Ford Focus

Injectors on the 2.0 TDCi family show measurable wear from around 150,000 km. Leaking copper sealing washers allow combustion gases to escape ('Black Death'). Replacing one injector soon necessitates replacing all, as wear state is similar across the set.

Symptoms: Rough running, diesel knock, black soot deposits around injectors, power loss

At higher mileages the high-pressure pump wears internally and leaves metal swarf in the fuel filter. Swarf can damage injectors. The pump can fail suddenly on the motorway.

Symptoms: Golden metal swarf in the diesel filter housing, engine drops into limp mode or stalls under full load, difficult cold starting.

Ford specifies 200,000 km or 10 years as the replacement interval (automatic: 100,000 km). A belt with 15 cm of missing teeth has been documented at only 99,000 km. Belt failure destroys rocker arms and the camshaft.

Symptoms: No prior warning on belt snap — sudden engine stall on the motorway, loud banging from the engine.

The diesel particulate filter blocks up in frequent short-trip use when regeneration temperature is not reached. Fuel enters the engine oil and measurably dilutes it. Oil level check every 5,000 km recommended.

Symptoms: Engine management light, power reduction, elevated oil level, regular motorway runs required

The dual-mass flywheel wears over time. Verified failure documented at 270,000 km (Mondeo estate), total cost approx. £1,050 including clutch and labour. With normal use trouble-free operation beyond 200,000 km is possible.

Symptoms: Metallic rattle on gear changes, vibration at idle, shudder on take-up

From 75,000–100,000 km, poorly maintained examples develop axial play in the turbocharger shaft. The oil feed line to the turbo can coke up, leading to oil starvation.

Symptoms: Whistling or metallic rattling on acceleration, power loss, bluish smoke.

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.