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Ford Focus and Mondeo with MTX 75 manual transmission

Problem: There is what appears to be a crunching noise when changing into 3rd gear.

Solution: Models fitted with the MTX 75 (Galaxy VXT 75) are known to have problems with the 3rd gear synchroniser ring. Front wheel drive Transits are also affected upto 2001.

Ford Focus and Mondeo upto 1999

Problem: Interior light stays on even after doors are closed and / or the anti-theft warning system not activating.

Solution: It has been identified that a faulty contact switch in the lock striker of the B or C pillar is failing and therfore preventing the interior light light from switching off. Also, as the PATS (Passive Anti Theft System) thinks a door is still open, it will not arm the system. An upgraded lock striker with revised contact switches ahould be fitted.

Ford Focus 1999 - 2003

Problem: For the first two minutes of driving, there is a particularly hard brake pedal.

Solution: A common problem is reduced brake booster assistance caused by low manifold vacuum. The solution is to fit a new revised brake booster vacuum hose and air cleaner outlet tube and have the PCM (Powertrain Control Module, ECM) cleared of codes and reprogrammed.

Ford Focus and Mondeo 2001 - 2002 Transmission MTX-75

Problem: Very hard to engage fifth gear or cannot be engaged at all.

Solution: A commom problem with the MTX-75 manual transmission is a loose roll pin in the selector mechanism. Also check and adjust if necessary if possible the gearshift cables. If the adjustment is ok, a new revised selector mechanism must be fitted.

Ford Focus upto 2001 1.8 TDCi

Problem: When the clutch is used, there is a squeaking noise coming from the clutch pedal area.

Solution: This porblem is most likely caused by excessive sticking of the coils of the clutch pedal return spring. A new revised clutch pedal return spring should be fitted.

Ford Foucs 1999 and Mondeo upto 2001

Problem: Inaccurate reading of the fuel gauge.

Solution: A common situation is the fuel gauge reading zero after a fill-up. The problem is caused by a faulty fuel pump module which will have a poor / open circuit contact. A new revised fuel level sender card assembly should be fitted.

Ford Focus ST170 2002

Problem: Oil leaks around the timing belt cover area of the cylinder head cover.

Solution: The oil leaks will often be caused by the bolt of the variable camshaft timing actuator working loose. Clean the bolt and refit with thread-locking Loctite and tighten to 10Nm.

Ford Focus

Problem: There is a 'buzzing' noise after the engine is switched off.

Solution: This is most likely caused by noise from the Inlet Manifold Runner Control (IMRC) actuator being transmitted through the chassis of the car. The solution is to isolate the actuator with rubber washers or similar which will prevent the sound to be transmitted.

Ford Mondeo 2001 - 2002 2.0 TDCi and Focus 1.8 TDCi

Problem: Engine does not run properly or fails to start.

Solution: A problem has been identified with the diesel pump and wear to the rollers and shoes. This is caused by insufficient bedding in when the car is new. This can also create small metal particles to contaminate the diesel and damage many components including the injectors. A sample of diesel should be inspected. A new diesel pump with revised rollers and shoes should be fitted along with new injectors and other parts if required.

Ford Focus 2000 - 2001 1.4 1.6 Zetec

Problem: Speedometer fails or jumps erratically.

Solution: A common problem is the cylinder head temperature sensor and ignition cables touching. This will cause a number of electrical gremlins including the speedo, wipers not working, electric mirrors, interior lights coming on etc. The solution is to re-route the cylinder head temperature sensor around the ignition cables and secure in place.

Ford Focus upto 2002 1.8 Di & TDCi

Problem: Coolant temperature unusually hot.

Solution: If the above problem is in conjunction with oil in the coolant and leaks around the engine oil cooler, the most likely cause is internal leaks in the engine oil cooler. The solution is to fit a revised oil cooler / oil filter housing. The cooling system should then be thoroughly flushed.

Ford Focus and Mondeo 1.8 2.0 TDCi 2000 - 2003

Problem: Engine hard to start, lack of power, rough idling etc.

Solution: A common problem has been identified with the above models and an insufficient signal from the camshaft postion sensor (CPS). The fault code P0340 may have been triggered which relates to the CPS. A revised wiring harness / sensor should be installed which increases the sensor signal from 5 volts to 12 volts. The increase in voltage will provide an improved signal from the sensor.

Ford Focus 1999 - 2001

Problem: Turn indicators do not self cancel.

Solution: A common problem is a faulty self cancelling cam on the clockspring. A revised mechanism has been fittted since 11/2001. The solution to the problem is to fit a new clockspring along with a spacer to prevent repeat failure.

Ford Focus ST170 2002

Problem: Loss of power and fault code P1381

Solution: If there is a loss of power and diagnostic fault codes P1381 is triggered, the probable cause is the inlet camshaft valve timing has moved out of specification. This will lead the variable valve timing (VVT) to no longer function. The solution is to reset the timing to a revised specification. Other problems should also be investigated including air leaks, the brake servo pipe connection on the inlet manifold, oil level and the oil level indicator sealing ring. Special tools will be required to set the new revised timing. New camshaft timing has been used since 04/2002.

Ford Focus RS 2003 model

Problem: When pulling away from a stand still, there is a metallic noise from around the drive shafts.

Solution: This is most likely due to a lack of grease on the thrust surfaces of the constant velocity joints. The halfshaft constant velocity joints should be removed from the spindle carriers, and copper grease should be applied to the thrust surfaces. Extra copper grease has been used since 08/2003.

Ford Focus 1999 - 2003

Problem: Water ingress into the passenger footwell.

Solution: The Focus can commonly suffer from water ingress into the passenger footwell. The cause is most likely insufficient sealing between the cowl panel grille and the windscreen around the pollen filter. On vehicle built upto 04/1999, a revised cowl panel grille should be installed with additional sealing strips. Cars manufactured after 04/1999 have the revised cowl panel grille but will require the extra sealing strip to be installed.

Ford Focus and Fiesta 1.8 Endura diesel engine 2001

Problem: Exhaust gas leak from exhaust manifold.

Solution: The most likely cause is the port 4 upper and lower exhaust manifold bolts working loose. Revised bolts should be fitted and tightened to 24 Nm.

Ford Fiesta and Focus 2001 - 2002 1.8 TDCi and Di engines with A/C

Problem: Excessive noise from the accessory drive belt.

Solution: The A/C (air conditioning) compressor supporting bracket works its way loose. The bracket will need to be realigned and tighten the four bolts to 23Nm.

Ford Focus 2001

Problem: Grinding and / or vibrations from the rear wheels.

Solution: The probable cause is damaged wheel bearings caused by moisture ingress inside of the spindle carrier and corrosion of the bearing running surfaces and rollers. The solution is to fir new rear wheel bearings with an additional sealing ring with protective cap and an additional stainless steel oil seal carrier. The additional seal and carrier have been fitted since 06/2001.

Ford Focus ST170 upto 2002

Problem: Poor throttle response and engine revs staying high after throttle release during warm up phase.

Solution: The cause is incorrect software settings in the PCM (engine control module). The solution is to have the PCM re-calibrated.

Ford Focus 1.8 Di and TDCi 2001-2002

Problem: Excessive black smoke and loss of power.

Solution: A common problem is the EGR valve sticking in the open position. This will cause excessive black smoke from the exhaust and will result in a lack of performance. The solution is to fit a revised EGR valve which has a protective sleeve to prevent it from sticking. The revised EGR valve has been fitted since 03/2002.

Ford Focus 1.8 Di 1999 - 2001 with MTX75 manual transmission

Problem: Hesitation between 1500-2000 rpm.

Solution: A common problem is the clutch switch being accidentally activated. The solution is to move the clutch pedal switch closer to the main pivot shaft of the pedal box. This allows more movement before the clutch pedal switch is activated, i.e. driver resting foot on clutch pedal.

Ford Focus upto 2000

Problem: Loss of power steering assistance.

Solution: The Focus tends to suffer from contamination in the power steering fluid which can cause blockages in the pressure control valve. The solution is to fit a new PAS (Power Assisted Steering) pump and a new fluid reservoir. The system should be thoroughly flushed. Since 06/2000 the PAS fluid has been specially filtered before being used in production.

Ford Focus 2.0 Zetec manual 1999 - 2000

Problem: Intermittent high idle and noises.

Solution: The probable cause is acoustic resonance of the IAC (Inlet Air Control) system. The problem can be rectified by fitting a new revised intake manifold, distributor vacuum hose and crankcase vacuum hose. A revised intake manifold has been fitted since 08/2000.

Ford Focus 1.8 Di with booster heater 1999 - 2000. Denmark, Norway, Finland and Sweden models

Problem: Booster heater does not come on after stopping a cold engine (below 10ºC).

Solution: The probable cause is is the programming of the booster heater control module prevents the booster heater coming on if the coolant temp in the booster heater reaches above 10ºC. The solution is to fit a revised booster heater control module. The revised control module has a modified temperature switch and has been installed since 12/2000. Ford part numbers XS4h-18K463-AB, AC ro AD should be replaced with the revised control module.

Ford Focus upto 2002

Problem: Blower motor problems with a melting plastic smell.

Solution: The probable cause is a poor electrical contact of the connector on the blower motor control switch. The solution is to fit a revised blower motor control switch and revised connector. The revised control switch and connector have been installed since 07/2000.

Ford Focus with rear drums

Problem: Rear brakes locking in cold snowy climates.

Solution: The most likely cause is snow ingress into the drums between the drum and backing plate. The snow can melt and then re-freeze in the drum causing the brake lining to lock onto the brake drum. The solution is to dismantle and clean the interior of the drums and then install a shield to protect the gap between the drum and backing plate.

Ford Focus 1998 - 2002

Problem: Metallic knocking noises from rear suspension.

Solution: There are two common known problems with the rear suspension. One problem is the rear spring colliding with the rear lower arm during rebound. This is caused by a lack of support in the rear lower arm and the upper spring seat. The solution is to fit a spring isolator sleeve to prevent the metal to metal knocking. Another common problem is knocking of the top coils of the springs. A revised rear lower arm spring seat has been fitted since 02/2002.

Ford Focus and Mondeo with dual fuel LPG/petrol

Problem: Lack of power and poor idle.

Solution: When converting a petrol engine into a LPG fuel system, an approved Ford cyclinder head should be used that has special nitration hardened valves and valve seats. This will prevent premature wear and lack of power, poor idling etc.

Ford Focus 1999 - 2001 Endura Di engine

Problem: Loss of power.

Solution: A common problem is uneven thickness of the charge air cooler hose. This can cause the holding clamps to move and the charge air cooler hose to come loose and detach from the inlet and outlet pipes. The solution is to fit revised charge air cooler hoses that have flared ends. Revised clamps and revised hoses have been fitted since 05/2001.

Ford Focus

Problem: Knocking noise when braking, cornering or going over bumps form the pedal box area.

Solution: A common problem is the movement of internal parts in the pedal box. The solution is to fit reinforcement bars and/or a new pedal box.

Ford Focus 1.4 1.6 Zetec engine

Problem: Speedo needle jumps when accelerating.

Solution: The probable cause is contact between the electrical supply cable to the cylinder head temperature (CHT) sensor and the ignition lead for the second cylinder. This can create interference and cause the speedo needle to jump about. The solution is to use a cable tie to secure the supply cable of the CHT sensor onto the low pressure line brakcet to prevent contact.

Ford Focus with Zetec engine upto 2001

Problem: Screeching/squealing noises from accessory drive belt during warmup.

Solution: The problem may be due to bearing interferences in the accessory drive belt idler pulley. The solution is to fit a revised idler pulley with modified bearing and improved surface. The revised idler pulley has been fitted since 03/2001.

Ford Focus 1999 - 2000 with 4F27E automatic transmission

Problem: Oil leaks on the A/T oil cooler inlet and return pipe take-off connection.

Solution: This may be due to insufficient sealing between the take-off connections and the oil cooler inlet and return pipe. The solution is to remove the inlet and return pipes and fit additional O-rings at the connections. Additional O-rings on the 4F27E automatic transmission take-off connections have been fitted since 02/2000.

Ford Focus 1999 - 2000

Problem: Brake pedal does not return after braking and/or brakes locking up.

Solution: The problem may be due to the brake pedal touching the pedal box retractor because of insufficient production clearance of the pedal box components and the front bulkhead. The solution is to fit two reinforcement brackets underneath the pedal box. A revised front bulkhead has been installed since 05/2000.

Ford Focus upto 1999

Problem: Windscreen wiper pivot shaft bearings rusting.

Solution: A common problem most likely caused by insufficient protective coating. The solution is to clean the bearings, apply grease and install revised protective caps to the pivot shaft bearings. Also a modified air cowl grille should be fitted on cars built upto 04/1999. Revised anti-corrosion protection coating has been used since 11/1999.

Ford Cougar, Escort, Focus, Mondeo all with MTX75 manual gearbox

Problem: 3rd gear hard to engage with crunching noises.

Solution: This particular problem is mostly likely caused by a defective 3rd gear synchroizer ring. The solution is to fit a new 3rd gear sycnhronizer ring, a new 3rd gear wheel and a new 3rd/4th gear selector fork. A revised synchronizer assembly has been fitted on the MTX75 transmission since 08/2001.

Ford Focus 1998 - 2000

Problem: Rear brake squeal.

Solution: This may be caused by vibrations between the brake lining material and the brake drum. These vibrations may then be increased by insufficient lubrication between the brake shoes and backing plate contact points. Install new brake shoes with a new lining material which has a lower friction level and grease the contact points between the brake shoes and backing plate to rectify the problem.

Ford Focus 1999

Problem: On load change, there are knocking noises from the engine compartment.

Solution: The rear engine mount may be sticking, or may be inhibited because the guide between the bracket and the engine mount is not centrally aligned. Install a new rear engine mounting bracket and a new engine mount to rectify the problem.

Ford Focus 1998 to 1999

Problem: Trip computer inaccurate/faulty fuel gauge.

Solution: This problem is probably caused by an inconsistent contact or open circuit in the fuel tank sender unit and should be solved by installing a new fuel tank sender unit.

Ford Focus 1999 - 2000

Problem: Not starting or starting after a long crank period.

Solution: Air may have entered the fuel system. This problem should be solved using the following check procedures and corrections:

1. Inspect the valve in the Fuel Injection Pump (FIP) supply line for diesel leakage.

- If there is a leak, go to step 2, if not go to step 5.

2. Disconnect the fuel supply line at the FIP and support clip on the front engine cover.

- Free the secondary latch.
- Squeeze the release button to allow it to slide through the connector housing.

3. Disconnect the fuel supply line at the filter.

- Release the black buttoned connector and pull the connector to remove it from the male stub tube.

4. The new fuel supply line should now be installed and the fuel line at the FIP and support clip connected.

5. Disconnect the fuel supply and fuel filter outlet lines.

6. Take away the fuel return line retaining clip.

7. Detach the fuel return line from the filter.

8. Check the O-rings for damage.

- If there is damage, go to step 9, if not go to step 11.

9. Remove the fuel return line.Release the fuel line from the support clip on the engine front cover.

10. Put in a new fuel return line. Make connections at the FIP outlet, fuel injector leak off, bundle and support clip.

11. Drain the fuel tank.

12. Refill it with 10 litres of diesel.

13. Via the quick connector at the bundle, remove the fuel supply line.

14. Install a piece of transparent hose, pushing one end over the exposed metal bundle on the fuel line and securing it with a band clip to prevent leakage.

15. Connect the fuel lines to the filter.

- Connect the other end of the transparent hose to the filter inlet tube with a clip to prevent leakage.
- Connect the fuel return line.
- Connect the filter outlet line.

16. Connect the hand pressure pump to the fuel return connection from the pump.

- Disconnect the fuel return line at the FIP end only.
- Connect the transparent hose from the hand pressure pump to the FIP fuel return connection.

17. Check the amount of air present in the fuel leaving the FIP.

- First you will see heavily aerated fuel, then a solid column of air free fuel. Stop pumping when you see the solid column.
- Take the transparent hose away and reconnect the vehicle return line to the FIP.

18. Check for air bubbles when watching the fuel passing through the transparent hose at the filter inlet.
- Start the vehicle.
- It is likely that the sender unit is damaged if a continuous stream of bubbles is still observed after 10 minutes. Go to the next step if this is the case, if not, got to step 22.

19. Remove and throw away the fuel tank sender unit.

20. Install a new fuel tank sender unit.

21. With the new sender unit installed, check for air bubbles in the fuel.

- Run the engine for a few minutes and check the fuel passing through the hose.
- Check the joint to the bundle and the quick-fit joints at the tank end of the bundle.

22. Fill the tank to the original level.

23. To purge remaining bubbles, start and idle the engine for a few minutes.

Ford Focus

Problem: Faulty charging system.

Solution: Ingress of salt water into the regulator or torque relaxation of the regulator earth bolt causing ground interference may lead to a faulty alternator. Resolve this issue by following this procedure:

Test Procedure

All Diesel Variants built up to 10.03.99 inclusive.

1. Detach the intercooler air guide and remove the intercooler.

2. Make sure the 3-pin connector wire branch isn't damaged. If it is, install a new wiring loom.

3. Attach the 3-pin connector wire branch to the fan shroud with cable ties.

All vehicles

4. Check the condition of the alternator 3-pin connector and surrounding alternator regulator area. If there is any damage, replace the alternator and/or the wiring loom.

5. Commence the charging system diagnostics program. If the alternator fails with an indictment code then replace it and re-test the system. If the alternator fails without an indictment code, go to the next step.

7. Voltage comparison test with 3-pin connector connected.

- Switch on dipped headlights and heated rear window, and run the engine at idle.
- Watch for 20 secs then record the voltage output across the battery terminals.
- If the output is not between 12.5 and 15.5 V, and /or is unsteady (ie. varies by +/- 0.2V) replace the alternator and re-test the charging system.
- Switch off the headlights, heated rear window and engine, and proceed to the next step if the output is steady and within range.

8. Make sure the ignition is off, then disconnect the alternator 3-pin connector and be certain that it is held in a safe position.
- Run the engine at idle, switch on the dipped headlights and heated rear window.
- Check that the output is steady by observing for 20 secs, then record the voltage output across the battery terminals. Switch the engine off.
- If this output is the same as the one from the previous test then the alternator is running in default mode and needs to be replaced. Re-test the charging system.
- Go to the next step if the output is different.

9.Ignition off load test. Re-connect the 3-pin connector, with the ignition off.

- Measure the vehicle key off current load between the battery ground cable and the battery negative terminal using an ammeter.
- The alternator is ok if the current is below 2 Amps.
- If not, disconnect the alternator battery positive connection and re-measure the vehicle key off load.
- If the current dips below 2 Amps, replace the alternator and re-test the charging system.

All Diesel variants built up to 10.03.99 inclusive

10.Re-install the intercooler and attach intercooler air guide.

Ford Focus

Problem: Knocking noise when braking on a rough surface.

Solution: A Bolt on the lower suspension arm may not be tightened to the correct torque. Torque must be increased to 100 Nm + 60º.

Ford Focus 1998

Problem: Engine not starting due to static charge build up resulting in no PATS recognition.

Solution: The LED display should be checked for code 13 after 1 minute. It might be possible to crank the engine after leaving the ignition key out of the lock for 5 mins to an hour.

Ford Focus 1999

Problem: Poor ventilation and misted glass.

Solution: Install a modified cover on the forced air extractors, remove part of the bumper padding to increase the air flow rate and install a new blower motor resistor.

Ford Focus 1999

Problem: Engine sometimes stalls.

Solution: The PCM may have incorrect calibration parameters. Don't assume the vehicle calibration is the problem. Use a diagnostic scanner to perform a full engine diagnostic. If this doesn't resolve the problem, re-program the module. The calibration amendments are loaded onto Ford Dealer CD28a and will prevent the vehicle from stalling.

Ford Focus

Problem: Noises from the front wheels, torque of the stub axle nut.

Solution: The stub axle nut should be tightened to 316 Nm (± 16Nm).

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