Real case

Clutch and DMF replacement on Mondeo Mk3 2.2 TDCi

Ford Mondeo Mk3 · 2004 · hatchback · 2.2 TDCi · MMT6 · Titanium. Idle vibration → clutch kit + dual-mass flywheel. Below: a structured photo article; separately: a YouTube guide.

From forum → article

Text and photos

Symptom and how it was checked

Around 248k km, cabin vibration at idle showed up. Quieter with the clutch pressed — a typical clue toward DMF / clutch, not “just the engine”. The owner matched it against several Mk3 TDCi forum threads: bag-of-spanners rattle, pedal vibration, sometimes starter dust after a flywheel break-up.

What was replaced

Full kit: disc, pressure plate, concentric slave (CSC in the bellhousing) and a new DMF. Also the rear crank seal behind the flywheel and the correct 2.2 DMF bolts (8 pcs). A single-mass conversion was skipped on purpose — some owners then get idle vibes on this engine.

How the job went

Car raised, subframe and MMT6 gearbox removed. The old DMF had clear segment play; the friction disc was worn out. After fitment — clutch alignment, reassembly, hydraulic bleed. Wheel alignment after the subframe drop is mandatory.

Result

Idle vibration was gone immediately. At 8,400 km after the repair there is no noise or judder — marked as mid-distance confirmed (L5), not a forever forecast.

Source: Aggregated Mk3 TDCi owner reports (forums)

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