Automatic Transmission Torque Converter problems of the 2002 Ford Focus

Ford dealership in woodruff, WI replaced front right drive axle and seal 4 times before they got it right and the leak stopped. This initial leak was found by the owner after the car was taken in for a full check upon purchasing indicating the dealership did not inspect the car as they stated and were paid to do. The same day after getting the car back for the last time shifting problems began to occur and I had to replace the overdrive solenoid because the car would not shift into overdrive. This solved that problem but now the car shudders between 40-50 mph as if it is shifting back and forth between gears. Nothing shows up on a diagnostic check, may be expensive torque converter problem. A large number of posts on the inernet show transmission problems and solenoids are a common problem with Ford Focus cars and unfortunately some people are led to believe they need a new transmission which they have replaced probably due to misdiagnosis and at a huge unnecessary expense.

This car was purchased new by grandma. She sold it to her grandson this year. It is "like new" and was always kept in an enclosed garage. It has had dealer servicing. The last 10,000 miles it has intermittently failed to maintain an idle. When coming to a stop the car will often die. We took it to the dealer twice and an independent shop once - everyone thought it was the fueling/emission system but there were no error codes and it was difficult to diagnose but because it only happened on occasion. Then the overdrive solenoid failed and gave an error code. By replacing the solenoid the idle problems stopped. My mechanic has a theory - the overdrive solenoid will start to fail without giving an error code, during this period the torque converter will occasionally stay locked-up in overdrive, thus the car when just idling can't overcome the transmission resistance and not idle properly or stop running, which ours did. Many dollars were wasted on fuel system checks and cleanings. Before we found the answer - it was also very dangerous. This part is very small and appears to be poorly made. Ford forums show it will fail again and again.

Excessive gear chattering has necessitated the replacement of the final drive gear. Was told by dealership that final drive gear was defective and a redesign was placed in vehicle. Because of redesign I needed new drive axles. Torque converter was also shot and a new differential was put into vehicle. New bearings had to be ordered but was told by dealership they are on national backorder untill December of 2004. Yes if you can believe it, 20 months from now. Dealership is ordering bearings that are close to the backordered parts, and measuring for fit. Total time in shop: 32 days and counting. Costs associated with car being on lift for 21 days is $13,860 excluding parts and labor of the master mechanic.