Ford Focus Problems

Ford replaced the Mark 1 Focus with the Mark 2 in June 2005, so interchangeability would depend on the build date of the 2005 Focus you have. While the Mark 1 and Mark 2 Focus both offered a two-litre four-cylinder engine (among others) the two engines were from different engine families. The earlier car used a member of the Zetec family, while the Mark 2 Focus two litre was from the Duratec family.

So, unless both Focuses are Mark 2 cars, there's very little chance of sharing things like intake manifolds, even if the spark plugs and ignition systems could be swapped between Mark 1 and Mark 2 cars.

It will all depend on when in 2005 the Focus in question was built. Ford changed from the Mk1 Focus (LR model) to the all-new Mk2 Focus (LS model) in April of that year, so an early-build car will not be the same as the 2009 model, although a later-2005 one might be.

These two versions of the Focus were built on different wheelbases and platforms, so there may not be too much interchangeability. Certainly the bodies were quite different, so panels and interiors won't be interchangeable at all. Even the steering systems were different model-to-model. The Mk1 used conventional power-steering, while the Mk 2 switched to electro-hydraulic power-steering.

The compliance plate under the bonnet will tell you all you need to know about the car's build date. Visually, the earlier car had a much more angular style at the front with almost triangular headlights, while the later car was more upright and conventional looking.

Don't be so sure your car isn't covered by Ford's factory warranty. If it was delivered brand-new (as opposed to built) after May 1 of that year, it's subject to a five-year/unlimited kilometre warranty, so would still be covered. However, if it was delivered before that date, the warranty would have been three years or 100,000km which has now run out. Even so, given the kilometres and the service record, I think you'd be a good case to have Ford come to the party with some help on the repairs on a pro-rata basis.

From what you've told me, I'm guessing you've only dealt with Ford at the dealership level. Go over their heads and talk directly with Ford HQ's customer service department. A quote for $3500 just to examine the car is, on the surface of it, absurd and should be treated with suspicion. Any competent mechanic should be able to diagnose what's going on and whether or not the engine needs to be replaced. My advice here would be to have the car inspected by your state motoring club (the RACV in Victoria) which can give a cost-effective and independent report on the car's condition (and won't cost anything like $3500). This is also excellent legal and evidential back-up if the case does progress to VCAT.

On the face of it, 62,000km is not a reasonable lifespan for a fully serviced engine and the manufacturer should shoulder at least some of the cost of putting it right. Your last resort should be to contact the ACCC and talk to that body regarding your rights under Australia Consumer Law which covers goods (including cars) that are not built to a reasonable level of quality or are unfit for service. A failed engine at such mileage may well fall into that category.

You’re talking about two distinct models of the Ford Focus, so if there’s any interchangeability it won’t be much. Perhaps there would be some mechanical parts in terms of the engine, but the 2007 model was a physically larger can than the original (2003) so even things like the suspension units and brakes are unlikely to be interchangeable.

As for body panels and interior fittings, I doubt there’d be any interchangeability at all. The later car had different panels and the interiors were also completely different. Changes to styling also mean that headlights, tail-lights, glass and even detail things like door handles would not be interchangeable.

Our first suspicion would be a bad earth somewhere on the vehicle. Dashboard faults are very often the result of a poor earth contact and the symptoms you describe are spot on for that very problem. So go around the car and check all the earthing points form the battery to the body of the car.

You could also be dealing with a broken solder in part of the circuit-board that controls the dashboard, too. A good auto electrician will be able to test the circuit for breaks and bad solders and repair them quite cheaply. Ultimately, though, the cost of this repair will be determined by how much of the car has to be disassembled to remove the circuit-board.

This is an issue that continues the haunt Ford even after it paid millions of dollars in fines levied by the ACCC for way it conducted itself in the face of the dual-clutch transmission fiasco. Fundamentally, about half the Fords delivered in Australia with the Powershift transmission, experienced either problems or outright transmission failures. Some of them on multiple occasions.

Ford’s response of initially ignoring the problem and then blaming its customers stands as a 24-carat example of how not to do things. And the ACCC agreed, fining and condemning the company’s behaviour. Eventually, Ford was forced to offer customers a good deal on the next model Focus which featured a conventional automatic gearbox. Even then, the ACCC’s view was that Ford should have offered a full refund, not a sweetened deal to trade up to the newer model. Simply replacing the problem gearboxes wasn’t a widespread permanent fix as the replacement units would have given precisely the same problems.

If you bought your car second-hand, that’s another problem because, really, the affected cars should have been scrapped, not resold to unsuspecting buyers (another beef the ACCC had with Ford at the time).

I think your first port of call should be to the ACCC who will be able to give you an idea of the current situation as far as the problem goes, and what Ford is currently doing about it. Bear in mind, though, the original problem surfaced many years ago, so you’re a late member of the Powershift club.

Even if you could get the radiator from a Focus (and you haven’t told me what year Focus) a radiator designed to cool a small four-cylinder engine probably wouldn’t have the capacity to cool a larger, V6 engine as found in a 2002 Ford Cougar. Perhaps it would work at moderate speeds in cool weather, but a freeway drive in high ambient temperatures would very possibly see it fail to cope. You’d also need to ensure that the radiator suited the transmission fitted (a radiator for a manual car can be different to one for an automatic).

From what I can see, the radiator to suit a 2002 Cougar is, in fact, interchangeable (on some level) with that of a six-cylinder Ford Falcon from 2002 to 2008. Perhaps that would be a better idea, but I’d still be running a tape measure over both cars and taking careful note of where the mounting points are. Or, simply buy the radiator that’s designed to fit the Cougar.

Not really sure what the axles have to do with a tyre that has jumped ship, but perhaps you mean the whole front wheel and tyre assembly came adrift. If so, you’re lucky not to have crashed or hurt yourself or somebody else. If this was caused by a broken axle (also called a driveshaft) then perhaps that’s the basis of your question.

However, the answer is probably no; the driveshafts from a 2002 and 2006 Focus are unlikely to be interchangeable. Even though the engines and gearboxes form each of these two Focus models were similar, the later car was 141mm wider, which almost certainly means it had longer driveshafts than the earlier car. But if a replacement driveshaft is what you need to get back on the road, I wouldn’t have thought finding one from a 2006 Focus (the same as yours) would be such a problem. Parts recyclers are likely to have plenty of these cars in stock, and specialist driveshaft shops can be a great source of spare parts also.

Ford used the same body on its Focus from 2011 until the model was replaced in 2018. On that basis, the front door from either of the cars you’ve listed should fit your car perfectly. You don’t even need to worry about finding a door from a sedan or hatch as opposed to a two-door Focus, as Ford didn’t offer that model in Australia in a two or three-door (which would have had longer doors). Even the sportiest Focus, the ST, was a five-door hatchback. Ford did give the Focus a mild facelift in 2015, but the styling changes were restricted to the front and rear, with the doors not altering at all.

Finding a second-hand door shouldn’t present too many problems the Focus sold in reasonable numbers and many ended up in recycling yards. You might even strike it really lucky and find the door in the same colour as your car which might negate the need to have it painted.

There’s a distinct line in the sand here. If the 2005 Ford Focus you’re referring to was a late Mark 1 Focus, then yes, the headlights should interchange with an earlier Focus as both cars were more or less the same. At the time, Ford was making use of what was called its `Edge’ styling philosophy which was all hard lines and sharp angles.

However, for the Mark 2 Focus which came along in May 2005, Ford had softened the styling considerably, and the headlights of an early Focus will definitely not fit the Mark 2 model as they are a totally different shape.

What puzzles me most is where you managed to obtain a 2000 Focus as the car was not introduced into Australia by Ford until late 2002. The car did exist prior to that, but not in this country. Perhaps you’re buying headlights online from an overseas seller. If that’s the case, make sure they’re for a right-hand-drive Focus as they’ll physically point the wrong way if they’re for a left-hand-drive car. They’ll also be technically unroadworthy if that’s the case.