Ford introduced its compact Focus in 1999, and the car immediately climbed its way to the top of the compact car ladder by the sheer force of its reasonable cost. As of March 2010, Ford had issued over 100 recalls and TSBs (Technical Service Bulletins, a memo noting known malfunctions) detailing the car's many minor faults. Some of these are covered by warranty, others are not.
One endemic problem with almost all Focuses produced until 2008 has been random stalling. Conditions can vary, but the stalling can occur while idling, cruising or accelerating, and it sounds as though the car is running out of gas. Other more severe problems are a direct result of factory-approved replacement fuel filters simply falling off the car.
In November 2003, Ford issued a recall for over 671,000 2001 Focuses to replace their faulty fuel filters. These filters can easily become clogged by debris, causing intermittent stalling. Ford also issued a recall in 2006 to address incorrectly designed fuel filters sold under the trade name Purolator. These fuel filters have a habit of disconnecting tfrom the car, causing stalling, massive fuel leakage and potential fires.
In November 2002, Ford issued a recall of 291,854 vehicles sporting the company's Zetec four cylinder, many of which were Focuses. Ford's engineers mis-routed the battery cables, damaging many of them. These damaged battery cables can short out on the frame, damaging the computer and battery, which can potentially cause fires.
As of March 2010, Ford has yet to issue a recall notice for its faulty Powertrain Control Modules (engine and transmission control computers), but PCM failure is a common fault amongst first and second generation Focuses. Cause has yet to be determined, but fortunately, most PCM failures seem to occur while the car is still covered under warranty. PCM failures usually involve gauge and lighting malfunctions, followed by sudden engine or transmission failure.
Ford has issued a number of other less severe TSBs regarding the Focus. Some examples include: belt squeal (TSB 17536), engine oil leaks (TSB 16408), engine vibration at idle (TSB 042410), rough idle and operation in wet environments (TSB 17505, indicated by a check engine light and trouble codes P402 and P403), high idle (TSB 16746, check engine light and trouble code P0171) and a check engine light indicating a fuel level sensor malfunction (TSB 16881). That list comprises less than half of all TSBs issued for the 2000 model year Focus engine alone. Other model years have similar problems.
