Ford Focus

The 1.6 Ti-VCT has narrow oil drillings in the cylinder head (production up to 2007). The phaser oil-logs and rattles on cold start. Ford improved the design from spring 2007; older engines more frequently affected.

Symptoms: Diesel-like rattle on cold start that disappears after warm-up; power drop under hard acceleration

The Sigma/Ti-VCT pencil coils fail at around 100,000–140,000 km. Typical at 1,500–2,500 rpm under load. Aftermarket coils (BERU) are considered more reliable than cheap own-brand units.

Symptoms: Misfires and power loss at mid-range RPM, OBD fault code P030x, rough running

The Ti-VCT cam phaser in the 1.6L naturally aspirated Focus DYB can seize from oil sludge deposits. A blocked oil filter in the cylinder head prevents variable adjustment. Short oil change intervals reduce the risk.

Symptoms: Check engine light P0011/P0014, slight power loss when warm, rattle on cold start

The plastic thermostat housing becomes brittle from heat cycles and vibrations and develops hairline cracks. Coolant loss leads to overheating if ignored. Particularly affects Focus Mk1 with 1.6 Zetec-S.

Symptoms: Coolant level drops without visible puddle; temperature gauge fluctuates or rises into red; coolant smell in engine bay.

Vehicles with 6-speed manual gearbox and 1.0/1.5/1.6 EcoBoost (Aug 2012–Jun 2016) were recalled due to faulty clutch pressure plates. In some cases a complete clutch replacement was required.

The PTU of the GKN all-wheel drive system has no active cooling. Above 150°C the system switches to FWD. TSB 5461 for oil leaks 2016–2017. An aftermarket cooling kit is strongly recommended for track use.

The GKN torque-vectoring rear differential (RDU) of the Focus RS Mk3 requires fresh specialist oil every 48,000 km. Neglecting this causes the clutch plate packs to overheat and the gears to wear prematurely.

Springs and shock absorbers are frequently flagged at inspection. The sportily tuned suspension of the MK3 wears chassis components more rapidly than its predecessor.

The Getrag six-speed shows synchromesh wear in 2nd and 3rd gear at higher mileages. A gearbox oil change with specialist fluid can delay early failure. Repair 1,500–3,000 EUR.

Rear wheel arch openings rust at the bumper transition edge. The roof above the rear doors can deform through body torsion. Boot water ingress through leaking spoiler fixings is widespread.

Launch control and drift mode put enormous strain on the clutch. Replacement including labour over 1,000 EUR. Clutch test: 5th gear, 50 km/h, full throttle — if revs rise without vehicle accelerating, the clutch is worn.

The standard 350×25mm one-piece discs on the Focus RS Mk3 overheat with aggressive driving and warp. Particularly after track days or hard mountain passes. Noticeable as pedal vibration under braking.