200 - €900
Valve sticks due to carbon deposits, causes hesitation and flat spots · more· less
The EGR valve becomes clogged with carbon deposits over time, causing hesitation between 1800-2000 RPM when feathering the throttle, misfires, and flat spots during light throttle use. Cleaning provides only temporary relief - the valve typically needs replacement every 18-24 months once problems start. A new EGR valve costs €200-400 for parts, with professional replacement costing €700-900 total as the ECU may need reconfiguration. The EGR is located at the back of the engine with 4 bolts. Quality fuel additives can help reduce carbon buildup. Short journeys accelerate the problem.
Wet-clutch DCT more reliable than Focus/Fiesta version, but still needs attention · more· less
The Mondeo uses the 6DCT450 wet-clutch Powershift gearbox, which is significantly more reliable than the dry-clutch DPS6 in the Focus and Fiesta. However, problems can still occur if the oil isn't changed every 50,000 km (or 3 years). Common symptoms include jerky shifts, slipping, delayed gear selection, and banging into gear. Issues are often caused by the mechatronic valve body, hydraulic pressure faults, or solenoid problems rather than the clutch packs themselves. Average repair cost is around €800 for minor issues. Clutch replacement costs €2,400-3,000. A factory exchange gearbox is €4,500+. Early diagnosis is crucial - driving with symptoms causes further damage.
Turbo actuator / turbo failure€150 - €1,500
Electronic actuator is common failure point, full turbo usually lasts well · more· less
The electronic turbo actuator is a very common failure point on the 2.0 TDCi. Symptoms include loss of power, limp mode, and turbo not boosting properly. Ford dealers quote to replace the complete turbocharger as they don't sell the actuator separately. However, specialists can repair the actuator for €150-250 with warranty. According to taxi drivers on forums, the turbo itself typically lasts 300,000+ km if oil is changed regularly. Full turbo replacement costs €800-1,500 at an independent garage. Poor oil circulation and extended oil change intervals accelerate turbo wear.
Injector failure€400 - €1,500
Can fail randomly, often related to fuel quality or contamination · more· less
Common rail injector failures cause erratic running, low power, poor emissions, white/black smoke, and audible knocking. The injectors typically last 200,000+ km but can fail earlier due to fuel contamination or poor quality fuel. If you smell diesel through the vents, the injector seals may be leaking - look for black carbon buildup at the base of injectors. Seal replacement is only €15 in parts but labour is significant due to carbon buildup potentially sticking injectors in the head. Full injector replacement is expensive - €400-1,500 for a set. Always use genuine Delphi or Ford fuel filters (2 micron screen) - aftermarket filters with 5-10 micron screens are inadequate.
Timing belt wear€500 - €800
Due every 10 years / 200,000 km - preventive replacement, not a common failure · more· less
The 2.0 TDCi timing belt should be replaced at 10 years or 200,000 km (125,000 miles), whichever comes first. This is a conventional timing belt setup (not the problematic wet belt of the 1.8 TDCi). Ford's fixed price for timing belt replacement is around €525, with independent garages typically charging €400-600. It's highly recommended to replace the water pump, tensioners, and idler pulleys at the same time since the labour overlaps - total cost €600-800 including water pump. DIY-friendly with the right tools - an SKF kit (belt, tensioners, water pump, crankshaft bolt) costs around €150.
Glass roof squeak (hatchback)€0 - €300
Fixed panoramic roof squeaks and groans - Ford's fix doesn't always work · more· less
The fixed glass roof on the Mondeo Mk5 hatchback is known to squeak and groan, sometimes severely. Even dealer demo cars have exhibited this issue. Ford's official fix involves levering up the rubber seal and injecting lubricant underneath. Results are mixed - some owners report improvement, others say it made the problem worse. There are Technical Service Bulletins (TSBs) for this issue. If under warranty, Ford should attempt the fix for free. Outside warranty, expect €100-300 for attempts at fixing. Some owners simply live with the noise. The estate/wagon version does not have this problem.
Keyless entry system failure€100 - €500
Intermittent failures can strand owners or lock them out · more· less
The keyless entry and ignition system on high-spec Mondeos can stop working intermittently. Common causes include dead 12V battery (the car draws current when locked, draining the battery within weeks if not driven), key fob synchronization issues, water ingress into door handle contacts, or Body Control Module (BCM) faults. Try re-syncing the key fob first (turn ignition switch from position 1 to 2 four times within 6 seconds, then press any button on the remote). If that doesn't work, an auto locksmith costs around €200, or dealer BCM reprogramming may be needed.
Reliable executive car with predictable maintenance needs
The Mondeo Mk5 2.0 TDCi scores among the best in its class for reliability. The engine is proven and durable, with taxi examples regularly exceeding 250,000 km. Most issues are preventable with regular maintenance and motorway use. Manual gearbox versions are more reliable than Powershift automatics. Verify all recalls are completed on 2014-2015 cars.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete service records essential. Verify oil changes at proper intervals (every 20,000 km or annually).
Tires
Check tread depth, age (date codes), and uneven wear patterns. Common sizes are 235/45 R18.
Cold start
Must start engine completely cold. Listen for unusual sounds, excessive smoke.
Body condition
Check for rust, accident damage, paint mismatch.
Test drive
Minimum 30 minutes including motorway speeds to trigger DPF regeneration and get gearbox up to temperature.
Specific for this vehicle
Check DPF status and driving history
Ask about typical journeys. Short trips only = high DPF risk. Check for DPF warning light or "Engine Malfunction" warnings. Verify oil level is not overfilled (diesel contamination from failed regenerations).
Listen for DMF/clutch noise at idle (manual)
With engine running in neutral, listen for rattling or rumbling. Press clutch pedal - noise should change or disappear. Vibration through clutch pedal indicates wear.
Test Powershift gearbox thoroughly (automatic)
Drive for 20+ minutes in varied conditions. Feel for jerky shifts, hesitation, slipping, or banging into gear. Ask when gearbox oil was last changed - should be every 50,000 km.
Check for hesitation at 1800-2000 RPM
Feather the throttle gently at motorway speeds. Hesitation or flat spots indicate EGR valve carbon buildup.
Verify timing belt replacement if over 150,000 km
Due at 200,000 km / 10 years. Check service records for proof of replacement. Budget €600-800 if needed.
Test glass roof for squeaks (hatchback)
Drive over rough surfaces and listen for squeaking/groaning from the panoramic roof area.
Check all recall work completed
Contact Ford with VIN to verify all recalls addressed, especially oil sump/overheat (2014-2015), headlamp (2014-2015), and Takata airbag recalls.
Contact Ford with the VIN to verify all recalls have been completed. Early production cars (2014-2015) have multiple recalls - thorough verification is essential before purchase.
Warranty Status
Factory warranty (3 years / unlimited km)Expired on most Mk5s
Powertrain warranty (5 years)Check with Ford using VIN
Corrosion warranty (12 years)May still be active (2014+ cars)
Most 2014-2019 Mondeo Mk5s are outside their original warranty. Ford Protect extended warranty plans are available through Ford dealers. EU Block Exemption law means independent garage servicing does not void the warranty. Check with Ford if any remaining coverage applies to your specific vehicle.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.