FORD MONDEO MK3 MK2 ELECTRIC

SEAT MOTOR - Brass Gear -

FordMondeoElectricSeatHeightAdjusterDevice
TheoriginalelectricseatheightadjustmentdeviceinFordsMondeo(Models19972006)is
madeofplasticandoftenbreaks.Whentheplasticteethstripfromthedrive,thegearwill
notturn.Themotorcontinuestobuzzbuttheseatdoesnotmove.Fordwillhavemorethan
250onlyforacompletelymotorwithoutAssembling.
Thesmallplasticdrivegearisnotavailabletobuy.

Butyoucangetmysolutioninabrassversionandthedrivegearwillneverdestroyedin
future.Brassisaspecialmetalofhighfirmnessincomparisontoplastic.
Theassemblingcanbedonebyyourself.Theoldplasticdrivegearmustberemovedwitha
tongorsmallsawandafterthatasmallthreadbehindmustbewhet.Attheendyoumust
drillaholeforthefixationandassemblethebrassgear.
Includedwithyourpurchasearewritteninstructionsandillustrationstoassurecompletion
ofthissimpledoityourselfprojectwhichcanbedoneinshorttime.

RepairmanualsfortheseatregulationFordMondeo
Constructionofthebrasscogwheelasreplacementfor
thefaultyserialplasticcogwheel.

Donotuseacordlessscrewdriver!Riskofthetriggering
oftheAirbag.

Image 1 + 2:
First of all, you have to loose the guide rail and the electronic connections under the seat.
Image 3:
Unscrew the seat of the vehicle and lay it on the head in order to have a good access to the
seat motor. Here you can see the inverted seat with view and position of the motor spindle
unit.
Image 4:
This is the dismantled motor spindle unit. It can be possible that the spindle is longer or
shorter, this depends on the year of construction, but the cogwheel is always the same.
Image 5:
3 screws have to be released, in order to open carefully the cap of the worm. (Attention, there
can be small pieces, which will be needed!)
Image 6:
The shown cogwheel is damaged and will be replaced by the brass cogwheel.
Image 7:
The old plastic cogwheel can be removed by filing, rasping or removing with the help of a
gripper. It can be easier made with a grinder. At the same time, it will be possible to remove
directly the old winding which is located under the old cogwheel.
Naturally it is possible to fill by hand or to remove it by an engine lathe.
Image 8:
It should be necessary that the measures of the material remain alike.
Image 9:
First of all push the grommet on the spindle (green arrow on the picture). After you have to
push the new brass cogwheel till the end of the grinded area of the spindle. Control the
position and the drive direction of the new cogwheel (the yellow arrows are showing the
grade which is only be on one side).
Image 10:
Then you have to bore through the cogwheel and through the spindle a whole with a borer of
2,5 mm (blue point image 9) in order to counter sink completely the standardized ferrule and
for the reason that it is not possible for the cogwheel to get out of place. (In this picture you
can see, that the ferrule is already connected with the spindle)
Image 11:
Here you can see all single components which should be available for the construction.
Image 12:
This is the way how the new cogwheel should be constructed in the gearing of the motor.
Please give a little bit fat on the cogwheel, remove the old rest of the old plastic cogwheel
(very important) and close and screw the cap. (Do not forget the small metal plate, red arrow).
Build in the motor under the seat and assemble the plug-in connection.
Thats it!