Ford Focus reliability

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Fix: Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Recalled models: FOCUS (sDPF) · 1 vehicles

On affected vehicles the clutch pedal spring may touch the Electric Power Assisted Steering wiring harness which may lead to clutch spring heat up and fall out a short circuit and loss of steering power assistance.

Fix: Inspect and adjust the position of the wiring and if necessary repair any wiring damage.

Recalled models: FOCUS · 5,152 vehicles

While monitoring vehicles in operation we have identified a number of Focus vehicles where the passenger belt minder chime is not activated when the vehicle goes over 15 mph. Regulatory requirements mandate that an audible chime must activate when the first-row passenger seatbelt is unfastened and the vehicle speed exceeds 15 mph.

Fix: Update the instrument panel cluster IPC configuration.

Recalled models: FOCUS · 1,311 vehicles

A number of Focus vehicles have been identified where the warning chimes may not be operating as intended. The chimes may not be audible when the driver is not holding the steering wheel for longer than 30 seconds while using Lane Centering Assist which does not meet ECE regulations.

Fix: Updating software in control unit.

Recalled models: FOCUS · 85 vehicles

On affected vehicles the Lighting Driver Module software may be incorrectly configured which could potentially cause the adaptive headlamps to not work as intended.

Fix: Software update and/or headlamp adjustment in order to restore feature functionality.

Recalled models: FOCUS · 96 vehicles

On certain vehicles tape used to protect the end of the ground connection wiring harness of the 48V battery may have become trapped beneath the nut securing the wiring harness.

Fix: Inspect the ground connection harness. If required the tape on end of the connector will be reapplied and the nut tightened to the specified torque.

Recalled models: FOCUS · 3 vehicles

Certain vehicles may be fitted with a seatbelt that does not meet the high specification expected by Ford due to a rivet that is holding the buckle not being fully secured.

Fix: Dealers will inspect all vehicles and if found necessary will replace the part that is not meeting specification.

Recalled models: FOCUS · 2,196 vehicles

A possibility that vehicles could have a front suspension knuckle that was incorrectly manufactured.

Fix: Inspect and if necessary replace the affected components.

Recalled models: FOCUS · 179 vehicles

It may be possible that the eCall feature will stop functioning due to a malfunction.

Fix: The Telecommunication Module will need to be replaced

Recalled models: FOCUS · 9,388 vehicles

The Garnish Panel from the Panorama roof may detach.�

Fix: Test the adhesion of the panel bonding material and if necessary replace the panel.�

Recalled models: FOCUS · 12 vehicles

Certain vehicles could have an engine oil separator that may have been damaged prior to engine assembly.

Fix: Inspect the engine oil separator and if found to be damaged and/or leaking a replacement engine oil separator must be installed

Recalled models: FOCUS · 9,818 vehicles

The nuts on the 48V battery poles may not be torqued to specification.

Fix: Remove both positive and negative poll nuts and inspect the wiring for signs of damage. Any damaged wiring will be replaced. Both nuts will be refitted and torqued to specification.

Recalled models: FOCUS · 17 vehicles

The screw which secures the ground cable of the 48v battery may not be fully secured.

Fix: Replace the ground cable bolt on all vehicles and torque to specification

Recalled models: FOCUS · 11 vehicles

Vehicles may have an issue with the current software that controls the functionality of the eCall system.

Fix: Carry out a software update.

Recalled models: FOCUS · 100 vehicles

Possible transmission stud damage to wiring loom following repair.

Fix: Check that the correct transmission stud has been replaced. If not the correct stud must be replaced and the wiring loom should be inspected for damage and repaired as necessary.

Recalled models: FOCUS · 1,273 vehicles

A nut securing the mHEV battery connection may not be torqued to specification.

Fix: Remove the nut and inspect the wiring for signs of damage. Any damaged wiring will be replaced. A new nut will be fitted and torqued to specification in all circumstances.

Recalled models: FOCUS · 13 vehicles

The engine wiring loom may touch a bolt on the transmission housing which could lead to damage to the wiring loom.

Fix: Check for enough wiring loom clearance replace the clip and secure harness if not. Any damage to the wiring harness to be repaired as necessary.

Recalled models: FOCUS · 542 vehicles

Engine wiring loom may touch a stud on the transmission housing

Fix: Transmission stud to be replaced with a bolt and rerouting of the wiring loom

Recalled models: FOCUS · 2,664 vehicles

A defect on the Power Distribution Box (PDB) pins may potentially cause an intermittent poor connection on a number of terminals.

Fix: Inspect for potential damage If present replace Power Distribution Box and interfacing wiring loom pins

Recalled models: FOCUS · 4,538 vehicles

Seat belt anchors and seat bolts may not be secured as per specification

Fix: Check tighten and torque all identified bolts to specification

Recalled models: FOCUS · 11 vehicles

Bolts fixing the front suspension to the vehicle may not be tightened to the correct torque.

Fix: The front suspension bolts must be inspected and set to the correct torque.

Recalled models: FOCUS · 22 vehicles

A number of vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Recalled models: FOCUS · 66,497 vehicles

Potential for the rear doors to open when the rear windows are lowered.

Fix: Ensure the door release cable is in the correct position and adjusted if necessary.

Recalled models: FOCUS · 1,729 vehicles

A brake pedal hinge bolt which does not meet specification.

Fix: Check torque of brake pedal hinge bolt. If the vehicle fails the test replace the brake pedal box

Recalled models: FOCUS · 5,336 vehicles

Rear door latch child lock may not function correctly.

Fix: Check child locks for correct activation and replace if necessary.

Recalled models: FOCUS · 3,021 vehicles

Affected vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Recalled models: FOCUS · 122,199 vehicles

A small batch of alloy wheels may have a casting defect that may initiate a fatigue crack and result in wheel failure.

Fix: Check wheels on affected vehicles for a specific batch code. Replace those wheels which have the identified batch code.

Recalled models: FOCUS · 80 vehicles

The engine control module calibration may not adequately detect an overheat condition in certain 2.0L Duratorq Diesel engines. In extreme cases an overheated engine can result in a breach of the oil sump leading to loss of the engine oil.

Fix: Recall the vehicles that are likely to be affected and download revised software for the control module calibration that improves overheat detection and provides an instrument cluster warning indicator to the driver and engine de-rate strategy.

Recalled models: FOCUS · 48,595 vehicles

Localized overheating of the engine cylinder head may cause the cylinder head to crack.This may cause a pressurized oil leak which in extreme circumstances could result in a fire in the engine compartment.

Fix: On affected vehicles Inspect engine and cooling system. Replace affected components and fit a Coolant Level Sensor along with associated software to provide and audible and visual warning to the driver.

Recalled models: FOCUS · 15,228 vehicles

The airbag initiator may be defective and may prevent the side airbag(s) and/or knee airbag deploying in the event of an accident. In a collision the airbags not deploying could put the occupants at further risk.

Fix: Recall the 1943 vehicles that are likely to be affected to check and where necessary replace the side and knee protection airbags complete with initiators.

Recalled models: FOCUS · 1,943 vehicles

Engineering investigations have identified that vehicles operated in countries which have high road salt usage during winter months may experience an increased risk of corrosion build up. In extreme cases the corrosion can propagate into the electronic circuits and result in overheating. In rare cases the overheating may be sufficient to ignite the module and surrounding wiring and components.

Fix: A supplemental wiring loom that removes the power supply to the fan control module when the ignition is switched off is required to be fitted to affected vehicles. An additional water shield must also be fitted to protect the module against water entry and corrosion build up.

Recalled models: FOCUS · 34,119 vehicles

Due to high road salt usage in winter the engine cooling fan module may suffer from corrosion and may overheat and ignite.

Fix: Recall affected vehicles to modify wiring loom and to fit water shield to module.

Recalled models: FOCUS · 1,531 vehicles

Due to high road salt usage in winter the engine cooling fan module may suffer from corrosion and may overheat and ignite.

Fix: Recall affected vehicles to modify wiring loom and to fit water shield to module.

Recalled models: FOCUS · 26,586 vehicles

Due to high road salt usage in winter the engine cooling fan module may suffer from corrosion and may overheat and ignite.

Fix: Recall affected vehicles to modify wiring loom and to fit water shield to module.

Recalled models: FOCUS · 919 vehicles

Due to high road salt usage in winter the engine cooling fan module may suffer from corrosion and may overheat and ignite.

Fix: Recall affected vehicles to modify wiring loom and to fit water shield to module.

Recalled models: FOCUS · 4,999 vehicles

It has been identified that a batch of vehicles converted by SVP have been fitted with a split charging system the relays of which may not be to specification and could subsequently fail. This can result in wiring loom damage and the possibility of a fire.

Fix: Whereas the converter has approached 89 customers and supplied revised parts. It is proposed that Ford will contact the owners of the outstanding vehicles to emphasise the importance of end users contacting the convertor thus ensuring that the remaining vehicles are reworked.

Recalled models: FOCUS · 109 vehicles

Due to high road salt usage in winter the engine cooling fan module may suffer from corrosion and may overheat and ignite.

Fix: Recall affected vehicles to modify wiring loom and to fit water shield to module.

Recalled models: FOCUS · 29,325 vehicles

During engine warm up it is possible that the non return valve within the vacuum pump may stick. It is possible that if sufficient brake applications are made before the valve releases the vacuum stored within the brake booster will be used up and a hard brake pedal and longer stopping distances may result.

Fix: Recall the vehicles that are likely to be affected to fit a revised design of non return valve to the brake vacuum pump.

Recalled models: FOCUS · 13,029 vehicles

It has been identified that due to a specification change to the engine cooling fan module vehicles operated in countries which have high road salt usage during the winter months may experience an increased risk of corrosion build up. In extreme cases the corrosion can penetrate the electrical circuits and result in overheating. In rare cases the overheating may be sufficient to ignite the cooling fan control module and surrounding wiring whilst the vehicle is parked.

Fix: Recalled vehicles will be fitted with a supplementary wiring loom that removes the power to the fan control module when the ignition is switched off. Additionally a further water shield will be fitted to protect the module against water entry and corrosion build up.

Recalled models: FOCUS · 22,325 vehicles

It has been identified that a batch of vehicles may have been fitted with section of power assisted steering hose that is not to specification. This could result in premature failure of the hose with loss of steering assistance and in extreme cases the possibility of an engine bay fire occasioned by escaping hydraulic fluid coming into contact with hot components.

Fix: Recalled vehicles will have the subject hose production code checked. The hose will be changed should it fall within the given criteria.

Recalled models: FOCUS CC · 14,878 vehicles

The rear hub retaining bolts may become loose because some bolts are not to the required specification.

Fix: Recall the vehicles that are likely to be affected to replace the rear hub retaining bolts with those of a revised specification.

Recalled models: FOCUS · 14,027 vehicles

In markets where salt is used on roads in winter corrosion may form and propagate into the electronic fan control module and in extreme cases may cause the module to overheat. In rare cases the overheating may be sufficient to ignite the module surrounding wiring and components.

Fix: Recall affected vehicles and replace the cooling fan and motor assembly.

Recalled models: FOCUS · 8,506 vehicles

It has been identified that on affected vehicles the roll over protection system securing bolts may either be loose or not fully tight. In this condition the roll over protection may not be fully effective in the event of a roll over occurring.

Fix: Recalled vehicles will have the protection units checked for the correct number of securing bolts with bolts being installed as necessary. In addition all securing bolts will be checked to ensure that they are tightened to the correct specification.

Recalled models: FOCUS · 3 vehicles

Hard brake pedal may occur in low ambient temperatures which is caused by a non return valve in the vacuum pump sticking.

Fix: Recall the vehicles that are likely to be affected to fit a revised non return valve to the brake vacuum pump.

Recalled models: FOCUS · 17,972 vehicles

It has been identified that a batch of engines have misaligned oil feed holes between the cylinder head and the camshaft bearings. The reduced oil flow could cause premature wear of the camshaft bearings and may also result in seizure of the engine without prior warning.

Fix: Recalled vehicles will be checked by dealers for the presence of the relevant build code and the engine will be renewed if it is within the specified range.

Recalled models: FOCUS C MAX · 167 vehicles

Water may enter the wiper motor via the wiper arm spindle. If the water contains salt it is possible that an electrical short circuit can cause the wiper to fail. In extreme cases the short circuit can result in the wiper assembly overheating. The increased temperature can be high enough to melt the trim components in the area of the motor assembly.

Fix: Recalled vehicles will be fitted with a revised cover and sealing grommet which will replace the existing sealing system.

Recalled models: FOCUS · 68,996 vehicles

The fuel return pipe is not specification and will degrade. This could lead to seapage of fuel.

Fix: Recall the vehicles that are likely to be affected and replace the fuel return pipe.

Recalled models: FOCUS · 904 vehicles

Left and right hand rear brake flexible hoses may chafe on the wheel arch liners.

Fix: Check the brake hoses for damage and modify the rear wheel arch liners.

Recalled models: FOCUS · 30 vehicles

Alternator B+ terminal may break due to incorrect hardness leaving battery +cable loose.

Fix: Dealers are to check the Alternator B+ terminal type (visual check) and where necessary replace the alternator.

Recalled models: FOCUS · 4,447 vehicles

Excessive crankshaft end-float may allow the torque converter to contact the crankshaft position sensor. Damage to the crankshaft position sensor may lead to engine cut-out/stall.

Fix: Recall affected vehicles for fitment of a revised crankshaft thrust bearing assembly and a new crankshaft position sensor.

Recalled models: FOCUS · 3,121 vehicles

Oil filler cap may become loose resulting in oil dripping onto the exhaust heat shield.

Fix: Replace oil filler cap with a new redesigned version.

Recalled models: FOCUS · 81,256 vehicles

Engine may lose power due to a malfunction in the power train control module software.

Fix: Recall affected vehicles and re-programme the power train module.

Recalled models: FOCUS · 20,577 vehicles

Some vehicles have been built with door latches which may not be to specification. An internal plastic pawl within the assembly may seize which results in the latch failing to function as designed preventing the door being securely shut.

Fix: Recall affected vehicles and fit quality assured replacement door latches.

Recalled models: FOCUS · 32,232 vehicles