Two problems related to manifold/header/muffler/tail pipe have been reported for the 2012 Ford Focus. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2012 Ford Focus based on all problems reported for the 2012 Focus.
Ran out of fuel in this vehicle, once when my daughter was driving on a highway, even though the fuel gauge would say there was between 75-100 miles before empty. The last time this happened the interior of the vehicle had a strong smell of gas. I then proceeded to take it to the dealership and after diagnosis the service manager said some valve remained open causing the gas tank to crack and in turn gas flowed back into the intake manifold. The cost to fix would be approximately $3100. The problem has been a known issue with this vehicle for quite some time, but Ford refuses to recall or even pay for the work. I even had an extended warranty and they wouldn't cover it either.
Bought 11/9/2012 six months later rec'd emission recall, 1yr later would not start, dead in grocery parking, dealer said emission again, 2nd yr radio went out, 3rd yr catalylict converter need to be changed, 5/16/2017 was charged $1805. 72, said not emission but it was doing the same thing as before, dead had to be towed again to dealer, dealer said, "codes po420, po7a3 tested, found converter stopped up, shift actuator faulty, removed transmission replaced clutch actuatorsand clutch, removed & replaced manifold/coverter assembly. Now twice so far engine malfunction light, no power, goes 5 miles. . . . . . . When turned off in about 45-1 hr, starts. . . . All this while driving or parked in a parking lot.