Ford Focus 1.5 TDCi Mk3

The Focus Mk3 uses an electric power-assisted steering rack with an integrated motor and control module. This is a well-documented weak point on 2011-2015 models, though facelift cars from 2014 onwards have a lower failure rate thanks to improved sealing. Failure modes include complete loss of power assistance without warning, intermittent assistance on startup, or the message 'Power Steering Fault Service Required' on the dashboard. Water ingress through the column side of the rack corrodes internal electronics. The EPAS control unit and rack are matched at the factory and cannot be separated, so the entire rack assembly must be replaced. A remanufactured unit costs 600-1,200 euros, with 3-5 hours of labour since the subframe must be partially lowered. Total repair at an independent garage runs 1,200-1,800 euros, rising to 2,500 euros at a Ford dealer with a new OEM rack.

In December 2024, Ford issued a global recall affecting approximately 768,000 diesel vehicles including the Focus 1.5 TDCi, covering production years 2014-2023. The DPF filter material develops hairline cracks over time from repeated regeneration cycles, allowing particulate matter to bypass the filter. This results in failed emissions tests and elevated exhaust particle output. The applicable campaign is 24E06 (KBA reference 14555R). Ford's fix involves a software calibration update and, if necessary, DPF replacement free of charge. Owners who previously paid for DPF replacement can claim reimbursement with proof of payment. There is no special long warranty on the replacement filter: Ford's European recall FAQ gives recall repairs a 12-month or 12,000-mile guarantee. Verify with your VIN whether this recall has been completed. If you are purchasing a car that has not had this recall done and the DPF is already damaged beyond software repair, replacement costs 800-1,500 euros if done outside the recall programme.

Independent of the recall above, the DPF requires sustained driving at motorway speeds for 15-20 minutes to reach the temperatures needed for passive regeneration. Cars used primarily for short urban trips accumulate soot faster than it can be burned off. Each incomplete active regeneration attempt dumps unburned diesel into the engine oil, raising the oil level and diluting lubrication. Symptoms include the DPF warning light, loss of power, and limp mode. A forced regeneration at a garage costs 100-150 euros. Professional DPF cleaning costs 300-500 euros. A new aftermarket DPF costs 500-800 euros fitted. In severe cases where oil has been heavily diluted, an oil flush and change are also necessary. Check the oil level carefully before purchase: significantly above the maximum mark indicates diesel contamination from failed regeneration cycles.

Ford action 16B42 covers 1.5 TDCi cars built between 1 October 2014 and 30 April 2015. It was issued as a service and customer-satisfaction action rather than a formal safety recall, which does not make it any less worth checking. The camshaft sprocket can develop cracks, and if it fractures the timing belt loses synchronisation, causing piston-to-valve contact and catastrophic engine damage. The repair takes approximately 4 hours and replaces the sprocket and timing belt. This is critical to verify before purchasing any early 1.5 TDCi Focus. If the work was never performed and the sprocket has already failed, engine replacement costs 3,000-3,500 euros. Even on later production cars not covered by this action, it is prudent to inspect the sprocket condition when the timing belt is replaced.