Ford Focus

The diesel particulate filter on the 1.5L TDCi (TZJA) is prone to internal cracking from uncontrolled regeneration processes. Failed filters cause poor emissions and emissions test failure. Ford released a software update; nevertheless many filters fail between 80,000–100,000 km.

Symptoms: DPF warning lamp, power reduction via limp mode, increased fuel consumption, emissions test failure

Ford recalled approximately 8,400 vehicles (production October 2014 to April 2015) because the camshaft sprocket can fracture due to material fatigue and damage the engine.

The EGR cooler develops cracks under extreme thermal cycling. Coolant enters the intake tract and forms black foam in the expansion tank. In the worst case a hydraulic lock results.

Symptoms: Black or oily foam in the coolant expansion tank, coolant loss with no external leak, white exhaust smoke, tendency to overheat.

The 1.5 TDCi frequently suffers from DPF clogging. Regeneration temperature is not reached on short trips, resulting in failed regeneration cycles and fuel dilution of the oil. Widely reported as the most common warranty complaint.

Symptoms: Check engine light, power loss, raised oil level, DPF warning lamp

As with PSA-related 1.6 TDCi engines, oil sludge and coked oil passages can damage the turbocharger. Regular oil changes at shortened intervals are strongly recommended.

Symptoms: Whistling turbo noise, power drop, increased oil consumption

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.