2004 Ford Focus diesel: common problems and MOT failures

What goes wrong more than usual on a 2004 Ford Focus diesel?

Parts flagged at MOT more often on the 2004 Ford Focus diesel than on all cars registered in 2004.

• Coil springs2× usual
  Ford Focus

  21.8% All 2004 cars

  10.7%

  Failed outright at MOT: 2.9%, against 2.7% of all 2004 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.

• Suspension arm3.6× usual
  Ford Focus

  12.1% All 2004 cars

  3.4%

  Failed outright at MOT: 2.2%, against 0.4% of all 2004 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 around suspension or steering mountings2.4× usual
  Ford Focus

  14.5% All 2004 cars

  6.1%

  Failed outright at MOT: 6.5%, against 2.9% of all 2004 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.

• Track rod ends2× usual
  Ford Focus

  13.3% All 2004 cars

  6.5%

  Failed outright at MOT: 7.5%, against 3% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £50–£150 (one end, plus about £30–£50 if it needs a wheel alignment) ClickMechanic

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

• Sub-frame2.2× usual
  Ford Focus

  11% All 2004 cars

  5.1%

  Failed outright at MOT: 0.9%, against 0.3% of all 2004 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.

Common 2004 Ford Focus diesel MOT failures and advisories

The share of 2004 Ford Focus diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Suspension
  62% 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
  51% 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
  38% 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
  33% of testsRough price £10–£80

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

• Oil and fluid leaks
  21% 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.

• Rust and bodywork
  16% 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.

Known faults on the 2004 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.

• Turbo failure (1.6 TDCi)

  1.6 TDCi diesel

  The 1.6 TDCi diesel’s turbo can fail, and it has to be replaced rather than repaired.

  At the viewing: Listen for whining or whistling, and watch for smoke or a lack of power when you accelerate.

  Source: Haynes: Ford Focus Mk2 common problems (2005-2011)

• Blocked particulate filter (1.6 TDCi)

  1.6 TDCi diesel

  The diesel particulate filter and the additive it needs often weren’t renewed on schedule. A clogged filter can push fuel into the engine oil.

  At the viewing: Ask for proof the DPF and its additive have been done, and smell the dipstick for diesel.

  Source: Haynes: Ford Focus Mk2 common problems (2005-2011)

• Fuel leak from the injector return pipe (2.0 TDCi)

  2.0 TDCi diesel

  A badly fitted fuel return pipe on the injectors can leak and set off engine warning lights.

  At the viewing: Smell for diesel and look for wetness around the injectors on top of the engine.

  Source: Haynes: Ford Focus Mk2 common problems (2005-2011)

• Brake warning light on for no reason

  All engines

  A damaged speed sensor ring on a front hub can turn on the brake and ABS warning lights. The fix is a new hub.

  At the viewing: Make sure the brake and ABS lights go out after starting.

  Source: Haynes: Ford Focus Mk2 common problems (2005-2011)

• Creak from the front when pulling away

  All engines

  A driveshaft without enough sealant on its splines creaks as you set off.

  At the viewing: Pull away gently with the window down and listen for a creak.

  Source: Haynes: Ford Focus Mk2 common problems (2005-2011)

Questions to ask the seller before buying a 2004 Ford Focus diesel

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

1. Has the turbo been replaced, and has the oil been changed on time?
2. Any recent work on the coil springs? (Flagged at MOT 2× as often on the 2004 Ford Focus diesel as on other cars the same age.)
3. Any recent work on the suspension arm? (Flagged at MOT 3.6× as often on the 2004 Ford Focus diesel as on other cars the same age.)
4. Any recent work on the rust around suspension or steering mountings? (Flagged at MOT 2.4× as often on the 2004 Ford Focus diesel as on other cars the same age.)
5. Can I see the service history and receipts for any big jobs?