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We have had three Fuel Pump failures in just over three years, normally about a month after the 12 month warranty expires and a cost of circa $1,000 per failure. Clearly there is a problem with these components given the AA servicemen know exactly where to strike the fuel tank with a rubber mallet to effect temporary "get home repairs". Need advice to determine how to overcome this issue permanently. The car has been repaired by the authorised service agents, John Andrew Ford on all occasions.

Hi there,
If genuine parts have been used, I recommend going back to Ford and asking for some answers as to how this can happen 3 times and asking that they replace it with a decent part without having to pay for the job again. I don't think the repair has lasted for a reasonable amount of time, as expected from a service provider.

Based on your call out technician's knowledge of the issue and the temporary remedial action with the rubber hammer, is this a common problem with Ford Mondeo's or any vehicle with in tank fuel pump?

I've heard of a few in tank pumps that you can di this to when they start faulting, once started they usually go until the engine is switched off. This is very common for older turbo Subaru's, not heard of the Mondeo being a problem till now.