hartleyhare

When mine started to fail, you could feel a vibration at certain speeds with the clutch engaged, which disappeared completely when the clutch was dipped. With time, the vibration got worse especially under acceleration and there was a noticeable loss of power. If yours is on its way out, I suggest you get it looked at sharpish as I left mine and eventually had to replace the gearbox, driveshafts and complete clutch assy..... There was a warranty recall on this fault, but apparently it only applied to 130bhp versions for some reason ????? 2003 TDi Mk II 115bhp 150,000km on the clock

Fair comment, - I guess the secret is to check the state of the brushes on the second hand blower before buying it ! I did find a company who specialise in brushes in the UK who would create some for it for around

Hi My 03 Galaxy front blower motor started to play up - whatever speed setting I had selected - working for a minute or two then with a pungent smell I can only describe as almost garlic-like, the fan slowed to a stop. After a few seconds i could start it again for it only to stop again moments later. Since the auxillary heater isnt working at the moment ( ! ) I needed to get the front blower working again to clear misted windows if nothing else. I took the blower assembly out and inspected the brushes on it - one of them in particular had completely worn down to the plastic it is mounted in. Does anyone know a source of new brushes ( and in my case I need a replacement brush holder too )? Seems crazy that a 10 minute job could get this up and running again like new for a matter of a few quid for new brushes. Hope someone can help ?

I had this very problem myself towards the middle of last year with my Galaxy 1.9tdi ( 2003 ). If the problem disappears when you dip the clutch then I am sure you have the same issue - quite common by the sounds of it although Ford only did a warranty recall on the 130BHP engine version. It was the dual mass flywheel - so I needed a new clutch, dual mass flywheel - driveshafts and a gearbox - all of which has sustained damage as a result of the failure of the flywheel. If you catch it early enough you may not be as unlucky as me !!!

Oops - I meant 3 of the 4 I have .... its that Friay afternoon feeling.....

Add me to the list of failing headlamp motor mechanisms !! Just converted my Spanish Galaxy 1.9TDI to UK headlamps and sorted out the motors at the same time. With mine ( four of the three I have ) the tracks inside the variable resistor are being worn away by the movement of the contact brushes that slide up and down the tracks which is scarey since I hardly ever adjust the height of the headlights. Unsoldered and took the variable resistors apart and touched up the worn part of the tracks with electrically conductive paint then reassembled everything and hey presto - they work perfectly - without the extra grease. Not sure it wouldnt be simpler to just buy replacements lol !!