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Exhaust Heatshield Fixing When Loose Due To Corrosion

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The Ford Mondeo hit our roads in 1993, and has consistently been a sales success. Now on its 4th incarnation, it remains a drivers favourite.
For more information, visit the Ford Mondeo forum on, the definitive resource site covering all Fords from the present day to the 1970's.

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Overview Guide
Ford Model: Mondeo
Petrol/Diesel: ????
Estimated Cost: ????
Difficulty? ????
How long does this take? ????

Task In Theory

Basically the exhaust heat shield gets eaten away at the fixing points due to corrosion of the metal fixing nut used to secure it to the car & becomes loose, these methods basically give the fixings nuts new materials to hold up & stop the shield rattling.

Tools Required

Method 1

24mm Socket T-Bar Or Other Such Tool Long Extension Bar

Method 2

24mm Socket T-Bar Or Other Such Tool Long Extension Bar Drinks Can(s) ( amount requirement depends on how many fixes you need to make - a can is good for 2 or 3 fixes depending on usage ) Sturdy scissors or other such metal cutting tool

( suitable hand protection is advised for handling the cut metal )

( other materials can be substituted for the drinks cans if you don't have any cans to hand )

The Fix

Method 1

Basically the 1st time you have problems you have the option to undo all the fixings of the heat shield & just push/pull the shield to one side to move it enough to give the fixing nuts something to grip onto.

This method can be seen to some degree in this picture.

Heatshield Fix Method 1.jpg

Method 2

If you have already used method 1 & the rust bug has got hold once more or you just want to only fix the one point with minimal under the car time then this is the method for you.


Simply get your drinks can ( or other material of your choice is similar ) cut out a suitably large piece of metal that will cover the hole in the shield & also plenty of the surrounding shield too.

Now punch a small hole in the centre of the patch you have just made.

Now your ready & can remove the Fixing nut & clean off as much loose material that you can from the heat shield/car.

Now push on the new patch/washer onto the fixing nuts captive bolt.

Now tighten the Fixing nut back up ( if you have trouble due to excessive corrosion of the captive bolt then hit the centre of the captive bolt to tighten the fixing thread & then try again & if all else fails, push the begger back onto the bolt using a pair of pliers & it should eventually find the threads once more )

When your done you should end up with something like this.


or this

Bodged 2.jpg