Ford Focus

The Duratec HE is prone to crankcase breather clogging. Crankcase pressure forces oil past seals. The valve cover gasket and EGR valve should be checked at the same time.

Symptoms: Whistling or hissing noises, oil mist on engine, oil loss without visible external leak

Duratec HE thermostats fail in both directions: stuck open → no warm-up; stuck closed → overheating with potential head gasket damage. Preventive replacement every 100,000 km advisable.

Symptoms: Temperature gauge wildly fluctuating or permanently at limit/red zone; heater output noticeably changed

The plastic swirl flaps in the Duratec HE intake manifold break off from around 80,000 km. Fragments can enter the combustion chamber and cause severe damage. Ford dealers only supply complete intake assemblies for ~£520; repair kits available from £25.

Symptoms: Rattling from engine bay at 80,000–120,000 km, false air, power drop, check engine light

The 1.8L Duratec HE commonly shows increased oil consumption from 120,000–130,000 km from worn piston rings. Up to 1 litre per 1,000 km in extreme cases. Wrong oil and short trips accelerate ring wear.

Symptoms: Oil level falls between changes, blue smoke from exhaust, oil checks required more frequently

The electronic throttle body on the 1.6 Duratec (e.g. Focus Mk2 petrol) frequently fails above 150,000 km from potentiometer wear or moisture. Fault codes P2108 and P2176 appear; the OEM unit costs £480.

Symptoms: Sporadic engine fault warning, engine won't accept throttle, idle hunting, intermittent stumble on pull-away

Despite full galvanising, sills and wheel arches rust heavily, especially at the junctions between the wing and the bumper. The tailgate rusts under the roof spoiler when water ingresses.

Wheel bearing failures frequently noted in inspection reports, especially from 2010 model year. Track rods and suspension components wear above average. Control arm bushes and lower arms fail prematurely.

Plastic thermostat housings are prone to cracking and coolant loss. Coolant temperature can become unstable; in the worst case the engine overheats.

The brake pressure sensor in the ABS block corrodes and cannot be replaced individually — the entire ABS unit must be swapped. Primarily affects vehicles up to model year 2007.

Up to model year 2007, water accumulates at the junction between the rear bumper and wheel arch, leading to rust. Ford had to carry out multiple repaints. Check carefully before buying.

Ford does not supply an individual wheel bearing — only the complete hub (approximately 290 EUR). Lower RevoKnuckle needle bearings can seize. Press-fitting requires specialist tools. High front tyre wear accelerates deterioration.

Wheel arch edges are almost universally affected without cavity wax treatment. Water penetrates through rear light seals and spoiler fixings into the boot floor, which then corrodes from the inside.

ABS cables chafe on suspension components, ranging from a simple warning light to complete ABS failure. Cable repair is needed, not just a sensor swap.