Adjusting the trunk lid (Mondeo 3)

1. Place your car on a level surface and open the trunk lid.
2. Unscrew all the rod screws on the rear end sheet (indicated by arrows).
   
   

   Remove all rod screws (arrows) on the rear end sheet.

3. Remove the left upper cover gasket (indicated by the arrow) and…
   
   

   Remove the cover gasket.

4. …unscrew the two buffers at the rear end of the trunk lid.
5. Now remove the trunk lid rotary damper and…
6. …align the lid hinge with the screws (arrows) on the side piece. Loosen the screws enough to allow the lid to move.
   
   

   Align the lid hinge with the screws (indicated by arrows) on the side piece.

7. Loosen the screws on the trunk lid just enough to allow the lid to move.
8. Close the lid and install a 4 mm thick spacer (indicated by the arrow) at the rear between the side edge of the trunk lid and the side wall.
   
   

   Insert a 4 mm thick spacer (indicated by the arrow) between the side edge of the trunk lid and the side wall.

9. Once the lid is aligned with the gap, remove the spacer and carefully lift the lid. It should now not move in the hinges.
10. Now tighten the hinge screws to a torque of 23 Nm and…
11. …then loosen the hinge screws (indicated by arrows) on the body so that it is possible to move the cover with force.
    
    

    Loosen the hinge screws (indicated by arrows) on the body slightly.

12. Close the lid and press it down in the hinge areas so that it has a gap of 2 mm from the side walls.
    
    

    Create a gap of 2 millimeters.

13. Carefully open the lid – the hinges should not slip – tighten the fastening screws to a torque of 23 Nm.
14. Screw in both rear bumpers until the closed trunk lid fits snugly.
15. Carry out the installation in reverse order.

Removing the rear door

Replacing the rubber seal

1. If the rear door has already been removed, then immediately check its seals as well: unsealed areas "give away" themselves by traces of dust or water runoff on both sides of the sealing surfaces. If the seal has become brittle or cracked, sacrifice a new shaped part to your Mondeo. To do this, remove the old seal and clean the folds from the remains of the previous gasket and dirt.
2. Squeeze some new sealant (e.g. joint sealant, silicone) into the groove. If you don't have a ready-made shaped piece, place the sealant in the middle of the lock and then press it down on the edges. Trim the protruding ends properly with a side trimmer. Give this butt joint a little tension and then tap it gently with a rubber mallet on the rebate.