2002 Ford Focus diesel: common problems and MOT failures

What goes wrong more than usual on a 2002 Ford Focus diesel?

Parts flagged at MOT more often on the 2002 Ford Focus diesel than on all cars registered in 2002.

• Rust around suspension or steering mountings2.7× usual
  Ford Focus

  18.1% All 2002 cars

  6.7%

  Failed outright at MOT: 10.5%, against 3.5% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £100–£450 our estimate

  At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

• Coil springs1.8× usual
  Ford Focus

  18.8% All 2002 cars

  10.2%

  Failed outright at MOT: 2.5%, against 2.3% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £175–£400 (pair, one axle) ClickMechanic

  At the viewing: Look behind each wheel for a snapped spring coil, and listen for a clunk or twang when turning the wheel lock to lock with the car stopped.

• Sub-frame2.8× usual
  Ford Focus

  12.1% All 2002 cars

  4.3%

  Failed outright at MOT: 1%, against 0.2% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £300–£1,000 our estimate

  At the viewing: Look underneath at the frame the suspension bolts to. Flaky rust or holes are expensive to fix.

• Suspension arm3× usual
  Ford Focus

  9.3% All 2002 cars

  3.1%

  Failed outright at MOT: 1.1%, against 0.3% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £120–£180 (one arm) ClickMechanic

  At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

• Rust in key structural areas3.8× usual
  Ford Focus

  6.4% All 2002 cars

  1.7%

  Failed outright at MOT: 4.7%, against 1.2% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £80–£250 our estimate

  At the viewing: Pull each seatbelt sharply. It should lock, and retract cleanly.

Common 2002 Ford Focus diesel MOT failures and advisories

The share of 2002 Ford Focus diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Suspension
  58% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Brakes
  46% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Tyres
  37% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Lights and electrics
  32% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Rust and bodywork
  20% of testsRough price £150–£1,000

  At the viewing: Check the sills, wheel arches and underneath for rust, and look along the panels for uneven gaps or paint.

• Oil and fluid leaks
  19% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

Known faults on the 2002 Ford Focus diesel

Reported by owners, mechanics and buying guides for this model and age. Check which engine the car has, as some apply to one engine only.

• Cambelt changes often skipped

  All engines

  A failed cambelt can wreck the engine, and because the job can cost close to what the car is worth, some owners skip it. Many specialists advise changing it more often than 100,000 miles or ten years, especially on diesels.

  At the viewing: Check the service history for a cambelt change.

  Source: What Car?: Ford Focus (1998-2004) reliability

• Sill rust

  All engines

  The sills can corrode with age.

  At the viewing: Look along and under the sills for rust.

  Source: What Car?: Ford Focus (1998-2004) reliability

• Electrical faults, wet lights and windscreen heater

  All engines

  Electrical parts are prone to fail, water gets into the headlights and tail lights and blows bulbs, and the Quickclear heated windscreen elements fail.

  At the viewing: Check all lights for water inside, and test the heated windscreen.

  Source: What Car?: Ford Focus (1998-2004) reliability

Questions to ask the seller before buying a 2002 Ford Focus diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. When was the cambelt last changed, and is there a receipt?
2. Any recent work on the rust around suspension or steering mountings? (Flagged at MOT 2.7× as often on the 2002 Ford Focus diesel as on other cars the same age.)
3. Any recent work on the coil springs? (Flagged at MOT 1.8× as often on the 2002 Ford Focus diesel as on other cars the same age.)
4. Any recent work on the sub-frame? (Flagged at MOT 2.8× as often on the 2002 Ford Focus diesel as on other cars the same age.)
5. Can I see the service history and receipts for any big jobs?