Manifold/header/muffler/tail Pipe Problems of Ford Focus

Check engine light comes on and the engine has stopped while in motion, have had it checked out 4 times already. 1st time dealer said there were some wires that are close to the manifold were frayed and then repaired. The last 3 times the check engine light came on I pulled over while driving, turned the engine off waited a few minutes and restarted the car and was able to drive a few miles. I have now taken the car to a different for dealer 3 times in the past 5 weeks and every time it's a different code with the exception of the 3rd time. They replaced the battery at no charge now today 5 days later the check engine light came on again. This will be the 5th time! this has happened on the highway and on city streets. We have spent over $500 and my time getting back and forth from this dealership to remedy this problem.

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While driving down the expressway at 70mph my vehicle loss power entirely and stalled. I was nearly hit by the vehicle behind me and forced to pull over to the side of the road. The check engine light came on at the same time and indicated a camshaft position sensor, crankshaft position sensor, and ignition errors. I've owned this vehicle from the day it arrived at the dealership. The problem at fault has been previously identified by Ford in a TSB for the engine wiring harness chaffing on the intake manifold. Owners are not notified through mail on TSB's and this vehicle has been serviced by the dealer since the TSB was issued. I believe this should be a recall condition due to the accident potential this problem creates.

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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.

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The contact owns a 2013 Ford Focus. While the contact's daughter was driving 70 mph, the driver heard a loud scraping sound from underneath the vehicle. The vehicle was taken to north brothers Ford (33300 Ford rd, westland, mi 48185) where it was diagnosed that the muffler detached from the rest of the vehicle and was dragging on the road. The vehicle was not repaired. The manufacturer was not made aware of the failure and stated that they would not assist because the vehicle was no longer under warranty. The approximate failure mileage was 19,000.

The car vibrates; shakes. I was told by two auto repairman before I was aware of just what the problem was. It is now a little worse. I need to get it repaired soon and I will. I was hoping there is a recall on the mounts. I was told there was by adams street muffler in tallahassee. Tallahassee Ford says they have no recall.

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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.

I was stopped at a red light, when the light turned green and I engaged the gas pedal the car began to clank and jerk loudly and violently. I drove� the car about two feet before the steering seized up, the car could not be put into neutral, died completely, and had to be pushed to the side of the road. One of the pistons, cylinder # 1, was extensively damaged, due to the valve seat failure which shattered the piston, broke off pieces of the piston skirt, and bent the connecting rod. No damage was done to the cylinder wall, but pieces of the piston skirt were found in the oil pan, and pieces of the piston crown were found in the bottom of intake manifold. Valve seat breakage in the older model Focus, is so common that aera engine rebuilders association issued two bulletins (tb 1725 & tb 1939) to alert the industry to this issue. These bulletins state that the ¿intake valve seats are made of a powdered metal that shatters easily�. On October 29, 2012, after the vehicle had been repaired, I phoned Ford to request a refund for the cost of the parts and was informed, that since there was no recall no refund could be issued. The valve seats have subsequently been modified from the faulty powdered metal type, this shows that Ford is and was aware of this issue. . Read more...

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2001 Ford Focus. Consumer request reimbursement for repairs and investigation for possible recall. The consumer is requesting an investigation into the common problem of valve seat breakage in Fords older engines. The breakage was due to intake valve seats that were made of a powered metal that shattered easily. The consumer wrote to Ford requesting reimbursement for the damage caused to her engine. On September 17, 2012, roughly two miles after exiting the highway, the consumer came to a complete stop at a red light. When the light turned green, she engaged the gas pedal, and the vehicle began to make an unusual noise and jerked loudly and violently. She was able to drive the vehicle abut two more feet, before the steering seized. The vehicle would not go into neutral and it died completely and had to be pushed to a parking lot on the side of the road. The vehicle was then towed to a mechanic and a diagnosis revealed, one of the pistons, cylinder #1 was extremely damaged, due to the valve seat failure which shattered the piston and broke off pieces of the piston skirt and bent the connecting rod. There was no damage to the cylinder wall, as pieces of the piston skirt were found in the oil pan and pieces of the piston crown were found in the bottom of the intake manifold.

I purchased a 2003 Ford Focus in February of 2012. Immediately after purchasing it, I had to spend $700. 00 to fix the motor mounts, bearings in the front wheel, something regarding a cover for the tail pipe/muffler area, a/c, (twice repaired, and went out). Fuel pump, door jambs in front (2 door), locks on the doors would automatically lock whether you wanted them locked or not. Door on passenger side refuses to open from the outside. Spent over $4,000 in fixing, replacing, engine & body parts. Etc. Just when I bought a second set of new tires last week and did the 3 month oil change, it konked out on me, after a shrilling, high-pitched noise. Just got off the expressway. Found out from a repair shop that this model, especially the 2003 is known for transmission, shoddy parts, and is a safety hazard! the pump inside the transmission broke. This car came with 124,000 miles and over 2 years, spent $4,000. 00 on top of the used private purchase of $2,400. 00. Car repair shop wants $2,400 (what I paid for it) to put a new transmission in. One thing after the other went wrong. Iplaint sexperienced, and it has cost me so much money, I feel Ford needs to replace every penny us consumers paid on this model. Never again need to recall the whole car, it is a death trap.

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Thermostat housing has started leaking coolant. This is reportedly a common failure on Focus with 2. 0l dohc engine (zetec). The thermostat housing failure may or may not be a connection to the valve cover leaking oil onto the thermostat housing and hot exhaust manifold which produces a faintly noticeable burning smell when driving.

The valve cover gasket leaks prematurely, which causes oil to drip onto the exhaust manifold. The burning oil creates fumes. The poorly designed seals around intake air box allow fumes from the engine compartment to enter the passenger compartment. These two design failures combine with each other to expose passengers to burning oil fumes. Now, I have to replace the valve cover gasket to avoid exposing myself to burning oil fumes.

My daughter was driving around 30 to 40 mph and when she hit or tap the brake the car would vibrate and try to cut off. The car did cut off and would not start . I towed the car to a shop and found that the valve seat came loose and fell on the pinions, therefore, destroying the engine. The valve seat was totally gone and went through the exhaust. Ford mechanic recommended replacing with new motor and manifold plenum since they would not be able to get all the metal from the valve seat out of the plenum. I could get a used motor but found other on the internet that had the same problem, therefore the problem could happen again.

The exhaust manifold blew on the 2000 Ford Focus due to a leaking valve cover gasket.

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I have a 2001 Ford Focus and there is an exhaust tube that runs off the right side (looking from the front) of the manifold which broke from rusting. I searched some forums online and found that many other people are having the same problem. My car only has 60000 miles on it so I don't believe it should of rusted and cracked like it did.

While driving at unknown speed engine light illuminated. Then, vehicle stalled, and consumer restarted the vehicle. Dealership informed the consumer that problem pertained to the head gasket valve failure. However, the problem was not resolved.

This is a complaint made to the Ford company on 11-18-2004. Dear ms. Andrea hollis, mr. Constance stevens has forwarded to my home both your letters that were dated October 12, 2004 and November 3, 2004. Your letters were written in addressing my original complaint (file no. : 1670904, VIN#: 3fafp3131332r167333) regarding the safety feature of the 2002 Ford Focus vehicle my daughter purchased from the jacob twin Ford dealership, located at 6750 w. Grand avenue, chicago, IL united states 60707, phone (866) 276-4943. I would like to clarify that I am not only complaining about the ?leak? and ?rust? problem, but I also deeply concerned about the fact, which I discovered after I came back home from chicago in September 2004, that there is no weather strip at all under the hood. Because of this lacking of a weather strip, the salty vapors may have been sucked into the engine compartment during the winter seasons in chicago causing rusting problem. I have requested that Ford must investigate this potential safety hazard and make up recalls to install a weather strip to fix this "safety"-related problem.

At 88,000 miles my Focus started losing power and cutting off completely. It would start back up when cranked. The dealership (way brothers) would always say its not doing it now or we can't find anything wrong with it. After taking it back several times with the same results it started knocking and cut off completely. The dealership told me it would cost 3500-4000 to fix (that's without knowing exactly what was wrong with the engine) I had another engine installed and it drove fine for a year and started doing the same thing (losing power and cutting off) the dealership told me the same thing (can't find anything wrong) now it is knocking and smoking from the pipe leading to the manifold. This is my second engine what is the problem with 2000 Focus or is it all Focus.

I received a notice of a recall on my 2000 Ford Focus concerning the defective fuel pump design. The notice recommended waiting until the new design was available in January 2004 before taking the vehicle to the dealer. The vehicle was not showing any symptoms at this point but did so shortly afterward. Shortly before getting a schedule to take it in,the check engine light came on and stayed on. The dealer replaced the recall fuel pump system but found the engine light was on because of a sticking exhaust valve on one side of the engine which would have to be replaced at a cost of $1900. This was in addition to a $100 diagnostic fee. The condition was described as not likely to cause stalling or furthur damage if the vehicle was driven. I took the car to the dealer where the car was purchased. Prior to arriving at the 2nd dealer's shop the check engine light was no longer on. The diagnosis was similar and the cost was put at $2100 plus an $85 diagnostic fee. After requesting an explanation of why this damage would occur on a car with just 28k miles and only after the fuel pump symptoms started,the repair cost was reduced to $600. Because the car was purchased a little over 3 years ago the 36,000 miles engine warranty did not apply. The car was running fine and appeared to have no problems until the fuel pump malfunctioned as Ford expected. I am certain this caused the engine damage. I will also file a complaint with Ford .

Since October of 2003 my vehicle has been experiencing the following problems: engine hesitation, loss of power when I am stopped a traffic lights or stop signs it would just shut off and sometimes I get power surges and lastly, the engine will sound as if it wants to shut off and or is gasping for air. I have paid for several services, such as ignition switch and other column issues, because my key got stuck in the ignition one time as well. I have several other underlined issues with this problem, first Ford has issued a recall for this apparent engine problem, however they have authorized the dealer only to make repairs if it not up to specfications(fuel pump). The dealers are telling me they will charge me for a diagnostic evaluation if the problem is not the fuel pump. I do not have the money to pay for a diagnostic for service evaulation for something on my vehicle that is "not" a problem.

This is the second failure, of the same parts. These studs failed in February of 2001. This is not exactly 12/12,000 for the warranty to cover the repair, but it is pretty darn close. I purchased an extended warranty through my credit union, they said they will not cover the repair because I added two aftermarket modifications to the engine. Ford said they will not cover the repair, because the extended warranty coverage refused to fix the problem. What they keep stepping around is the fact that this same failure happened a year ago, before I made any modifications. The engine was still stock.

Service bulletin for oil leaking into air conditioning from manifold. Ford says do not smoke in vehicle. Dealer offered to spray with deodorant.

The consumer noticed that the vehicle jerked, stalled, and vibrated. The vehicle also made a loud noise while driving. The dealership serviced the vehicle and indicated that the manifold needed to be replaced. Please provide any additional information.

Vehicle hesitated/stalled. Also, a steering problem and a burning smell. This vehicle was recalled for these defects. However, the same problems continue to exist.