yep i just bought an '03 mondeo ghia x from the auction and the bonnet wouldn't open on that either,1st of all i spent 20 mins looking all under the dash for a pull release to no availl then had to dig out the owners manual to find out how to open the bonnet bit embarassing for an ex mechanic,it's a key behind the Ford badge,and it's knackered !!
The part you need to pull through the hole you create behind the badge is a triangle shape with rounded points, it measures 5.5cm x 2.8cm, you cant just drill out the shear bolts expecting it to drop out you have to pull the lock and and assembly back through the hole you've made, pull out a white plastic shaft behind the lock and then youll see a cross head pattern quite far back, use quite a long chunky screwdriver to turn that left and then right to open the bonnet.
my key turned left and right prior to this procedure and a couple of times it popped to the first point but never the second,looking at the parts it's the white shaft that the problem it has split at the top so with a new white piece if i can get one from Ford i should be able to put it back together with original key and barral.
Tools requires
Drill
pilot drill bit 3mm to pilot hole as close to ctr as you can get on the shear bolts then maybe use a 5-6mm drill bit but you will need to finish with a 10mm bit !! not a 9mm or an 11 mm it NEEDS to be a 10mm 9 isnt big enough and 11mm damaged my lock casing.
Long nosed pliars to pull lock assembly through hole, (watch you dont loose little spring)
Stanly knife to didy up edges.
hoover to hoover up all metal shavings from under tray.
time taken a good hour if your lucky i wasnt and my one shear bolt thread was stuck fast in the hole and wasnt going to budge, ended up drilling it completly out which then melted the plastic and it all came out so unless i can slip a washernut in the back i'll be hoping it will hold with one new bolt and the other glued in for show
kevin hughes
August 2010