Ford Mk4 Mondeo Galaxy S-max Broken Snapped Bonnet Release Cable Fix Inner Repair Kit Stainless Steel New Replacement Instructions Install Guide

The Problem

The poor-quality metal core of the release cable snaps, preventing release of the bonnet.

The OEM bonnet release cable on these vehicles features a galvanised steel inner cable, this rusts and snaps, preventing release of the bonnet. This is a very common fault on these vehicles even on low mileage vehicles. There is a sharp bend in the cable just after the bonnet release mechanism, water tends to gather there and inevitably the cable deteriorates and snaps. Until now it has only been possible to replace the complete cable not only is this a very time-consuming job but ultimately replacing like for like the cable would only fail again in future.

Symptoms of the fault

Cable has gone loose, frayed, bonnet not releasing, cable snapped, broken, bonnet stuck shut, won’t release, wont open.

Vehicles affected and compatibility

Compatible with all Ford Mondeo MK4 models from 19-02-2007 to 2014.

Compatible with all Ford S-Max MK4 from 06-03-2006 to 08-04-2015.

Compatible with all Ford Galaxy MK4 models from 06-03-2006 to 08-04-2015.

Associated part numbers:

1751277, 1708879, 6M21-16C657-AN , 6M2116C657AN , 6M21-16C657-AM

Our solution

Our solution allows you to replace just the inner cable which snaps causing this fault.

Our kits allows you to feed in our replacement internal stainless steel cable, this makes install very easy as the complete cable outer doesn’t have to be removed / replaced. Replacing the complete cable is very time consuming with many parts under the bonnet having to be removed.

Replacing the internal metal cable with our stainless-steel part, this will not deteriorate like the OEM part and will last the life of the vehicle. Our internal cable can be installed very easily please check out our instructions and video. Typical install takes under 15 minutes!

Our stainless-steel cable is soldered / braised to make feeding very easy. It is then very easily fitted to the bonnet release lever using the Allen key included. No specialist tools required.

This is a very common fault on these vehicles, we recommend replacing the cable before it inevitably snaps, this could happen at an inopportune time and makes replacement tricky as the latch has to be manipulated from under the vehicle. Check out our instructions in case your cable has snapped we show how to release the bonnet so our replacement cable can be installed.

You will receive

High quality stainless steel cable

End nipple with fastening screw

Grease

Allen key tool

Unbolt and remove the front under-tray, some vehicles have two covers a large one covering the sump and a smaller cover over the lower part of radiator, in this instance both need to be removed.

Position yourself under the radiator and look upward, using a torch in front of the main radiator you will see the bonnet catch mechanism.

There is a metal plate covering the bottom of the mechanism. Bend this back with a screwdriver.

You can then access the release lever (shown in purple on illustration) push the release lever towards the passenger side to release the bonnet.

Locate the two grommets on the front of the trim.

Using a Philips screw driver release the top part of the grommet.

Slide a pry tool or flat bladed screwdriver under the top section of the grommet and lever out of position.

Slide the pry tool under the lower section of the grommet and lever out of position.

Locate top section in to lower section and retain for reinstall.

Repeat this for the second grommet.

Lift to release the 3 tabs at the back of the trim and lift trim out of position.

Look down behind the latch mechanism and you will see a black bracket which holds the mechanism, this is retained by two bolts.

Using a 10mm socket remove the left hand bolt.

Locate the wiring clips and remove to allow access to the right hand bolt.

Remove right hand bolt.

Remove bracket, note orientation here, this is important for reinstall.

Move the latch out of position to reveal the end of the bonnet release cable.

Remove the stop end from the release lever and lift the cable end out of position.

If cable has already snapped pull on stop end to remove metal cable from the cable sheath.

If cable hasn't snapped cut cable with wire cutters.

Retain the black rubber part shown, note orientation this needs to be slide on to the new cable later on.

Pry off plastic grommet, locate square section of grommet and lever out using a small flat bladed screwdriver.

Using long nose pliers compress the two tabs within the lever to release the lever, pull lever away.

Remove stop end from lever mechanism this will twist and lift out.

Pull through and remove remnants of old cable.

Take our new cable and fit the rubber grommet as orientated, push this down cable to stop end.

Install stop end in to release lever, push in and twist to locate.

Take the grease and lubricate the complete length of the cable.

Pull back the flexi black rubber sheath on the sharp bend at the start of the cable outer.

Push the cable through the hole (before the sharp bend) and pull through full length of cable.

Push the cable through the hole after the sharp bend. Feed the cable through from a high position as shown to push the cable through the plastic outer in to the vehicles cabin.

Using long nose pliers pull the cable through.

Push through the remaining length of the cable.

Lubricate the sharp bend with the grease.

Push flexi rubber sheath over sharp bend and back in to position.

Push rubber end grommet back in to position.

Refit cable end to latch mechanism.

Refit latch mechanism.

Push back in to position, the latch has a stud that will locate on the front of the mechanism so it will hold in position before bracket is fitted.

Refit the bracket as orientated and fasten the two bolts.

Refit the electric wire clips to secure.

Insert screw driver in to latch to simulate locked bonnet. Push past first latch and down on second latch. Screwdriver should stay locked in position and should not be able to be pulled upwards.

Push our stop end on to the end of the cable.

Slide up the cable length.

Pull on the cable length not so as to release the bonnet but just so it is taut.

Locate the stop end in to its locator on the release lever and fasten the grub screw not fully tight but so as it wont slide.

Using wire cutters cut the wire as close as possible to the cable end.

Once cut there will be some cable that protrudes from the stop end. Release the grub screw lightly and slide the stop end a tiny amount so that there is no cable protruding from the stop end.

Fully tighten the grub screw. Using the pliers grasp the stop end and fully tighten the grub screw as tight as possible.

Push the stop end in to the recess on the lever mechanism.

Push in with the Allen key in the grub screw and pull the cable in to position using the long nose pliers.

Push the release lever on to the release mechanism.

Refit the plastic grommet locating the square section in to the square recess.

Pull on the lever to release the bonnet latch and the screwdriver!

Refit plastic trim.

Refit 2x grommets remembering the two sections.

Push down on the three top tabs to secure.

This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on +44 01843 446643 or email us at sales@x8r.co.uk. Please also check out our instruction guide on YouTube. www.x8r.co.uk Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2018.